WO2020210070A1 - Stiffened lightweight laminates providing visible light switching - Google Patents

Abstract

Laminates disclosed comprising a first substrate; an interlayer disposed on the first substrate; a light responsive material encapsulated in the interlayer, the interlayer having a plasticizer content such that the performance of a light responsive material therein is not substantially adversely affected; and a second substrate disposed on the interlayer, wherein the laminate is optionally complexly curved.

Description

STIFFENED LIGHTWEIGHT LAMINATES PROVIDING VISIBLE LIGHT SWITCHING

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority under 35 U.S.C. § 1 19 of U.S. Provisional Application Serial No. 62/832,459 filed on April 1 1 , 2019 the content of which is relied upon and incorporated herein by reference in its entirety.

BACKGROUND

[0002] Laminates are often utilized as windows and glazing in architectural and vehicle or transportation applications, including automobiles, rolling stock, locomotive and airplanes. Such laminates can also be used as glass panels in balustrades and stairs, and as decorative panels or coverings for walls, columns, elevator cabs, household and industrial appliances and other applications. The laminates can be a transparent, semi-transparent, translucent or opaque part of a window, panel, wall, enclosure, sign or other structure. Common types of laminates are used in architectural and/or vehicular applications include clear and tinted laminated glass structures.

[0003] Conventional laminate constructions typically used in automotive applications include two plies of 2 mm soda lime glass with a polyvinyl butyral (PVB) interlayer. Such laminates exhibit, among other drawbacks, limited impact resistance; higher weight; poor performance characteristics, including a higher probability of breakage when struck by roadside debris; insufficient stiffness; and insufficient sound transmission loss.

[0004] Accordingly, there is a need for laminates that are thin and lightweight; are stiff; have desirable sound dampening qualities for use in, e.g., automotive applications; and can incorporate light response functionality.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] FIG. 1 is a plot of percent transmission at 550 nm as a function of time before and after 200 hours SAE J2412 exposure of a laminate with a stiff acoustic interlayer that does not contain plasticizer. Switching was accomplished by application of +/- 1.5 volts dc. The laminate is made from 2.1 mm soda lime glass (SLG), a layer of a stiff acoustic interlayer, electrochromic dynamic tinting film, another layer of a stiff acoustic interlayer, and finally a 0.7 mm layer of Gorilla Glass®. The figure shows laminate switching time characteristics before and after exposure to SAE J2412 UV/temperature/humidity durability test. The graph has 3 plots; initial (before exposure), 200 hours exposure covered, and 200 hours exposure uncovered. There is little change in switching time between initial, exposed covered and exposed uncovered indicating this laminate construction is durable through 200 hours.

[0006] FIG. 2 is a plot of percent transmission at 550 nm as a function of time before and after 200 hours SAE J2412 exposure of a laminate with acoustic PVB (APVB) containing about 25 wt.% to about 35 wt.% plasticizer (e.g., 28 wt.%). Switching was accomplished by application of +/- 1.5 volts dc. The laminate is made from 2.1 mm soda lime glass (SLG), a layer of APVB interlayer, electrochromic dynamic tinting film, another layer of APVB interlayer, and finally a 0.7 mm layer of Gorilla Glass®. The figure shows laminate switching time characteristics before and after exposure to SAE J2412 UV/temperature/humidity durability test. The graph has 3 plots; initial (before exposure), 200 hours exposure covered, and 200 hours exposure uncovered. After 200 hours exposure in both covered and uncovered conditions the laminate failed to switch.

[0007] FIGS. 3A-3C are side views of laminates of the disclosure, each comprising two possible configurations of edge seals.

[0008] FIG. 4 is a perspective view of the laminates of FIGS. 3A-3C.

[0009] FIG. 5 is a side view of a cold formed laminate prior to formation.

[0010] FIG. 6 is a side view of the cold formed laminate shown in FIG. 5.

[0011] FIG. 7 is a plot of sound transmission loss (STL) vs. frequency for 2.1 mm SLG/ lnterlayer/0.7 Gorilla Glass® laminates where the interlayer is either a stiff acoustic interlayer or QP51 acoustic PVB from Eastman.

[0012] FIG. 8 is bar graphs showing the stiffness of laminates according to the disclosure. FIG. 8 contains a comparison of ball-on-ring stiffness test results for 12” x12” laminates of construction 2.1 mm SLG/lnterlayer/0.7 Gorilla Glass® (GG) for APVB and stiff acoustic interlayers. Rate of deformation was 0.0017 mm/sec. The stiff acoustic interlayer has an average 10% greater stiffness than a corresponding laminate made using APVB. These laminates do not comprise light responsive material. But it is not expected that the presence of light responsive material will have any effect on sound transmission loss (STL).

[0013] In the drawings, which are not necessarily drawn to scale, like numerals describe substantially similar components throughout the several views. Like numerals having different letter suffixes represent different instances of substantially similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.

DESCRIPTION

[0014] Laminates described herein have both greater stiffness and improved acoustic attenuation than comparable laminates with standard auto or architectural grade interlayers. The acoustic attenuation, as measured by sound transmission loss, is higher for stiffened laminates described herein at frequencies above 5000 Hz than laminates of comparable thickness made using industry standard acoustic polyvinyl butyral (PVB). In addition, the laminates described herein also comprise a light responsive material (e.g., a dynamic tint film) encapsulated within the interlayer. Such light responsive materials are useful in both the auto and architectural markets for glazing whose light transmission can be electronically controlled. Such glazings provide privacy, reduced glare, and reduced solar heating loads within auto cabins or within buildings.

[0015] It has been surprisingly found that it is advantageous to use interlayers having a plasticizer content such that the performance of the light responsive material encapsulated therein is not substantially adversely affected. For example, interlayers are contemplated having low plasticizer content (e.g., less than about 28 wt.%, less than about 25 wt.%, less than about 20 wt.%, less than about 15 wt.%, less than about 10 wt.%, less than about 5 wt.%, less than about 2 wt.%, less than about 1 wt.%; from about 0.1 wt.% to about 25 wt.%, about 1 wt.% to about 5 wt.%, about 0.1 wt.% to about 1 wt.% or about 5 wt.% to about 10 wt.%); substantially no plasticizer (e.g., less than about 17 wt.%, less than about 15 wt.%, less than about 10 wt.%, less than about 5 wt.%, less than about 2 wt.%, less than about 1 wt.%; from about 0.1 wt.% to about 15 wt.%, about 1 wt.% to about 5 wt.%, about 0.1 wt.% to about 1 wt.%, about 5 wt.% to about 10 wt.% or about 0 wt.%); or no plasticizer whatsoever, such that the performance of the light responsive material encapsulated therein is not substantially adversely affected. For example, the light responsive material encapsulated in the interlayer can have a switching time after at least 200 hours (e.g., 500 hours) that does not substantially change (e.g., it changes less than 50%, less than 25%, less than 20%, less than 15%, less than 10%, less than 5%, less than 2%, less than 1 %, about 1 % to about 5%, about 0.1 % to about 2%, about 0.1 % to about 1 %, or at most about 1 % to about 10% over at least 200 hours) after thermal cycling, humidity cycling, and UV exposure in accordance with SAE J2412. See, e.g. , FIG. 1. As such, the probability that the light responsive material encapsulated within the interlayer will fail due to the presence of plasticizer is substantially minimized. Whereas when the interlayer has, e.g., about 28 wt.% plasticizer as is the case with commercially available PVB, the switching time is significantly adversely affected. See FIG. 2, where the change in switching time is dramatic relative to FIG. 1. In addition, it has been found that the durability of the light responsive material encapsulated in the laminates described herein can be significantly improved by using a sealant around the edges of the light responsive material. Such edge seals can consist of butyl rubber, urethane rubber, polyethylene vinyl acetate), composite rubber/moisture barrier films such as HelioSeal PVS 101. Such edge seals can act as moisture and/or oxygen barriers and protect the electrical connections of electrodes to conductive surfaces of encapsulated light responsive materials, including dynamic tinting films. Finally, it has been found that it is advantageous to have the edges of the light responsive material recessed in from the laminate edges so that the film is substantially completely encapsulated within the interlayer material or edge sealant. While not wishing to be bound by any specific theory, it is believed that recessing the light responsive films from laminate edges helps prevent oxygen and moisture ingress into the films that can cause their performance to degrade. Also recessing the films protects them from physical damage that could occur if they extended to the laminate edges.

