| HS Code | 264397 |
| Visible Light Transmission | >91% |
| Haze | <0.3% |
| Yellowness Index | <1.0 |
| Uv Transmission | <1% (290-380 nm) |
| Refractive Index | 1.48 |
| Density | 1.07 g/cm³ |
| Tensile Strength | ≥20 MPa |
| Elongation At Break | ≥200% |
| Glass Transition Temperature | 30-35°C |
| Available Thicknesses | 0.38 mm, 0.76 mm, 1.52 mm |
| Adhesion Strength | High (to glass) |
| Water Absorption | <0.5% |
As an accredited Trosifol UltraClear factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
| Packing | Trosifol UltraClear is supplied in cardboard boxes, each containing a roll of 100 metres, sealed in moisture-resistant foil. |
| Container Loading (20′ FCL) | Trosifol UltraClear rolls loaded upright in 20′ FCL, secured with dunnage and airbags to prevent movement. |
| Shipping | Trosifol UltraClear is shipped as rolled PVB interlayer film on spools, wrapped in moisture-barrier foil with desiccant, and packed in sturdy cartons or pallets. Standard dry, temperature-controlled transport is required. It is not classified as hazardous material under ADR/IMDG, but must be kept dry and protected from deformation. |
| Storage | Store Trosifol UltraClear in its original sealed packaging in a cool, dry, well-ventilated area. Avoid direct sunlight, moisture, and heat sources. Maintain temperatures between 5°C and 30°C, with moderate humidity. Store rolls flat on their sides to prevent deformation. Use stock in rotation to ensure freshness. |
| Shelf Life | Shelf life is typically 12 months from delivery when stored cool, dry, and in original sealed packaging. |
In architectural laminated safety glazing for facades, skylights, and structural barriers, Trosifol UltraClear is processed as a polyvinyl butyral film between low-iron float glass substrates. The typical vertical facade make-up is 4 mm / 0.76 mm / 4 mm; overhead glazing uses 1.52 mm or 2.28 mm interlayer stacks to maintain post-fracture load retention under EN 12600. Optical acceptance is not satisfied by glass selection alone: the interlayer must be conditioned to a moisture content between 0.35 wt% and 0.50 wt%, determined by Karl Fischer titration per ISO 15512, because residual moisture above 0.60 wt% produces edge bubbles during autoclave heating. Opened rolls exposed to plant air above 30% RH for more than 30 min require reconditioning at 18–20°C and 15–20% RH for 24–48 h before lamination. De-airing is conducted in a vacuum bag at -0.9 bar gauge with infrared preheating to 100–120°C; the assembly is then autoclaved at 130–140°C and 11–13 bar for 30–60 min depending on total stack thickness. A production-scale failure mode is edge bubble formation at the trailing edge of the autoclave load caused by premature adhesion without complete de-airing. Thermocouple mapping of a 2.4 m × 4.8 m glass stack often shows center-to-edge temperature differentials above 5°C when circulation air is obstructed; the resulting adhesion gradient can exceed 1 pummel unit across the pane. After lamination, edge clarity is inspected under 10° oblique light, and laminate haze is held below 1.0% per ISO 14782. The finished facade unit is tested for impact classification to EN 12600. Frameless installations with exposed PVB edges are restricted to environments with relative humidity below 60%; at higher humidity, neutral-cure structural silicone meeting ASTM C1184 is applied at an edge coverage of at least 10 mm. Amine-based secondary sealants are excluded because amine migration accelerates edge yellowing and adhesion drift at the glass/interlayer interface. Terminal components include curtain wall spandrels, canopies, skylights, and glass floors where low-iron substrates with total iron content below 0.01 wt% as Fe₂O₃ avoid the green tint that would otherwise shift transmitted color coordinates when measured against ISO 9050.
