INJECTION MOLDED MULTIPLE LAYER GLAZINGS

• US 20080047655A1
• Filed: 08/23/2006
• Published: 02/28/2008
• Est. Priority Date: 08/23/2006
• Status: Active Grant

• Current Assignee: Solutia Incorporated (Eastman Chemical Company)
• Original Assignee: Solutia Incorporated (Eastman Chemical Company)
• Inventors: Karagiannis, Aristotelis, Yuan, Ping, Koran, Francois Andre
• Granted Patent: US 9,242,401 B2
• Time in Patent Office: Days
• US Class Current: 156/109
• CPC Class Codes: B29C 45/0001 characterised by the choice of material
• CPC Class Codes: B29C 45/14467 Joining articles or parts of a single article B29C45/14377, B29C45/14385, B29C45/14581, B29C45/14614 and B29C45/006 take precedence
• CPC Class Codes: B29C 45/14778 the article consisting of a material with particular properties, e.g. porous, brittle
• CPC Class Codes: B29K 2031/04 Polymers of vinyl acetate, e.g. PVAc, i.e. polyvinyl acetate
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2709/08 Glass
• CPC Class Codes: B29K 2995/0088 Molecular weight
• CPC Class Codes: B29L 2031/7782 Glazing
• CPC Class Codes: B32B 17/10036 comprising two outer glass sheets
• CPC Class Codes: B32B 17/10743 containing acrylate (co)polymers or salts thereof
• CPC Class Codes: B32B 17/10761 containing vinyl acetal
• CPC Class Codes: B32B 17/1077 containing polyurethane
• CPC Class Codes: B32B 17/10788 containing ethylene vinylacetate
• CPC Class Codes: B32B 17/10917 between two pre-positioned glass layers

Abstract

The present invention is directed to the use of injection molding to form polymeric interlayers directly between two rigid substrates that are positioned so that after injection of the melted polymeric material and after cooling, the resulting multiple layer panel functions as a safety panel that can be used in any appropriate conventional safety glazing application. Methods of the present invention utilize a relatively low molecular weight polymer, multiple injection points, mold compression, and/or a heated substrate in order to facilitate the injection of polymer into the relatively narrow space between glazing substrates that is typically found in safety glazings.

Claims

1. A method of making a multiple layer glazing panel, comprising:

providing two rigid glazing substrates;

positioning said glazing substrates in position relative to each other, thereby forming a gap between said glazing substrates; and

,

injecting a polymer melt into said gap, thereby forming said multiple layer glazing panel, wherein said polymer melt comprises a polymer having a molecular weight of less than 150,000 Daltons and wherein said polymer melt comprises poly(vinyl butyral), polyurethane, ethylene-vinyl acetate copolymer, or ionomers of partially neutralized ethylene/(meth)acrylic acid copolymer.

2. The method of claim 1, wherein said molecular weight is less than 100,000 Daltons.

3. The method of claim 1, wherein said molecular weight is less than 70,000 Daltons.

4. The method of claim 1, wherein said substrates are glass.

5. A method of making a multiple layer glazing panel, comprising:

providing two rigid glazing substrates;

positioning said glazing substrates in position relative to each other, thereby forming a gap between said glazing substrates; and

,

injecting a polymer melt into said gap, thereby forming said multiple layer glazing panel, wherein one or both of said rigid glazing substrates are heated to at least 80°

C. prior to said injecting and wherein said polymer melt comprises poly(vinyl butyral), polyurethane, ethylene-vinyl acetate copolymer, or ionomers of partially neutralized ethylene/(meth)acrylic acid copolymer.

6. The method of claim 5, wherein one or both of said rigid glazing substrates are heated to at least 150°

C. prior to said injecting.

7. The method of claim 5, wherein said polymer melt comprises poly(vinyl butyral).

8. The method of claim 5, wherein said substrates are glass.

9. A method of making a multiple layer glazing panel, comprising:

providing two rigid glazing substrates;

positioning said glazing substrates in position relative to each other, thereby forming a gap between said glazing substrates; and

,

injecting a polymer melt into said gap, thereby forming said multiple layer glazing panel, wherein at least two separate gates are used for said injecting and wherein said polymer melt comprises poly(vinyl butyral), polyurethane, ethylene-vinyl acetate copolymer, or ionomers of partially neutralized ethylene/(meth)acrylic acid copolymer.

10. The method of claim 9, wherein at least four separate gates are used.

11. The method of claim 9, wherein said polymer melt comprises poly(vinyl butyral).

12. The method of claim 9, wherein said substrates are glass.

13. A method of making a multiple layer glazing panel, comprising:

providing two rigid glazing substrates;

positioning said glazing substrates in position relative to each other, thereby forming a gap between said glazing substrates; and

,

injecting a polymer melt into said gap, thereby forming said multiple layer glazing panel;

wherein said polymer melt comprises a polymer having a molecular weight of less than 150,000 Daltons;

wherein one or both of said rigid glazing substrates are heated to at least 80°

C. prior to said injecting;

wherein at least two separate gates are used for said injecting; and

,

wherein said polymer melt comprises poly(vinyl butyral), polyurethane, ethylene-vinyl acetate copolymer, or ionomers of partially neutralized ethylene/(meth)acrylic acid copolymer.

14. The method of claim 13, wherein said molecular weight is less than 100,000 Daltons, wherein one or both of said rigid glazing substrates are heated to at least 150°

C. prior to said injecting, and wherein at least four gates are used.

15. The method of claim 13, wherein said polymer melt comprises poly(vinyl butyral).

16. The method of claim 13, wherein said substrates are glass.

17. A method of making a multiple layer glazing panel, comprising:

providing two rigid glazing substrates;

positioning said glazing substrates in position relative to each other, thereby forming a gap between said glazing substrates; and

,

injecting a polymer melt into said gap, thereby forming said multiple layer glazing panel;

wherein said polymer melt comprises poly(vinyl butyral), polyurethane, ethylene-vinyl acetate copolymer, or ionomers of partially neutralized ethylene/(meth)acrylic acid copolymer; and

,

A) wherein said polymer melt comprises a polymer having a molecular weight of less than 150,000 Daltons;

B) wherein one or both of said rigid glazing substrates are heated to at least 80°

C. prior to said injecting;

or,

C) wherein at least two separate gates are used for said injecting.

18. The method of claim 17, comprising exactly two of A), B), and C).

19. The method of claim 17, wherein said polymer melt comprises poly(vinyl butyral).

20. The method of claim 17, wherein said substrates are glass.