[0016] Reference will now be made in detail to various embodiments, examples of which are illustrated in the accompanying drawings.

[0017] A first aspect of this disclosure pertains to laminates comprising first and second substrates; at least one interlayer having a low plasticizer content (e.g., less than about 28 wt.%, less than about 25 wt.%, less than about 20 wt.%, less than about 15 wt.%, less than about 10 wt.%, less than about 5 wt.%, less than about 2 wt.%, less than about 1 wt.%; from about 0.1 wt.% to about 25 wt.%, about 1 wt.% to about 5 wt.%, about 0.1 wt.% to about 1 wt.% or about 5 wt.% to about 10 wt.%); substantially no plasticizer (e.g., less than about 17 wt.%, less than about 15 wt.%, less than about 10 wt.%, less than about 5 wt.%, less than about 2 wt.%, less than about 1 wt.%; from about 0.1 wt.% to about 15 wt.%, about 1 wt.% to about 5 wt.%, about 0.1 wt.% to about 1 wt.%, about 5 wt.% to about 10 wt.% or about 0 wt.%); or no plasticizer whatsoever; and a light responsive material disposed (e.g., encapsulated) between the substrates. As shown in FIGS. 3A, 3B, and 4, the laminate 10 includes a first substrate 12 and a second substrate 16, which include an interlayer 14 and a light responsive material 1 1 disposed between the first substrate and the second substrate. In this example, the light responsive material is completely encapsulated in the interlayer 14 and the edges, 18 and 20 of the light responsive material, are recessed in from the laminate 10/interlayer 14 edges 24 and 26 so that the light responsive material is substantially completely encapsulated. In this example, the light responsive material 11 comprises edge sealant 22, which can be optionally present. The first substrate 12 includes a first surface 13, a second surface 15. The second substrate 16 includes a third surface 17 and a fourth surface 19.

[0018] FIG. 3C shows a laminate 10, wherein the laminate includes a first substrate 12 and a second substrate 16, which includes a first interlayer 14 and a first light responsive material 11 disposed between the first substrate and the second substrate; and a second light responsive material 1 T disposed within a second interlayer 14’. In this example, the first and second light responsive materials are completely encapsulated in the interlayer 14 and 14’, respectively, and the edges, 18 and 20/18’ and 20’ of the first and second light responsive materials, are recessed in from the laminate 10/interlayers 14/14’ edges 24 and 26 and 24’ and 26’ so that the first and second light responsive materials are substantially completely encapsulated. In this example, the first and second light responsive materials 1 1/1 1’ comprises edge sealant 22/22’, which can be optionally present. The first substrate 12 includes a first surface 13, a second surface 15. The second substrate 16 includes a third surface 17 and a fourth surface 19.

[0019] The disclosure also relates to a laminate comprising: a first substrate; an interlayer disposed on the first substrate; a light responsive material encapsulated in the interlayer, the interlayer having a plasticizer content such that the performance of a light responsive material therein is not substantially adversely affected; and a second substrate disposed on the interlayer, wherein: the laminate is optionally complexly curved; the first and second substrate are strengthened; the laminate has a stiffness of at least about 30 N/mm (e.g., at least about 40 N/mm, at least about 50 N/mm, at least about 60 N/mm, at least about 70 N/mm, at least about 80 N/mm, at least about 90 N/mm; from about 30 N/mm to about 100 N/mm, about 30 N/mm to about 90 N/mm, about 40 N/mm to about 60 N/mm, about 40 N/mm to about 90 N/mm or about 50 N/mm to about 90 N/mm— all of these ranges being applicable to the various other laminates disclosed herein); and the first and second substrate have a thickness of 1 mm or less.

[0020] As used herein, a "layer" refers to a material portion including a region having a substantially uniform thickness. A layer may extend over the entirety of an underlying or overlying structure or may have an extent less than the extent of an underlying or overlying structure. Further, a layer can be a region of a homogeneous or inhomogeneous contiguous structure that has a thickness less than the thickness of the contiguous structure. For example, a layer can be located between any pair of horizontal planes between, or at, a top surface and a bottom surface of the contiguous structure. A layer may extend horizontally, vertically, and/or along a tapered surface. A substrate can be a layer, can include one or more layers therein, or may have one or more layers thereupon, thereabove, and/or therebelow.

[0021] In one or more embodiments, the light responsive material comprises an electrochromic material, a photochromic material, a suspended particle material, a micro-blind material, a liquid crystal material or combinations thereof. The light responsive material changes the transmittance of the laminate between an opaque or translucent state and a transparent state. In some embodiments, the appearance state includes an opaque state on one surface of the laminate (e.g., reference numeral 13 in FIG. 3), and a translucent or transparent state on another surface (e.g., reference numeral 19 in FIG. 3), similar to a two- way mirror. In such embodiments, the electrochromic light responsive materials may provide a reflective surface on one surface of the laminate (e.g., reference numeral 13, FIG. 3), while the opposite surface (e.g., reference numeral 19, FIG. 3) remains translucent or transparent, and thus the appearance state changes between transparent and opaque or mirrorlike.

[0022] The light responsive material can be a multi-layer composite. The outer layers of the composite can be transparent conductive film layers such as ITO coated PET. Laminated between the conductive film layers is a film or a coating dynamic tinting material. The dynamic tinting film or coating can be electrochromic (EC), polymer dispersed liquid crystals (PDLC), dyed or pigmented PDLC, suspended particle device (SPD) or other dynamic tinting technology. The overall dynamic tinting film can be about 300 pm in thickness. For the case of electrochromic dynamic tinting, laminates transition between a low light transmission dark state to a transparent high light transmitting state upon application of a low voltage (0.5 to 1.5 volts dc) and then back to the dark state when voltage polarity is reversed.

[0023] The transparent state may have an average transmittance of 60% or greater over the visible spectrum. The translucent state may have an average transmittance in the range from about 10% up to about 60% over the visible spectrum (e.g., from about 400 nm to about 720 nm). The opaque state may have an average transmittance of less than 10% over the visible spectrum. In some embodiments, the transparent state may have about 60% or greater transmittance over the visible spectrum and an opaque state may have about 1 % transmittance over the visible spectrum.

[0024] In one or more embodiments, the light responsive material can be described as a darkening material. The light responsive material can be used to adjust the amount of light being transmitted through the laminate. Where a display unit is integrated into the laminate or being utilized otherwise, the light responsive material can adjust the light being transmitted through the laminate to the user or viewer to enhance the contrast of the displayed image at a surface of the laminate.

[0025] The adjustment between the appearance state can be controlled automatically (e.g., in response to exposure of the display surface to a particular wavelength of light, such as ultraviolet light, or in response to a signal generated by a light detector, such as a photoeye) or manually (e.g., by a user/viewer). In some instances, the change in appearance state between opaque or translucent and transparent can be actuated by a display unit (as will be described herein) being turned on, which can be combined with additional controls dependent on the amount of ambient light detected and/or a user or viewer's preference. In one or more embodiments, the change in appearance state between the opaque or translucent and transparent can be completed in less than about 10 minutes (e.g., less than about 5 minutes, less than about 2 minutes, or less than about 1 minute), depending on the size of the laminate.