Automotive HUD windshields incorporating Trosifol UltraClear demand simultaneous control of luminous transmittance above 70% for the windshield zone, haze below 1.0% per ISO 14782, and a wedge-angle gradient that suppresses ghost images between the inboard and outboard glass surfaces. The primary processing conflict is that vacuum bag de-airing alone cannot extract trapped air from a wedge-shaped PVB film; production lines therefore use nip-roller de-airing at 60–80°C with line speed held between 2.5 m/min and 4.0 m/min to avoid film thinning at the thick edge. The wedge geometry typically ranges from 0.76 mm at the base to 0.95 mm at the top edge across the HUD projection field, corresponding to a local wedge gradient of 0.3 mrad to 0.8 mrad; confirmation is performed by laser profilometry before and after autoclave. Autoclave parameters are set to 135°C and 12 bar with a hold of 45–60 min; local overheating above 140°C must be avoided because plasticizer redistribution in the PVB changes the refractive index gradient and alters ghosting performance. Line stoppages longer than 15 min at 60°C cause pre-tack of PVB to glass, entrapping air pockets at the wedge thick edge. Moisture control is tighter than general architectural work: pre-lamination moisture in the PVB wedge is held below 0.45 wt% to prevent haze formation and interfacial bubble defects after thermal cycling. Compliance is evaluated under ECE R43 and ANSI Z26.1 for optical quality and impact retention; HUD-specific ghosting is measured with a secondary-image displacement test at a projected virtual image distance of 2.0 m or as specified by the automaker. Terminal products include HUD-compatible windshields for passenger vehicles and heavy trucks, where the PVB interlayer also contributes to ejection mitigation and UV absorption below 380 nm. Published data for this specific configuration is limited for aftermarket replacement lines; original-equipment process validation is mandatory before serial production.
Frameless balustrades and interior partitions made with low-iron glass and Trosifol UltraClear are specified as 6 mm / 1.52 mm / 6 mm or 8 mm / 1.52 mm / 8 mm symmetric stacks to achieve EN 12600 impact classification and post-breakage retention. The critical uncertainty is edge moisture ingress at the exposed PVB edge; unprotected PVB absorbs moisture at relative humidity above 60%, producing a visible white edge band and loss of adhesion within 90–120 days of continuous exposure. The specification therefore separates interior conditioned zones from high-humidity zones: for corridor partitions and staircase balustrades with incidental humidity, neutral-cure structural silicone meeting ASTM C1184 is applied at an edge bite of at least 10 mm, and the sealant must demonstrate water vapor transmission below 10 g/m²/day per ASTM E96. Acetic-cure silicone sealants are incompatible with the exposed PVB edge because acetic acid release at the interface causes pH reduction and local adhesion loss. Lamination follows a two-stage cycle: vacuum bag de-airing at -0.9 bar and 100°C for 30 min, then autoclave at 130°C and 11 bar for 60 min. Adhesion is checked by the pummel test; for balustrade applications the acceptance band is 3–6 units, because values below 3 do not retain glass fragments after fracture and values above 8 reduce the energy dissipation of the interlayer under impact. Nip roller pressure fluctuation above 0.6 MPa during pre-nip creates interlayer creases at the glass edge, which are visible as local white lines after autoclave. Terminal products include glass balustrades, corridor partitions, and frameless stair railings where the ultra-clear PVB prevents the yellow-green tint that lower-grade PVB would introduce against white or grey interior surfaces.
For building-integrated photovoltaic modules and architectural solar canopies, Trosifol UltraClear serves as the encapsulant between a 3.2 mm low-iron front glass and a 3.2 mm rear glass or transparent backsheet. The lamination route differs from EVA-based encapsulant processes because PVB requires a two-stage pressure-temperature sequence; a flatbed vacuum laminator is operated at a chamber pressure below 10 mbar with platen setpoint 145°C for 15–20 min, followed by autoclave treatment at 140°C and 12 bar for 45 min to collapse residual microbubbles. Vacuum lamination time below 12 min creates void clusters at cell busbar edges; post-lamination electroluminescence inspection is used to detect these defects. The formulation target for moisture is 0.35–0.50 wt% before lamination; higher moisture levels above 0.55 wt% cause interfacial bubbles and loss of peel adhesion after damp heat testing. Module performance is evaluated under IEC 61730-2 for safety qualification and IEC 61215 for performance; the UV preconditioning dose of 15 kWh/m² is applied to front-side materials to detect yellowing or adhesion drift. Unlike EVA, PVB encapsulant does not release acetic acid during thermal decomposition, but the edge seal remains the operational boundary: for installations at relative humidity above 80% and ambient temperature above 30°C, butyl edge tape or edge sealing must be applied because prolonged damp heat exposure at 85°C/85% RH beyond 1000 h can reduce adhesion at exposed edges. The terminal product includes BIPV spandrel panels, solar-view facades, and overhead PV canopies where laminated safety glass function must be combined with photovoltaic output and UV blocking below 380 nm. Published data for this specific configuration is limited for thin-film and bifacial module architectures; each stack design requires full-scale qualification because the PVB modulus and moisture uptake interact with cell spacing and backsheet properties.
