Pre-fractured glass composites and laminates with impact resistance and methods of making the same

Abstract

A pre-fractured glass laminate that includes: a glass substrate comprising a thickness, a pair of opposed primary surfaces, a compressive stress region, a central tension (CT) region and a plurality of cracks; a second phase comprising a polymer or a cured resin within the plurality of cracks; a backing layer; and an interlayer disposed between one of the primary surfaces of the substrate and the backing layer. The compressive stress region extends from each of the primary surfaces to a first selected depth in the substrate. Further, the plurality of cracks is located in the CT region.

What is claimed is: 
     
         1  A pre-fractured glass composite, comprising:
 a glass substrate comprising a thickness, a pair of opposed primary surfaces, a compressive stress region, a central tension (CT) region and a plurality of cracks; and 
 a second phase comprising a polymer or a cured resin within the plurality of cracks, 
 wherein the compressive stress region extends from each of the primary surfaces to a first selected depth in the substrate, and 
 further wherein the plurality of cracks is located in the CT region, and a majority of the plurality of cracks do not extend to the primary surfaces of the glass substrate. 
 
     
     
         2 . The composite according to  claim 1 , wherein a substantial portion of the plurality of cracks is devoid of air pockets. 
     
     
         3 . The composite according to  claim 1 , wherein the polymer or the cured resin is characterized by a refractive index within 10% of a refractive index of the glass substrate. 
     
     
         4 . The composite according to  claim 1 , wherein the composite is characterized by an average impact speed of greater than 400 mm/s prior to failure in a 110 Degree Diamond Dynamic Impact Test. 
     
     
         5 . The composite according to  claim 1 , wherein the plurality of cracks further comprises an average fragment size that is less than 5× the thickness of the glass substrate. 
     
     
         6 . The composite according to  claim 1 , wherein the plurality of cracks defines a plurality of fragments, and further wherein the plurality of fragments comprises an average aspect ratio of 4 or less. 
     
     
         7 . The composite according to  claim 1 , wherein the compressive stress region and the first selected depth are defined by an ion exchange or a thermal tempering process. 
     
     
         8 . A pre-fractured glass laminate, comprising:
 a pre-fractured glass composite according to  claim 1 ;   a backing layer; and   an interlayer disposed between one of the primary surfaces of the substrate and the backing layer.   
     
     
         9 . The laminate according to  claim 8 , wherein the interlayer comprises the polymer or the cured resin. 
     
     
         10 . The laminate according to  claim 8 , wherein the backing layer is characterized by an elastic modulus that is at least 25% greater than an elastic modulus of the interlayer. 
     
     
         11 . The laminate according to  claim 8 , wherein the laminate is characterized by an average impact speed of greater than 400 mm/s prior to failure in a 110 Degree Diamond Dynamic Impact Test. 
     
     
         12 . A consumer electronic product, comprising:
 a housing comprising front, back and side surfaces;   electrical components that are at least partially inside the housing; and   a display at or adjacent to the front surface of the housing,   wherein the composite of  claim 1  is at least one of disposed over the display and disposed as a portion of the housing.   
     
     
         13 . A vehicle interior system comprising:
 a base comprising a display, and a pre-fractured composite,   wherein the display comprises display elements and the pre-fractured composite is disposed over the display elements, and   wherein the composite of  claim 1  is at least one of disposed over the display and disposed as a portion of the housing.   
     
     
         14 . The vehicle interior system of  claim 13 , wherein the base comprises one of a center console base, a dashboard base, a dashboard steering wheel base, an armrest, a pillar, a seat back, a floor board, a headrest, and a door panel. 
     
     
         15 . A consumer electronic product, comprising:
 a housing comprising front, back and side surfaces;   electrical components that are at least partially inside the housing; and   a display at or adjacent to the front surface of the housing,   wherein the laminate of  claim 8  is at least one of disposed over the display and disposed as a portion of the housing.   
     
     
         16 . A vehicle interior system comprising:
 a base comprising a display, and a pre-fractured composite,   wherein the display comprises display elements and the pre-fractured composite is disposed over the display elements, and   wherein the laminate of  claim 8  is at least one of disposed over the display and disposed as a portion of the housing.   
     
     
         17 . The vehicle interior system of  claim 16 , wherein the base comprises one of a center console base, a dashboard base, a dashboard steering wheel base, an armrest, a pillar, a seat back, a floor board, a headrest, and a door panel.