[0026] Examples of electrochromic materials includes materials having light transmittance properties in response to voltage. Such materials can be disposed as a thin film by known deposition methods including vacuum deposition methods. The material can include W0₃, which is colorless until the insertion of hydrogen (H⁺) or alkali metal atoms (e.g., Li⁺, K⁺ or Na⁺) into interstitial sites of W0₃, at which point the material absorbs light and may take on a blue color. Such materials provide a user some degree of control over the transmittance through the material and thus the laminate. In one or more embodiments, the electrochromic material may change from a translucent state to a transparent state and vice versa. In some embodiments, the translucent state may exhibit a color to a viewer, or can be white or black. In such materials, the user actuates electricity to the material to initiate the change between a translucent state and a transparent state. Once the change occurs, electricity is no longer needed to maintain the appearance state. [0027] In one or more embodiments, photochromic materials include polymeric materials that change color under the influence of multi-color light or a monochromatic light (for example, UV light). Examples include naphthopyrans having a cyclic group annelated in position 6, 7. The photochromic materials can be integral with one or both substrates of the laminate. For example, one or both substrates can be glass and may have a composition that includes any one or more of Ag, Br, Cl and CuO. For example, the glass can include the composition disclosed in U.S. Patent No. 5,023,209, "Fast fading, high refractive index photochromic glass," which is incorporated by reference herein in its entirety. In other embodiments, the glass includes microcrystalline silver halides.

[0028] Photochromic glass can be made by fusion processes and/or chemically strengthened, as will be described below. In some embodiments, the photochromic material includes organic molecules (e.g., oxazines and/or naphthopyrans) in plastics or organic materials. The change between opaque or translucent and transparent can be achieved in less than about 5 minutes, less than about 2 minutes or less than about 1 minute. The transparent state may have an average transmittance of about 90% and the opaque or translucent state may have an average transmittance of about 15-20% over the visible spectrum. Photochromic materials are reliant on ambient environment for activation but can be used in combination with the other light responsive materials to provide dual activation (i.e., by a user or by the ambient environment).

[0029] Examples of suspended particle device (SPD) materials include thin films of rod- like nano-scale particles (which can be asymmetrical) that are suspended in a liquid, in some cases, the particles are light-absorbing and disposed in liquid bubbles embedded in a polymer matrix. The suspended particles are randomly oriented when in an inactive state (e.g., when no voltage is applied). The particles block and absorb light when in the inactive state. In the active state (e.g., when voltage is applied), the suspended particles align and permit light pass through the material and thus the laminate. The degree of voltage varies the degree of orientation. In this manner, the change between opaque or translucent and transparent can be varied. To activate the suspended particle device materials, various sensors (including photosensors and motion sensors), user applications and the like may be utilized. Suspended particle materials are believed to have a faster change time (e.g., less than 1 minute, less than 30 seconds or less than about 1 second), and thus, can be more useful in automotive applications when the ambient light environment can change quickly and drastically.

[0030] Micro-blind materials control the amount of light passing through in response to applied voltage. In some embodiments, the micro-blind materials can include switchable micro- electro-mechanical (MEMS) mirrors having dimensions that, when in an inactive state, the laminate is transparent, but in an active state, the laminate has an opaque or translucent appearance. The micro-blind materials can be formed using lithography and selective etching to provide the mirrors, which resemble louvers that open and close. More specifically, the micro-blind materials can include a metal layer deposited by known means (e.g., magnetron sputtering). The metal layer can be selectively etched by patterning by laser or lithography process. In some embodiments, a thin layer of a transparent conductive oxide (TCO) can be used along with a thin insulator that is deposited between the metal layer and the TCO layer for electrical disconnection. With no applied voltage, the micro-blinds are configured to permit light to pass through the laminate. The micro-blinds are configured to block or at least partially block light from passing through the laminate when there is a potential difference between the metal layer and the transparent conductive layer.

[0031] The micro-blind materials can incorporate an air gap to permit movement, while minimizing deflection of the mirrors. As with the suspended particle device materials, to activate the micro-blind materials, various sensors (including photosensors and motion sensors), user applications and the like can be utilized.

[0032] Examples of liquid crystal materials include polymer dispersed liquid crystal (PDLC) materials. In one or more embodiments, the liquid crystals are dissolved or dispersed into a liquid polymer. The polymer is then solidified and, during this process, the liquid crystals become incompatible with the solid polymer and form droplets throughout the solid polymer. The polymer and liquid crystals can be applied between the first and second substrate while in the liquid state with a thin layer of a transparent, conductive material. The polymer is then solidified. For activation, electrodes from a power supply are attached to the transparent electrodes. The liquid crystals are randomly oriented in the droplets when no voltage is applied, which results in light scattering as light is transmitted through the laminate (i.e., providing the opaque or translucent state). When a voltage is applied to the electrodes, the electric field formed between the two transparent electrodes on the glass causes the liquid crystals to align, permitting light to pass through the droplets with very little scattering and forming a transparent state. In some embodiments, the laminate appears white in the inactive state (when no voltage is applied) due to scattering by the liquid crystals. In some embodiments, a dye-doped polymer can be used to alterthe appearance of the laminate when in an inactive state. The dye-doped polymer provides light absorption and a darker color or appearance, while the liquid crystals provide scattering. The degree of transparency can be controlled by the applied voltage. The transparent state may have an average transmittance of about 75% or greater over the visible spectrum. The change between opaque or translucent and transparent can occur quickly (e.g., less than 1 minute, less than 30 seconds, or less than 1 minute).

[0033] In some embodiments, the light responsive material that are activated by voltage (i.e., electrochromic materials, PDLC materials, SPD materials and micro-blind materials) utilize a touch user interface that permits a user to apply voltage to select portions of the laminate to activate the light responsive material at the select portion(s). The light responsive material can be segmented so that portions are activated only in response to selective activation by the user (as opposed to the entire laminate changing appearance state when a user touches any portion of the touch user interface).

[0034] In some embodiments, the light responsive material darkens by providing absorption but does not provide a high degree of scattering. In some embodiments, a scattering layer can be added to the laminate to provide a surface that can function as a projection surface. The scattering layer can be disposed between the substrates, in front of the laminate with respect to the viewer or behind the laminate with respect to the viewer.

[0035] In one or more embodiments, the laminate can include a display unit disposed between the first and second substrate. In some instances, the display unit can be disposed between the interlayer and the second substrate or between the first substrate and the interlayer. In other embodiments, the display unit is integrally formed in one or both of the substrates. In yet other embodiments, the display unit is disposed behind the laminate or in front of the laminate, with respect to the viewer. The display unit can include an image panel comprising any one or more of a micro-LED array, an OLED array, an LCD array, a plasma cell array, and an electroluminescent (EL) cell array. In some embodiments, the display unit can be a projection source that utilizes the scattering surface formed by the light responsive materials or other layers, as described herein.

