LIGHT-WEIGHT, HIGH STIFFNESS GLASS LAMINATE STRUCTURE

• US 20150064374A1
• Filed: 08/28/2014
• Published: 03/05/2015
• Est. Priority Date: 08/30/2013
• Status: Active Grant

• Current Assignee: Corning Incorporated
• Original Assignee: Corning Incorporated
• Inventors: Jain, Anurag, Laurin, Michael M., Maas, Christianus Johannes Jacobus, Moore, Michael John, Wood, Charlie W.
• Granted Patent: US 10,279,567 B2
• Time in Patent Office: Days
• US Class Current: 428/34
• CPC Class Codes: B32B 17/10005 laminated safety glass or glazing
• CPC Class Codes: B32B 17/10018 comprising only one glass sheet
• CPC Class Codes: B32B 17/10036 comprising two outer glass sheets
• CPC Class Codes: B32B 17/10091 thermally hardened
• CPC Class Codes: B32B 17/10119 having a composition deviating from the basic composition of soda-lime glass, e.g. borosilicate
• CPC Class Codes: B32B 17/10137 Chemical strengthening
• CPC Class Codes: B32B 17/10678 comprising UV absorbers or stabilizers, e.g. antioxidants
• CPC Class Codes: B32B 17/10752 containing polycarbonate
• CPC Class Codes: B32B 17/10761 containing vinyl acetal
• CPC Class Codes: B32B 17/1077 containing polyurethane
• CPC Class Codes: B32B 17/10779 containing polyester
• CPC Class Codes: B32B 17/10788 containing ethylene vinylacetate
• CPC Class Codes: B32B 17/10798 containing silicone
• CPC Class Codes: B32B 2367/00 Polyesters, e.g. PET, i.e. polyethylene terephthalate
• CPC Class Codes: B32B 2369/00 Polycarbonates
• CPC Class Codes: B32B 2383/00 Polysiloxanes
• CPC Class Codes: B32B 37/18 involving the assembly of discrete sheets or panels only
• CPC Class Codes: E06B 3/66 Units comprising two or more parallel glass or like panes permanently secured together reforming and uniting glass sheets by fusing C03B23/00; joining glass to glass or to other materials C03C27/00; laminated glass B32B17/10
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 428/24868 Translucent outer layer
• CPC Class Codes: Y10T 428/24926 : including ceramic, glass, porcelain or quartz layer
• CPC Class Codes: Y10T 428/2495 : Thickness [relative or absolute]
• CPC Class Codes: Y10T 428/24967 : Absolute thicknesses specified
• CPC Class Codes: Y10T 428/31507 : Of polycarbonate
• CPC Class Codes: Y10T 428/31663 : As siloxane, silicone or silane

Abstract

A laminate structure having a first chemically strengthened glass layer, a second chemically strengthened glass layer, and a polymer interlayer structure intermediate the first and second glass layers. The polymer interlayer structure can include a first polymeric layer adjacent to the first glass layer, a second polymeric layer adjacent to the second glass layer, and a polymeric rigid core intermediate the first and second polymeric layers.

Claims

1. A laminate structure comprising:

a first glass layer;

a second glass layer; and

a polymer interlayer structure intermediate the first and second glass layers,

wherein the polymer interlayer structure is comprised of

a first polymeric layer adjacent to the first glass layer,

a second polymeric layer adjacent to the second glass layer, and

a polymeric core intermediate the first and second polymeric layers, the polymeric core comprising one or more of a polysiloxane, a polyester, a polycarbonate, a copolymer comprising one or more of the foregoing and combinations thereof, and

wherein the first glass layer is comprised of a strengthened glass.

2. The laminate structure of claim 1 wherein the strengthened glass of the first glass layer is chemically strengthened glass or thermally strengthened glass.

3. The laminate structure of claim 1 wherein the second glass layer is comprised of strengthened glass and wherein the strengthened glass of the second glass layer is chemically strengthened glass or thermally strengthened glass.

4. The laminate structure of claim 1 wherein one or more surfaces of the first and second glass layers are chemically etched.

5. The laminate structure of claim 1 wherein the thicknesses of the first and second glass layers are selected from the group consisting of a thickness not exceeding 1.5 mm, a thickness not exceeding 1.0 mm, a thickness not exceeding 0.7 mm, a thickness not exceeding 0.5 mm, a thickness within a range from about 0.1 mm to about 1.0 mm, a thickness from about 0.5 mm to about 1.0 mm, a thickness from about 0.5 mm to about 0.7 mm.

6. The laminate structure of claim 1 wherein the thicknesses of the first and second polymeric layers are selected from the group consisting of a thickness ranging from about 0.1 mm to about 0.8 mm, a thickness from about 0.1 mm to about 0.5 mm, a thickness from about 0.1 mm to about 0.3 mm.

7. The laminate structure of claim 1 wherein the thickness of the core is selected from the group consisting of a thickness ranging from about 2.0 mm to about 10.0 mm, a thickness from about 2.0 mm to about 8.0 mm, a thickness from 2.0 mm to about 5.0 mm, and a thickness from about 2.0 mm to about 3.8 mm.

