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Laminate for a safety glazing
| Details |
Inventors: Moran, James R.;
Assignee: Monsanto Company (St. Louis, MO)
Primary Examiner: Cashion, Jr.; Merrell C.
Assistant Examiner: Nakarani; D. S.
Attorney, Agent or Firm: Murphy; Michael J., Farrington; William J.
A laminate which is substantially free of distortion when used in a safety glazing comprising a transparent, thermoplastic substrate layer, optionally surface treated or coated to improve adhesion, bearing one or more functional performance layers, such as an infra-red radiation reflecting stack, and at least one layer of plasticized polyvinyl butyral bonded on one side to a functional performance layer or the substrate layer having a roughened deairing surface on its other side characterized by a roughness value, Rz, of at least 10 micrometers, such plasticized polyvinyl butyral layer, before bonding to the substrate layer or functional performance layer, possessing low surface waviness on each side characterized by a wave index value, WI, of less than 15,000 square micrometers. |
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DETAILED DESCRIPTION Now improvements have been made in laminates containing high performance layer(s) for use in safety glazings such as vehicle windows and the like.
Accordingly, a principal object of this invention is to determine the mechanism causing reflected distortion visible as an optical defect called "applesauce" in a safety glazing containing a performance layer such as a solar reflecting metal/dielectric stack.
Having determined such mechanism, another object is to substantially reduce or eliminate such visible reflected distortion rather than to mask its presence.
A further object is to provide a laminate usable in safety glazings having improved optical performance insofar as displaying reduced or no reflected distortion.
A specific object is to provide such an improved safety glazing with reduced reflected distortion using PVB sheet as made on a commercial sheet extrusion line without requiring further processing before combining it in a laminate with metallized film.
Other objects will in part be obvious and will in part appear from the following detailed description and claims.
These and other objects are accomplished, initially, by determining that the optical defect resulting in reflected distortion and appearing as applesauce in a finished safety glazing, which includes a performance layer on a substrate, is caused by non-planarity of the plasticized PVB/coated substrate interface, such non-planarity being associated with the quality of the surface of the PVB layer.
More specifically, applesauce appears when the PVB layer has an undulating surface topography characterized by a wave index (WI) (further explained hereinafter) greater than 15,000 square micrometers.
Having determined the cause of the problem, the invention substantially reduces or eliminates applesauce by providing, as one or more layers in a laminate for such a safety glazing, a plasticized PVB sheet where each sheet surface has a WI less than 15,000 square micrometers and, preferably less than 12,000 square micrometers, yet one and preferably both such surfaces is textured or roughened to facilitate deairing, as characterized by a roughness value (R
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Manufacturing Materials 