[0036] In one or more embodiments, the interlayer includes a polymer and can be made of a plurality of layers. Examples of polymer interlayers include materials such as, but not limited to, poly vinyl butyral (PVB; e.g., PVB with low plasticizer content such as Saflex® DG available from Eastman Chemical Company), polycarbonate, acoustic PVB, ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU), a thermoplastic material, and combinations thereof, so long as the interlayer material has a low plasticizer content (e.g., less than about 28 wt.%, less than about 25 wt.%, less than about 20 wt.%, less than about 15 wt.%, less than about 10 wt.%, less than about 5 wt.%, less than about 2 wt.%, less than about 1 wt.%; from about 0.1 wt.% to about 25 wt.%, about 1 wt.% to about 5 wt.%, about 0.1 wt.% to about 1 wt.% or about 5 wt.% to about 10 wt.%); substantially no plasticizer (e.g., less than about 17 wt.%, less than about 15 wt.%, less than about 10 wt.%, less than about 5 wt.%, less than about 2 wt.%, less than about 1 wt.%; from about 0.1 wt.% to about 15 wt.%, about 1 wt.% to about 5 wt.%, about 0.1 wt.% to about 1 wt.%, about 5 wt.% to about 10 wt.% or about 0 wt.%); or no plasticizer whatsoever, such that the performance of the light responsive material encapsulated therein is not substantially adversely affected. The interlayer may have a thickness of about 2 mm or less (e.g., about 1.7 or less, about 1.6 or less, about 1 .5 mm or less, or about 1 mm or less) and can include multiple sublayers of various compositions. In some embodiments, the interlayer comprises a stiff acoustic interlayer, since stiff acoustic interlayer interlayers can have higher shear modulus than conventional PVB interlayers (e.g., at least about 10 times greater shear modulus than conventional PVB at 20°C). Higher shear modulus increases laminate stiffness thus off-setting lower stiffness of thin laminate constructions. In addition to higher shear modulus, stiff acoustic interlayers also have a high level of acoustic damping that results in lower sound transmission through laminated glazing panels. For example, the acoustic attenuation, as measured by sound transmission loss, is higher for stiffened laminates described herein at frequencies above 5000 Hz than laminates of comparable thickness made using industry standard acoustic polyvinyl butyral (PVB). See FIG. 7, which is a plot of sound transmission loss (STL) vs. frequency for 2.1 mm SLG/ lnterlayer/0.7 Gorilla Glass® laminates where the interlayer is either a stiff acoustic interlayer or QP51 acoustic PVB from Eastman. Higher STL means less sound transmission through the laminates. STL of stiff acoustic interlayer laminates is 0.9 dB less than QP51 laminates at 3150 Hz but is 2.5 dB higher at 6300 Hz. These laminates do not comprise light responsive material. But it is not expected that the presence of light responsive material will have any effect on STL. In sum, laminates of the disclosure include those having a STL at above about 5000 Hz (e.g., between about 5000 Hz and about 10,000 Hz) of from about 35 to about 45 dB.

[0037] In various examples and non-limiting embodiments, one or more of the first and second substrate (12,16) can comprise a glass material (e.g., soda lime glass, alkali aluminosilicate glass, alkali containing borosilicate glass and/or alkali aluminoborosilicate glass), a glass- ceramic material, a polymeric material, and/or a poly-ceramic material. The substrate can, in various embodiments, be provided as a single sheet or as part of a laminate or stacked structure. A laminate or stacked structure can be employed for the substrate, the layers of the substrate can be chosen from the same or different materials, and the layers of the substrate may directly physically contact one another or can be separated from one another by an intervening layer (such as an adhesive layer) or by a gap (e.g., an air gap).

[0038] Glass materials used in embodiments of the laminate can be provided using a variety of different processes. For instance, the glass material can be formed using known forming methods including float glass processes and down-draw processes such as fusion draw and slot draw. In some embodiments, the glass material can be formed from a "phase-separable" glass composition which may undergo phase separation into two or more distinct phases upon exposure to a phase separation treatment, such as a heat treatment or the like, to produce a "phase separated" glass including distinct glass phases having different compositions.

[0039] A glass material prepared by a float glass process can be characterized by smooth surfaces and uniform thickness is made by floating molten glass on a bed of molten metal, typically tin. In an example process, molten glass that is fed onto the surface of the molten tin bed forms a floating glass ribbon. As the glass ribbon flows along the tin bath, the temperature is gradually decreased until the glass ribbon solidifies into a solid glass material that can be lifted from the tin onto rollers. Once off the bath, the glass material can be cooled further and annealed to reduce internal stress.

[0040] Down-draw processes produce glass materials having a uniform thickness that possess relatively pristine surfaces. Because the average flexural strength of glass materials is controlled by the amount and size of surface flaws, a pristine surface that has had minimal contact has a higher initial strength. When this high strength glass material is then further strengthened (e.g., chemically or thermally), the resultant strength can be higher than that of a glass material with a surface that has been lapped and polished. Down-drawn glass materials can be drawn to a thickness of less than about 2 mm. In addition, down drawn glass materials have a very flat, smooth surface that can be used in its final application without additional grinding and polishing steps.

[0041] The glass material can be formed using a fusion draw process, for example, which uses a drawing tank that has a channel for accepting molten glass raw material. The channel has weirs that are open at the top along the length of the channel on both sides of the channel. When the channel fills with molten material, the molten glass overflows the weirs. Due to gravity, the molten glass flows down the outside surfaces of the drawing tank as two flowing glass films. These outside surfaces of the drawing tank extend down and inwardly so that they join at an edge below the drawing tank. The two flowing glass films join at this edge to fuse and form a single flowing glass material. The fusion draw method offers the advantage that, because the two glass films flowing over the channel fuse together, neither of the outside surfaces of the resulting glass material comes in contact with any part of the apparatus. Thus, the surface properties of the fusion drawn glass material are not affected by such contact.

[0042] The slot draw process is distinct from the fusion draw method. In slot draw processes, the molten raw material glass is provided to a drawing tank. The bottom of the drawing tank has an open slot with a nozzle that extends the length of the slot. The molten glass flows through the slot/nozzle and is drawn downward as a continuous material and into an annealing region.

[0043] In some embodiments, the compositions used for the glass material making up first substrate 12 or second substrate 16 can be batched with about 0 mol% to about 2 mol. % of at least one fining agent selected from a group that includes Na₂S0 , NaCI, NaF, NaBr, K₂S0₄, KCI, KF, KBr, and Sn0₂.

[0044] Once formed, the glass substrate can be strengthened to form a strengthened glass material. It should be noted that glass-ceramics described herein may also be strengthened in the same manner as glass materials. As used herein, the term "strengthened material" generally refers to a glass material or a glass-ceramic material that has been chemically strengthened, for example through ion-exchange of larger ions for smaller ions in the surface of the glass or glass-ceramic material. However, other strengthening methods known in the art, such as thermal tempering, can be utilized to form strengthened glass materials and/or glass-ceramic materials. In some embodiments, the materials can be strengthened using a combination of chemical strengthening processes and thermally strengthening processes.

[0045] The strengthened materials described herein can be chemically strengthened by an ion exchange process. In the ion-exchange process, typically by immersion of a glass or glass- ceramic material into a molten salt bath for a predetermined period of time, ions at or near the surface(s) of the glass or glass-ceramic material are exchanged for larger metal ions from the salt bath. In one embodiment, the temperature of the molten salt bath is in the range from about 400°C to about 430°C and the predetermined time period is about four to about twenty four hours; however the temperature and duration of immersion may vary according to the composition of the material and the desired strength attributes. The incorporation of the larger ions into the glass or glass-ceramic material strengthens the material by creating a compressive stress in a near surface region or in regions at and adjacent to the surface(s) of the material. A corresponding tensile stress is induced within a central region or regions at a distance from the surface(s) of the material to balance the compressive stress. Glass or glass- ceramic materials utilizing this strengthening process can be described more specifically as chemically-strengthened or ion-exchanged glass or glass-ceramic materials.

[0046] In one example, sodium ions in a strengthened glass or glass-ceramic material are replaced by potassium ions from the molten bath, such as a potassium nitrate salt bath, though other alkali metal ions having larger atomic radii, such as rubidium or cesium, can replace smaller alkali metal ions in the glass. According to particular embodiments, smaller alkali metal ions in the glass or glass-ceramic can be replaced by Ag⁺ ions. Similarly, other alkali metal salts such as, but not limited to, sulfates, phosphates, halides, and the like can be used in the ion exchange process.

[0047] The replacement of smaller ions by larger ions at a temperature below that at which the glass network can relax produces a distribution of ions across the surface(s) of the strengthened material that results in a stress profile. The larger volume of the incoming ion produces a compressive stress (CS) on the surface and tension (central tension, or CT) in the center of the strengthened material. The compressive stress is related to the central tension by the following relationship:

where t is the total thickness of the strengthened glass or glass-ceramic material and compressive depth of layer (DOL) is the depth of exchange. Depth of exchange can be described as the depth within the strengthened glass or glass-ceramic material (i.e., the distance from a surface of the glass material to a central region of the glass or glass-ceramic material), at which ion exchange facilitated by the ion exchange process takes place.