8. The laminate structure of claim 1 wherein the thicknesses of the first and second glass layers are different.

9. The laminate structure of claim 1 wherein the composition of the first and second glass layers are different or the composition of the first and second polymeric layers are different or both.

10. The laminate structure of claim 1 wherein the first or second glass layer has a surface compressive stress of between about 250 MPa to about 350 MPa with a depth of layer of compressive stress of about 60 microns or more or wherein the first or second glass layer has a surface compressive stress of between about 400 MPa and about 900 MPa and a depth of layer of compressive stress of about 30 microns or more.

11. The laminate structure of claim 1 wherein the thickness of the core is a function of the thickness of the first glass layer, the thickness of the second glass layer, or both the thicknesses of the first and second glass layers.

12. The laminate structure of claim 1, wherein the core comprises a polysiloxane copolymer comprising:

a.) a polysiloxane unit of the formula;

13. The laminate structure of claim 1, wherein the core comprises a polysiloxane-polycarbonate copolymer derived from at least one dihydroxy aromatic containing polycarbonate unit, and at least one polysiloxane bisphenol of formula (1), formula (2), or a combination thereof

14. The laminate structure of claim 1, wherein the core comprises a first polymer comprising a polyetherimide-polysiloxane copolymer comprising (a) a repeating polyetherimide unit, and (b) a polysiloxane block unit, the polysiloxane block unit having the formula:

15. A multilayer article comprising:

a first glass layer, wherein the first glass layer is comprised of a thin, chemically strengthened glass having a surface compressive stress of between about 250 MPa and about 350 MPa and a depth of layer of compressive stress greater than 60 μ

m;

a first interlayer; and

a polymer layer;

wherein the polymer layer comprises a polysiloxane, a polyester, a polycarbonate, a copolymer comprising one or more of the foregoing, or a blend comprising one or more of the foregoing;

wherein the first glass layer is 0.1 to 1.5 mm, the first interlayer is 0.2 to 1.4 mm, and the polymer layer is 2 to 15 mm.

16. The multilayer article of claim 15, further comprising a second glass layer and a second interlayer;

wherein the second glass layer is comprised of a thin, chemically strengthened glass having a surface compressive stress of between about 250 MPa and 350 MPa and a depth of layer (DOL) of compressive stress greater than about 60 μ

m;

wherein the second glass layer is 0.1 to 1.5 mm and the second interlayer is 0.2 to 1.4 mm.

17. The multilayer article of claim 15, wherein the first interlayer comprises a thermoplastic polyurethane.

18. The multilayer article of claim 15, wherein the first interlayer comprises a poly(ethylene-co-vinyl acetate), wherein the poly(ethylene-co-vinyl acetate) comprises 0 to 0.01 wt % hindered amine stabilizer.

19. The multilayer article of claim 15, wherein the poly(ethylene-co-vinyl acetate) comprises a vinyl acetate content of 20 to 80 wt % based on the total weight of the poly(ethylene-co-vinyl acetate).

20. The multilayer article of claim 15, wherein the polymer layer comprises a polysiloxane copolymer comprising:

a.) a polysiloxane unit of the formula;

21. The multilayer article of claim 15, wherein the polymer layer comprises a polysiloxane-polycarbonate copolymer derived from at least one dihydroxy aromatic containing polycarbonate unit, and at least one polysiloxane bisphenol of formula (1), formula (2), or a combination thereof

22. The multilayer article of claim 15, wherein the polymer layer comprises a first polymer comprising a polyetherimide-polysiloxane copolymer comprising (a) a repeating polyetherimide unit, and (b) a polysiloxane block unit, the polysiloxane block unit having the formula:

23. The multilayer article of claim 15, wherein the polymer layer comprises one or both of an antidrip agent and a flame retardant.

24. The multilayer article of claim 15, wherein the polymer layer comprises an organophosphorus compound in an amount effective to provide 0.1 to 1.0 wt % of phosphorus, based on the total weight of the composition one or more flame retardants

25. The multilayer article of claim 24, wherein the organophosphorus compound is an aromatic organophosphorus compounds having at least one organic aromatic group and at least one phosphorus-containing group, or an organic compounds having at least one phosphorus-nitrogen bond.

26. The multilayer article of claim 25, wherein the aromatic organophosphorus compound comprises a C3-30 aromatic group and a phosphate group, phosphite group, phosphonate group, phosphinate group, phosphine oxide group, phosphine group, phosphazene, or a combination comprising at least one of the foregoing phosphorus-containing groups.

27. The multilayer article of claim 26, wherein the aromatic organophosphorus compound is of the formula:

28. The multilayer article of claim 27, wherein each of R¹⁶, R¹⁷, R¹⁸, and R¹⁹ is phenyl, X is of the formula

29. The multilayer article of claim 25, wherein the aromatic organophosphorus compound is bisphenol A bis(diphenyl phosphate), triphenyl phosphate, resorcinol bis(diphenyl phosphate), tricresyl phosphate, or a combination comprising at least one of the foregoing.