[0048] In one embodiment, a strengthened glass or glass-ceramic material can have a surface compressive stress of about 300 MPa or greater, e.g., 400 MPa or greater, 450 MPa or greater, 500 MPa or greater, 550 MPa or greater, 600 MPa or greater, 650 MPa or greater, 700 MPa or greater, 750 MPa or greater or 800 MPa or greater. The strengthened glass or glass-ceramic material may have a compressive depth of layer of about 15 pm or greater, 20 pm or greater (e.g., 25 pm, 30 pm, 35 pm, 40 pm, 45 pm, 50 pm or greater) and/or a central tension of about 10 MPa or greater, 20 MPa or greater, 30 MPa or greater, 40 MPa or greater (e.g., 42 MPa, 45 MPa, or 50 MPa or greater) but less than 100 MPa (e.g., 95, 90, 85, 80, 75, 70, 65, 60, 55 MPa or less). In one or more specific embodiments, the strengthened glass or glass-ceramic material has one or more of the following: a surface compressive stress greater than about 200 MPa, a depth of compressive layer greater than about 15 pm, and a central tension greater than about 18 MPa. In one or more embodiments, one or both of the first substrate and the second substrate is strengthened, as described herein. In some instances, both the first substrate and the second substrate are strengthened. The first substrate can be chemically strengthened, while the second substrate is thermally strengthened. In some instances, only one of the first substrate and the second substrate are chemically and/or thermally strengthened, while the other is not strengthened.

[0049] Any number of glass compositions can be employed in the glass material and include alkali aluminosilicate glass compositions or alkali aluminoborosilicate glass compositions, though other glass compositions are contemplated. Such glass compositions may be characterized as ion exchangeable. As used herein, "ion exchangeable" means that a material comprising the composition is capable of exchanging cations located at or near the surface of the material with cations of the same valence that are either larger or smaller in size.

[0050] For example, a suitable glass composition comprises Si0₂, B₂0₃ and Na₂0, where (Si0₂ + B₂0₃) > 66 mol.%, and Na₂0 > 9 mol.%. In an embodiment, the glass sheets include at least 6 wt.% aluminum oxide. In a further embodiment, a glass sheet includes one or more alkaline earth oxides, such that a content of alkaline earth oxides is at least 5 wt.%. Suitable glass compositions, in some embodiments, further comprise at least one of K₂0, MgO, and CaO. In a particular embodiment, the glass can comprise 61-75 mol.% Si0₂; 7-15 mol.% Al₂0₃; 0-12 mol.% B₂0₃; 9-21 mol.% Na₂0; 0-4 mol.% K₂0; 0-7 mol.% MgO; and 0-3 mol.% CaO.

[0051] A further example glass composition suitable for forming hybrid glass laminates comprises: 60-70 mol.% Si0₂; 6-14 mol.% Al₂0₃; 0-15 mol.% B₂0₃; 0-15 mol.% U₂0; 0-20 mol.% Na₂0; 0-10 mol.% K₂0; 0-8 mol.% MgO; 0-10 mol.% CaO; 0-5 mol.% Zr0₂; 0-1 mol.% Sn0₂; 0-1 mol.% Ce0₂; less than 50 ppm As₂0₃; and less than 50 ppm Sb203; where 12 mol.% < (U₂0 + Na₂0 + K₂0) < 20 mol.% and 0 mol.% < (MgO + CaO) < 10 mol.%. [0052] A still further example glass composition comprises: 63.5-66.5 mol.% Si0₂; 8-12 mol.% AI2O3; 0-3 mol.% B₂0₃; 0-5 mol.% U₂0; 8-18 mol.% Na₂0; 0-5 mol.% K₂0; 1-7 mol.% MgO; 0-2.5 mol.% CaO; 0-3 mol.% Zr0₂; 0.05-0.25 mol.% Sn0₂; 0.05-0.5 mol.% Ce0₂; less than 50 ppm AS₂0₃; and less than 50 ppm Sb203; where 14 mol.% < (Li₂0 + Na₂0 + K₂0) < 18 mol.% and 2 mol.% < (MgO + CaO) < 7 mol.%.

[0053] In another embodiment, an alkali aluminosilicate glass comprises, consists essentially of, or consists of: 61-75 mol.% Si0₂; 7-15 mol.% Al₂0₃; 0-12 mol.% B₂0₃; 9-21 mol.% Na₂0; 0-4 mol.% K₂0; 0-7 mol.% MgO; and 0-3 mol.% CaO.

[0054] In a particular embodiment, an alkali aluminosilicate glass comprises alumina, at least one alkali metal and, in some embodiments, greater than 50 mol.% Si0₂, in other embodiments at least 58 mol.% Si0₂, and in still other embodiments at least 60 mol.% Si0₂, wherein the ratio:

(Al₂0₃ + B₂0₃)/å modifiers > 1

where in the ratio the components are expressed in mol.% and the modifiers are alkali metal oxides. This glass, in particular embodiments, comprises, consists essentially of, or consists of: 58-72 mol.% Si0₂; 9-17 mol.% Al₂0₃; 2-12 mol.% B₂0₃; 8-16 mol.% Na₂0; and 0-4 mol.% K₂0, wherein the ratio:

(Al₂0₃ + B₂0₃)/å modifiers > 1

[0055] In yet another embodiment, an alkali aluminosilicate glass substrate comprises, consists essentially of, or consists of: 60-70 mol.% Si0₂; 6-14 mol.% Al₂0₃; 0-15 mol.% B₂0₃; 0-15 mol.% U₂0; 0-20 mol.% Na₂0; 0-10 mol.% K₂0; 0-8 mol.% MgO; 0-10 mol.% CaO; 0-5 mol.% Zr0₂; 0-1 mol.% Sn0₂; 0-1 mol.% Ce0₂; less than 50 ppm As₂0₃; and less than 50 ppm Sb₂0₃; wherein 12 mol.% < U₂0 + Na₂0 + K₂0 < 20 mol.% and 0 mol.% < MgO + CaO < 10 mol.%.

[0056] In still another embodiment, an alkali aluminosilicate glass comprises, consists essentially of, or consists of: 64-68 mol.% Si0₂; 12-16 mol.% Na₂0; 8-12 mol.% Al₂0₃; 0-3 mol.% B₂0₃; 2-5 mol.% K₂0; 4-6 mol.% MgO; and 0-5 mol.% CaO, wherein: 66 mol.%< Si0₂ + B₂0₃ + CaO < 69 mol.%; Na₂0 + K₂0 + B₂0₃ + MgO + CaO + SrO >10 mol.%; 5 mol.% < MgO + CaO + SrO < 8 mol.%; (Na₂0 + B₂0₃) < Al₂0₃ < 2 mol.%; 2 mol.% < Na₂0 < Al₂0₃ < 6 mol.%; and 4 mol.% < (Na₂0 + K₂0) < Al₂0₃ < 10 mol.%. Additional examples for generating ion exchangeable glass structures are described in Published U.S. Appl. No. US 2014- 0087193 A1 and U.S. Patent No. 9,387,651 the entirety of each being incorporated herein by reference.

[0057] In an alternative embodiment, the glass material comprises an alkali aluminosilicate glass composition comprising: 2 mol% or more of Al₂0₃ and/or Zr0₂, or 4 mol% or more of Al₂0₃ and/or Zr0₂. [0058] In some embodiments, the laminate 10 comprises a glass-ceramic material that can be fusion-formed or formed by other known methods such as rolling, thin-rolling, slot draw or float.

[0059] Glass-ceramics that can be used in various embodiments of the laminate 10 can be characterized by the processes by which they can be formed. Such glass-ceramics can be formed by float processes, fusion processes, slot draw process, thin rolling processes, or a combination thereof. Some glass-ceramics tend to have liquid viscosities that preclude the use of high throughput forming methods such as float, slot draw, or fusion draw. For example, some known glass-ceramics are formed from precursor glasses having liquidus viscosities of about 10 kP, which are not suitable for fusion draw, where liquidus viscosities of above about 100 kP or above about 200 kP are generally required. Glass-ceramics formed by the low throughput forming methods (e.g., thin rolling) may exhibit enhanced opacity, various degrees of translucency, and/or surface luster. Glass-ceramics formed by high throughout methods (e.g., float, slot draw, or fusion draw) can achieve very thin layers. Glass-ceramics formed by fusion draw methods may achieve pristine surfaces and thinness (e.g., about 2 mm or less). Examples of suitable glass-ceramics can include Li₂0-AI₂0₃-Si0₂ system (i.e. LAS-System) glass-ceramics, Mg0-AI₂0₃-Si0₂ system (i.e. MAS-System) glass-ceramics, glass-ceramics including crystalline phases of any one or more of mullite, spinel, a-quartz, b-quartz solid solution, petalite, lithium disilicate, b-spodumene, nepheline, and alumina, and combinations thereof.

[0060] In one or more embodiments, one or both the first and second substrate (12/16) comprise a thickness of about 3 mm or less. In some instances, one of the first and the second substrate has a thickness of about 1 mm to about 3 mm (e.g., from about 1 mm to about 2.8 mm, from about 1 mm to about 2.6 mm, from about 1 mm to about 2.5 mm, from about 1 mm to about 2.4 mm, from about 1 mm to about 2.1 mm, from about 1 mm to about 2 mm, from about 1 mm to about 1.8 mm, from about 1 mm to about 1.6 mm, from about 1 mm to about 1.4 mm, from about 1.2 mm to about 3 mm, from about 1.4 mm to about 3 mm, from about 1.6 mm to about 3 mm, or from about 1.8 mm to about 3 mm), and the other of the first and the second substrate has a thickness of less than 1 mm (e.g., about 0.9 mm or less, about 0.8 mm or less, about 0.7 mm or less, about 0.5 mm or less, about 0.55 mm or less, about 0.4 mm or less, about 0.3 mm or less, or about 0.2 mm or less). The combination of thicknesses for the first substrate and the second substrate can include but are not limited to 2.1 mm/0.7 mm, 2.1 mm/0.5 mm, 1.8 mm/0.7 mm, 1.8 mm/0.5 mm, 1.6 mm/0.5 mm, 1 mm/0.7 mm, and 1 mm/0.5 mm.

[0061] The laminates of the disclosure generally have a stiffness of at least about 90 N/mm, at least about 95 N/mm, at least about 99 N/mm; from about 90 N/mm to about 100 N/mm, about 95 N/mm to about 100 N/mm, or about 97 N/mm to about 100 N/mm as determined using a ball on ring method for determining stiffness at a rate of deformation of 0.0017 mm/sec. FIG. 8 is a plot of stiffness results for laminates with a stiff acoustic interlayer compared with acoustic PVB.

[0062] In one or more embodiments, the laminate may have a complexly curved shape. As used herein, "complex curve", "complexly curved", "complex curved substrate" and "complexly curved substrate" mean a non-planar shape having compound curves, also referred to as non- developable shapes, which include but are not limited to a spherical surface, an aspherical surface, and a toroidal surface, where the curvature of two orthogonal axes (horizontal and vertical one) are different, which can be for example a toroidal shape, an oblate spheroid, oblate ellipsoid, prolate spheroid, prolate ellipsoid, or where the surface's principle curvature along two orthogonal planes are opposite, for example a saddle shape or surface, such as a horse or monkey saddle. Other examples of complex curves include, but are not limited to, an elliptic hyperboloid, a hyperbolic paraboloid, and a spherocylindrical surface, where the complex curves may have constant or varying radii of curvature. The complex curve may also include segments or portions of such surfaces, or be comprised of a combination of such curves and surfaces. In one or more embodiments, a laminate may have a compound curve including a major radius and a cross curvature. The curvature of the laminate can be even more complex when a significant minimum radius is combined with a significant cross curvature, and/or depth of bend. Some laminates may also require bending along axes of bending that are not perpendicular to the longitudinal axis of the flat glass substrate.

[0063] In one or more embodiments, the laminate may have radii of curvature along two orthogonal axes. In various embodiments, the laminate can be asymmetrical. Some laminates may also include bending along axes that are not perpendicular to the longitudinal axis of the substrates, prior to forming (i.e., a flat surface or flat substrate).

[0064] In one or more embodiments, the radii of curvature can be less than 1000 mm, or less than 750 mm, or less than 500 mm, or less than 300 mm. In various embodiments, the laminate is substantially free of wrinkles or optical distortions, including at the edges of the laminate.

[0065] In one or more embodiments, the laminate can be characterized as a cold-formed laminate. In such embodiments, the laminate includes first curved substrate and a substantially planar second substrate, wherein the second substrate is cold formed to the curvature of the first substrate.

[0066] As used herein, cold form includes a forming process in which the substrates and/or the laminate is formed at a temperature less than the softening temperature of the first and second substrates to provide a complexly curved laminate.

[0067] Embodiments of the cold formed laminate can include at least one interlayer and at least one light responsive material, as both described herein, disposed between the first and second substrate. The cold formed laminate can include a display unit as described herein. In one or more embodiments, the second substrate is strengthened by forming to the curvature of the first substrate. The cold-formed laminate can be complexly curved as described herein.

[0068] FIGS. 5 and 6 generally describe a cold forming method wherein a flat substrate 230 can be laminated to a curved substrate 210, which can be complexly curved. In one or more embodiments, the complexly-curved substrate 210 has a convex surface 214 and a concave surface 212. The interlayer 220 may function as a bonding layer 220 when applied to the concave surface 212 leaving an exposed concave surface 222 to bond with the flat substrate 230. In other embodiments, the flat substrate 230 is formed to the curved substrate 210 without the interlayer 220 and the two separate substrates with the same curvature are then bonded to the interlayer 220 in a separate step. In various embodiments, the flat substrate 230 can be pressed against the exposed concave surface 222 of bonding layer 220, where the flat substrate 230 deforms to take on the shape of curved substrate 210. The resulting laminate is complexly curved.

[0069] The laminates described herein can be utilized in vehicles such as automobiles, boats, and airplanes (e.g., glazing such as windshields, windows or sidelites, mirrors, pillars, side panels of a door, headrests, dashboards, consoles, or seats of the vehicle, or any portions thereof), architectural fixtures or structures (e.g., internal or external walls of building, and flooring), appliances (e.g., a refrigerator, an oven, a stove, a washer, a dryer, or another appliance), consumer electronics (e.g., televisions, laptops, computer monitors, and handheld electronics such as mobile phones, tablets, and music players), furniture, information kiosks, retail kiosks, and the like.

[0070] A second aspect of this disclosure pertains to a method of forming a laminate. In one or more embodiments, the method includes providing a first substrate and a second substrate, laminating the first and second substrates to at least one interlayer and at least one light responsive material to form a laminate such that the interlayer and the light responsive material are disposed between the first and second substrate, and shaping the laminate to a complex curved shape. In one or more embodiments, the method incudes strengthening one or both of the substrates, as described herein. In one or more embodiments, the individual substrates can be heated in a lehr that is comprised of a number of furnaces arranged in series in which the temperature of the substrate(s) is gradually raised to accomplish sagging under gravity, prior to lamination. Systems for shaping the laminate and/or substrate(s) can include a shaping mold, a radiation heating source, and a radiation shield, wherein the radiation shield is positioned substantially between the radiation heating source and the laminate and/or substrate(s).