30. The multilayer article of claim 24, wherein organophosphorus compound containing a nitrogen-phosphorus bond is a phosphazene, phosphorus ester amide, phosphoric acid amide, phosphonic acid amide, phosphinic acid amide, tris(aziridinyl)phosphine oxide, a combination comprising at least one of the foregoing.

31. The multilayer article of claim 24, wherein the organophosphorus compound is effective to provide phosphorus in an amount of 0.3% to 0.8% of phosphorus, based on the weight of the composition.

32. The multilayer article of claim 15, wherein the article has one or more decorative layers applied to the polymer or glass layers by methods including but not limited to screen printing, laser marking, rotor gravure printing, pad printing, digital ink jet printing, hydrographics, laser etching, laser printing, and transfer printing.

33. The multilayer article of claim 15, wherein the article has one or more of an OSU integrated 2 minute heat release test value of less than 65 kW-min/m²;

a peak heat release rate of less than 65 kW/m² as measured using the method of FAR F25.4, in accordance with Federal Aviation Regulation FAR 25.853 (d);

an E662 smoke test D_max value of less than 200 when measured at a thickness of 1.6 mm.

34. The multilayer article of claim 15, wherein the article has one or more of an OSU integrated 2 minute heat release test value of less than 55 kW-min/m²;

a peak heat release rate of less than 55 kW/m² as measured using the method of FAR F25.4, in accordance with Federal Aviation Regulation FAR 25.853 (d);

an E662 smoke test D_max value of less than 200 when measured at a thickness of 1.6 mm.

35. The multilayer article of claim 15, wherein the article has a heat release according to EN45545 and ISO 5660 of less than 90 kW;

a fire propagation in accordance with the method shown in EN45545 and ISO 5658-2 of greater than 20 kW;

an EN 45545 and ISO 5659 for a smoke density at 240 seconds, a smoke density of less than 300, and a VOF4 smoke density of less than 600, and toxicity CIT_G, of less than 0.9 for an HL2 rating and 1.2 for an HL1 rating.

36. The multilayer article of claim 15, wherein the article can pass one or more of a SMP 800C and Boeing BSS 7239 test for toxicity;

the ASTM E162 test for flame spread;

the ASTM E662 test for smoke density;

the FAR25.853 (d) Appendix F Part V for smoke generation;

the CFR 49, Chapter II, Federal Railroad Administration, DOT, Part 223, Subpart B, Appendix A, Type I, Ballistic Threat using caliber .22 LR (long rifle), 40.0-grain, lead ammunition with a minimum impact velocity of 960 fps fired at the center of the test sample; and

a CFR 49, Chapter II, Federal Railroad Administration, DOT, Part 223, Subpart B, Appendix A, Type I, Block Threat using concrete blocks with a minimum weight of 25 lbs suspended and then dropped 30 feet, 1 inch onto the center of the test sample.

37. The multilayer article of claim 15, wherein the article passes a British test standards BS476 Part 7 test for flame spread;

a British test standards BS476 Part 6 for fire propagation;

a British test standards BS 6853;

1999 Annex D8.4. for smoke generation; and

a British test standards BS 6853;

1999 Annex B.2 for toxicity.

38. The multilayer article of claim 15, wherein polymer layer comprises a flame retardant.

39. A double pane window comprising:

a first pane comprising a first glass layer, wherein the first glass layer is comprised of a thin, chemically strengthened glass having a surface compressive stress of between about 250 MPa and about 350 MPa and a depth of layer (DOL) of compressive stress greater than 60 μ

m; and

a first interlayer located in between the first glass layer and a first polymer layer;

wherein the first polymer layer comprises a polysiloxane, a polyester, a polycarbonate, a copolymer comprising one or more of the foregoing, or a blend comprising one or more of the foregoing;

a second pane comprising a third glass layer, wherein the third glass layer is comprised of a thin, chemically strengthened glass having a surface compressive stress of between about 250 MPa and about 350 MPa and a depth of layer (DOL) of compressive stress greater than 60 μ

m; and

a third interlayer located in between the third glass layer and a second polymer layer;

wherein the second polymer layer comprises a polysiloxane, a polyester, a polycarbonate, a copolymer comprising one or more of the foregoing, or a blend comprising one or more of the foregoing;

a gap located in between the first pane and the second pane; and

a frame surrounding an edge of the first pane and the second pane.

40. The window of claim 39, wherein the first pane further comprises a second interlayer located in between a second glass layer and the first polymer layer and/or the second pane further comprises a fourth interlayer located in between a fourth glass layer and the second polymer layer.

41. A method of making a multilayer article comprising:

adding an interlayer with a 0.2 to 1.4 mm interlayer thickness to a polymer layer with a 2 to 15 mm polymer thickness;

adding a glass layer with a 0.1 to 1.5 mm glass layer thickness to the interlayer for form a multilayer structure; and

laminating the multilayer structure to form the multilayer article;

wherein the glass layer is comprised of a thin, chemically strengthened glass having a surface compressive stress of between about 250 MPa and about 350 MPa and a depth of layer (DOL) of compressive stress greater than 60 μ

m; and

wherein the polymer layer comprises a polysiloxane, a polyester, a polycarbonate, a copolymer comprising one or more of the foregoing, or a blend comprising one or more of the foregoing.