[0071] In one or more embodiments, the method includes cold forming a laminate. The method includes providing a curved first substrate, a substantially planar second substrate, at least one polymer interlayer and at least one light responsive material between the first and second substrate, and laminating the first substrate, second substrate, polymer interlayer and light responsive material together at a temperature less than the softening temperature of the first and second substrates to provide a complexly curved laminate. In one or more embodiments, laminating includes forming the second substrate to the curved shape of the first substrate. In some embodiments, the light responsive material is integral to the substrates and thus, the method includes providing a curved first substrate, a substantially planar second substrate, and at least one polymer interlayer between the first and second substrate, and laminating the first substrate, second substrate, and polymer interlayer together at a temperature less than the softening temperature of the first and second substrates to provide a complexly curved laminate.

[0072] In some instances, the interlayer is laminated to the substrates as a separate step, and thus, the method includes laminating the curved first substrate and the planar second substrate together at a temperature less than the softening temperature of the first and second substrates to provide two complexly curved substrates, which are then laminated to the interlayer and optionally the light responsive material to provide a laminate that is complexly curved.

[0073] It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the spirit or scope of the present disclosure.

[0074] While this description can include many specifics, these should not be construed as limitations on the scope thereof, but rather as descriptions of features that can be specific to particular embodiments. Certain features that have been heretofore described in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, although features can be described above as acting in certain combinations and can even be initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination can be directed to a subcombination or variation of a subcombination.

[0075] Similarly, while operations are depicted in the drawings or figures in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing can be advantageous.

[0076] In the foregoing description, like reference characters designate like or corresponding parts throughout the several views shown in the figures. It is also understood that, unless otherwise specified, terms such as“top,”“bottom,”“outward,”“inward,” and the like are words of convenience and are not to be construed as limiting terms. In addition, whenever a group is described as comprising at least one of a group of elements and combinations thereof, it is understood that the group may comprise, consist essentially of, or consist of any number of those elements recited, either individually or in combination with each other.

[0077] Similarly, whenever a group is described as consisting of at least one of a group of elements or combinations thereof, it is understood that the group may consist of any number of those elements recited, either individually or in combination with each other. Unless otherwise specified, a range of values, when recited, includes both the upper and lower limits of the range. As used herein, the indefinite articles“a,” and“an,” and the corresponding definite article“the” mean“at least one” or“one or more,” unless otherwise specified.

[0078] The term“about” as used herein can allow for a degree of variability in a value or range, for example, within 10%, within 5%, or within 1 % of a stated value or of a stated limit of a range.

[0079] The term“substantially” as used herein refers to a majority of, or mostly, as in at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more.

[0080] The term“substantially no” as used herein refers to less than about 30%, 25%, 20%, 15%, 10%, 5%, 3%, 2%, 1 %, 0.5%, 0.1 %, 0.05%, 0.001 %, or at less than about 0.0005% or less or about 0% or 0%.

[0081] Those skilled in the art will appreciate that many modifications to the embodiments described herein are possible without departing from the spirit and scope of the present disclosure. Thus, the description is not intended and should not be construed to be limited to the examples given but should be granted the full breadth of protection afforded by the appended claims and equivalents thereto. In addition, it is possible to use some of the features of the present disclosure without the corresponding use of other features. Accordingly, the foregoing description of or illustrative embodiments is provided for the purpose of illustrating the principles of the present disclosure and not in limitation thereof and can include modification thereto and permutations thereof.

[0082] Select embodiments of the present disclosure include, but are not limited to, the following:

[0083] Embodiment 1 relates to a laminate comprising: a first substrate; an interlayer disposed on the first substrate; a light responsive material encapsulated in the interlayer, the interlayer having a plasticizer content such that the performance of a light responsive material therein is not substantially adversely affected; and a second substrate disposed on the interlayer, wherein the laminate is optionally complexly curved.

[0084] Embodiment 2 relates to a roof (e.g., automotive roof) laminate comprising: a first substrate; an interlayer disposed on the first substrate; a light responsive material encapsulated in the interlayer, the interlayer having a plasticizer content such that the performance of a light responsive material therein is not substantially adversely affected; and a second substrate disposed on the interlayer, wherein: the laminate is optionally complexly curved; the laminate has a stiffness of at least 90 N/mm; and the second substrate has a thickness of 1 mm or less.

[0085] Embodiment 3 relates to the roof laminate of Embodiment 2, wherein, in use, the second substrate faces an interior of an automobile.

[0086] Embodiment 4 relates to the laminate of Embodiments 1 or 2, wherein the laminate comprises a first light responsive material encapsulated in a first interlayer and a second light responsive material encapsulated in a second interlayer.

[0087] Embodiment 5 relates to the laminate of Embodiments 1 or 2, wherein the interlayer has low plasticizer content; substantially no plasticizer; or no plasticizer whatsoever.

[0088] Embodiment 6 relates to the laminate of Embodiments 1 or 2, wherein the light responsive material encapsulated in the interlayer has a switching time after at least 200 hours that does not substantially change.

[0089] Embodiment 7 relates to the laminate of Embodiment 6, wherein the light responsive material has a switching time after at least 200 hours that changes less than 10% over at least 200 hours.

[0090] Embodiment 8 relates to the laminate of Embodiment 1 , wherein the laminate has a stiffness of at least 90 N/mm.

[0091] Embodiment 9 relates to the laminate of Embodiment 1 , wherein the laminate has a stiffness of from about 90 N/mm to about 100 N/mm.

[0092] Embodiment 10 relates to the laminate of Embodiments 1 -9, wherein the laminate has a higher sound transmission loss (STL) at frequencies above 5000 Hz than laminates of comparable thickness made using acoustic polyvinyl butyral (PVB).

[0093] Embodiment 1 1 relates to the laminate of Embodiments 1-10, wherein the laminate has a sound transmission loss (STL) at above about 5000 Hz of from about 35 to about 45 dB.

[0094] Embodiment 12 relates to the laminate of Embodiments 1-1 1 , wherein the light responsive material comprises edges and the edges are recessed in from laminate edges so that the film is substantially completely encapsulated within the interlayer material.

[0095] Embodiment 13 relates to the laminate of Embodiments 1-12, wherein the light responsive material comprises edges and the edges each comprises edge sealant.

[0096] Embodiment 14 relates to the laminate of Embodiments 1-13, wherein the light responsive material comprises any one or more of an electrochromic material, a photochromic material, a suspended particle material, a micro-blind material, and a liquid crystal material. [0097] Embodiment 15 relates to the laminate of Embodiments 1-14, further comprising a display unit, wherein the display unit is disposed between the first substrate and second substrate, integral to one or both the first substrate and the second substrate, or disposed behind the laminate with respect to a user.

[0098] Embodiment 16 relates to the laminate of Embodiment 15, wherein the display unit comprises an image panel comprising any one or more of a micro-LED array, an OLED array, a LCD array, a plasma cell array, and an electroluminescent (EL) cell array.

[0099] Embodiment 17 relates to the laminate of Embodiments 1-15, wherein the interlayer comprises a polymer and either one or both the first substrate and the second substrate is strengthened.

[00100] Embodiment 18 relates to the laminate of Embodiments 1-16, wherein the first substrate is strengthened and comprises first and second surfaces, the second surface being adjacent the interlayer, and the second substrate comprises third and fourth surfaces, the third surface being adjacent the interlayer and the fourth surface being opposite the third surface.

[00101] Embodiment 19 relates to the laminate of Embodiment 18, wherein the first surface comprises a surface compressive stress of greater than about 200 MPa and a depth of layer of compressive stress of greater than about 30 pm.

[00102] Embodiment 20 relates to the laminate of Embodiments 1-19, wherein either one or both the first and second substrate comprise a thickness of about 2.1 mm or less.

[00103] Embodiment 21 relates to the laminate of Embodiments 17-20, wherein the strengthened substrate comprises a thickness of about 1.0 mm or less.

[00104] Embodiment 22 relates to the laminate of Embodiments 1-21 , wherein the interlayer comprises a material selected from the group consisting of poly vinyl butyral (PVB), polycarbonate, acoustic PVB, ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU), a thermoplastic material, and combinations thereof.

[00105] Embodiment 23 relates to the laminate of Embodiments 1-22, wherein the interlayer comprises a stiff acoustic interlayer.

[00106] Embodiment 24 relates to the laminate of Embodiments 1 and 4-23, wherein the thickness of the interlayer is less than about 1.6 mm.

[00107] Embodiment 25 relates to the laminate of Embodiments 1-24, wherein at least one of the first and second substrate comprises a glass material, a glass-ceramic material, a polymeric material or a poly-ceramic material.

[00108] Embodiment 26 relates to an article comprising the laminate Embodiments 1-25, wherein the article comprises any one of a vehicle, an architectural fixture, an architectural structure, an appliance a consumer electronic device, furniture, an information kiosk, and a retail kiosk. [00109] Embodiment 27 relates to an automotive roof comprising the laminate of Embodiment 1.

[00110] Embodiment 28 relates to a method of forming a laminate comprising:

laminating a first substrate and a second substrate to at least one interlayer and at least one light responsive material to form a laminate such that the interlayer and the light responsive material are disposed between the first and second substrate; optionally shaping the laminate to a complex curved shape; and optionally strengthening one or both of the first and second substrates.

[00111] Embodiment 29 relates to the method of Embodiment 28, wherein strengthening one or both of the first and second substrates comprises chemically strengthening or thermally strengthening both the first and second substrates.

[00112] Embodiment 30 relates to the method of Embodiment 28, wherein the shaping is carried out before the strengthening.

[00113] Embodiment 31 relates to the method of Embodiment 28, wherein the strengthening is carried out before the shaping.

[00114] Embodiment 32 relates to the method of Embodiments 28-31 , further comprising disposing a display unit between the first and second substrate.

[00115] Embodiment 33 relates to a laminate comprising:

a first substrate; an interlayer disposed on the first substrate; a light responsive material encapsulated in the interlayer, the interlayer having a plasticizer content such that the performance of a light responsive material therein is not substantially adversely affected; and a second substrate disposed on the interlayer, wherein: the laminate is optionally complexly curved; the first and second substrate are strengthened; the laminate has a stiffness of at least 30 N/mm; and both the first and second substrate have a thickness of 1 mm or less.

Claims

What is claimed is:

1. A laminate comprising:

a first substrate;

an interlayer disposed on the first substrate;

a light responsive material encapsulated in the interlayer, the interlayer having a plasticizer content such that the performance of a light responsive material therein is not substantially adversely affected; and a second substrate disposed on the interlayer,

wherein the laminate is optionally complexly curved.

2. A roof laminate comprising:

a first substrate;

an interlayer disposed on the first substrate;

a light responsive material encapsulated in the interlayer, the interlayer having a plasticizer content such that the performance of a light responsive material therein is not substantially adversely affected; and a second substrate disposed on the interlayer,

wherein:

the laminate is optionally complexly curved;

the laminate has a stiffness of at least 90 N/mm; and

the second substrate has a thickness of 1 mm or less.

3. The roof laminate of claim 2, wherein, in use, the second substrate faces an interior of an automobile.

4. The laminate of claim 1 or 2, wherein the laminate comprises a first light responsive material encapsulated in a first interlayer and a second light responsive material encapsulated in a second interlayer.

5. The laminate of claim 1 or 2, wherein the interlayer has low plasticizer content; substantially no plasticizer; or no plasticizer whatsoever.

6. The laminate of claim 1 or 2, wherein the light responsive material

encapsulated in the interlayer has a switching time after at least 200 hours that does not substantially change.

7. The laminate of claim 6, wherein the light responsive material has a switching time after at least 200 hours that changes less than 10% over at least 200 hours.

8. The laminate of claim 1 , wherein the laminate has a stiffness of at least 90 N/mm.

9. The laminate of claim 1 , wherein the laminate has a stiffness of from about 90 N/mm to about 100 N/mm.

10. The laminate of any preceding claim, wherein the laminate has a higher sound transmission loss (STL) at frequencies above 5000 Hz than laminates of comparable thickness made using acoustic polyvinyl butyral (PVB).

11. The laminate of any preceding claim, wherein the laminate has a sound

transmission loss (STL) at above about 5000 Hz of from about 35 to about 45 dB.

12. The laminate of any preceding claim, wherein the light responsive material comprises edges and the edges are recessed in from laminate edges so that the film is substantially completely encapsulated within the interlayer material.

13. The laminate of any preceding claim, wherein the light responsive material comprises edges and the edges each comprise edge sealant.

14. The laminate of any preceding claim, wherein the light responsive material comprises any one or more of an electrochromic material, a photochromic material, a suspended particle material, a micro-blind material, and a liquid crystal material.

15. The laminate of any preceding claim, further comprising a display unit,

wherein the display unit is disposed between the first substrate and second substrate, integral to one or both the first substrate and the second substrate, or disposed behind the laminate with respect to a user.

16. The laminate of claim 15, wherein the display unit comprises an image panel comprising any one or more of a micro-LED array, an OLED array, a LCD array, a plasma cell array, and an electroluminescent (EL) cell array.

17. The laminate of any preceding claim, wherein the interlayer comprises a polymer and either one or both the first substrate and the second substrate is strengthened.

18. The laminate of any preceding claim, wherein the first substrate is

strengthened and comprises first and second surfaces, the second surface being adjacent the interlayer, and the second substrate comprises third and fourth surfaces, the third surface being adjacent the interlayer and the fourth surface being opposite the third surface.

19. The laminate of claim 18, wherein the first surface comprises a surface

compressive stress of greater than about 200 MPa and a depth of layer of compressive stress of greater than about 30 pm.

20. The laminate of any preceding claim, wherein either one or both of the first and second substrate comprise a thickness of about 2.1 mm or less.

21. The laminate of any one of claims 17-20, wherein the strengthened substrate comprises a thickness of about 1.0 mm or less.

22. The laminate of any preceding claim, wherein the interlayer comprises a material selected from the group consisting of poly vinyl butyral (PVB), polycarbonate, acoustic PVB, ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU), a thermoplastic material, and combinations thereof.

23. The laminate of any preceding claim, wherein the interlayer comprises a stiff acoustic interlayer.

24. The laminate of claim 1 and 4-23, wherein the thickness of the interlayer is less than about 1.6 mm.

25. The laminate of any preceding claim, wherein at least one of the first and second substrate comprises a glass material, a glass-ceramic material, a polymeric material or a poly-ceramic material.

26. An article comprising the laminate of any preceding claim, wherein the article comprises any one of a vehicle, an architectural fixture, an architectural structure, an appliance a consumer electronic device, furniture, an information kiosk, and a retail kiosk.

27. An automotive roof comprising the laminate of claim 1.

28. A method of forming a laminate comprising:

laminating a first substrate and a second substrate to at least one interlayer and at least one light responsive material to form a laminate such that the interlayer and the light responsive material are disposed between the first and second substrate;

optionally shaping the laminate to a complex curved shape; and

optionally strengthening one or both of the first and second substrates.

29. The method of claim 28, wherein strengthening one or both of the first and second substrates comprises chemically strengthening or thermally strengthening both the first and second substrates.

30. The method of claim 28, wherein the shaping is carried out before the

strengthening.

31. The method of claim 28, wherein the strengthening is carried out before the shaping.

32. The method of claim 28-31 , further comprising disposing a display unit

between the first and second substrate.

33. A laminate comprising:

a first substrate;

an interlayer disposed on the first substrate; a light responsive material encapsulated in the interlayer, the interlayer having a plasticizer content such that the performance of a light responsive material therein is not substantially adversely affected; and

a second substrate disposed on the interlayer,

wherein:

the laminate is optionally complexly curved;

the first and second substrate are strengthened;

the laminate has a stiffness of at least 30 N/mm; and

both the first and second substrate have a thickness of 1 mm or less.