| Stack class | De-airing method | Preheating temperature | Autoclave setpoint | Hold time | Final moisture limit |
|---|---|---|---|---|---|
| Thin facade/interior laminate, 0.76 mm interlayer | Vacuum bag at -0.9 bar | 100–120°C | 130–140°C, 11–13 bar | 30–60 min | 0.50 wt% |
| Multi-ply security stack, ≥2.28 mm interlayer | Extended vacuum bag with edge pressure | 90–100°C | 135°C, 12 bar | 60–90 min | 0.45 wt% |
| BIPV glass-glass, 0.76 mm encapsulant | Flatbed vacuum laminator below 10 mbar | 145°C platen | 140°C, 12 bar | 45 min | 0.50 wt% |
Lamination of multi-ply security glazing with Trosifol UltraClear is driven by the need to retain glass fragments and resist penetration under EN 356, EN 1063, UL 972, and ASTM F1233. A representative forced-entry stack is 4 mm glass / 4 × 0.76 mm UltraClear / 4 mm glass; thicker configurations use 6 mm glass faces and interlayer stacks of 2.28 mm to 3.04 mm. The process conflict is de-airing time: each additional 0.76 mm PVB ply increases the air-removal path and requires vacuum bag time extension to 60–90 min; autoclave hold time also increases by 15–20 min per additional 1.52 mm of interlayer. The autoclave must maintain internal air circulation of 5–7 m/s across the stack to prevent corner delamination from heat soak differences; circulation below 3 m/s produces premature edge seal that traps air in the central plies. Adhesion control in security glazing is shifted upward compared with balustrades; pummel values above 6 units are required to retain glass splinters during multiple impacts, but values above 9 can produce brittle interfacial failure in cold climates. Full-scale testing to EN 1063 and UL 972 is mandatory because the final classification depends on glass type, frame engagement, and edge bite, not on interlayer thickness alone. Terminal products include bank counters, detention windows, and forced-entry storefront glazing; laminated glass with multiple ultra-clear PVB plies also maintains visible light transmittance above 80% for thin security make-ups, which is required for transmitted detail to remain identifiable by security cameras. Polycarbonate overlays are not directly compatible with PVB without an adhesion-promoting interlayer; if a polycarbonate inner face is specified, a separate urethane or ionomer interlayer must be used in the stack.
Museum-grade display laminates and archive glazing use Trosifol UltraClear between 2.5 mm or 3 mm low-iron glass panes to achieve high luminous transmittance and UV blocking. The functional requirement is UV transmittance below 1% from 300 nm to 380 nm when measured per ASTM E903, combined with visible light transmittance above 90% per ISO 9050. Lamination follows a conservative thermal cycle: vacuum bag de-airing at 100°C and -0.9 bar, followed by autoclave at 130°C and 11 bar for 45 min. The critical operational boundary is edge adhesion under thermal and moisture cycling: exposure of an unsealed edge to 50°C and 90% RH for 500 h can produce edge haze deeper than 2 mm and reduce peel adhesion at the glass/PVB interface. Display cases that are relocated between conditioned galleries and non-conditioned transport require sealed edges with neutral-cure silicone meeting ASTM C1184; the edge seal must cover the full interlayer edge and overlap the glass by at least 5 mm. Anti-reflective coatings are restricted to the exterior face of the glass because direct PVB contact with porous sol-gel coatings can cause plasticizer migration and reduced coating durability. Acrylic or polycarbonate substrates are not laminated directly with PVB in display applications; a separate interlayer system is used if polymer substrates are required. The terminal product includes museum display cases, art packaging, and archive glazing for light-sensitive materials, where the ultra-clear PVB performs the dual function of UV filtration and safety-glass retention.
| Downstream application | Core standard | Test designation / acceptance |
|---|---|---|
| Architectural laminated glass | EN ISO 12543 | EN 12600 impact classification; haze per ISO 14782 |
| Automotive HUD windshield | ECE R43, ANSI Z26.1 | Wedge profile by laser profilometry; ghost displacement at 2.0 m virtual image |
| Balustrade and partition | EN 12600 | Pummel adhesion 3–6 units; edge sealant WVTR below 10 g/m²/day per ASTM E96 |
| BIPV module | IEC 61730-2, IEC 61215 | UV dose 15 kWh/m²; damp heat 85°C/85% RH |
| Forced-entry security glazing | EN 356, EN 1063, UL 972, ASTM F1233 | Full-scale impact and penetration test on final stack |
| Display and archive glazing | ISO 9050, ASTM E903 | Visible transmittance above 90%; UV transmittance below 1% at 300–380 nm |
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Trosifol UltraClear is a plasticised polyvinyl butyral interlayer manufactured by Kuraray for laminated safety glass in architectural, display-case, balustrade, overhead and selected transport glazing applications. The grade designation identifies the optical quality of the interlayer rather than a structural or acoustic modification. It is supplied in roll form with nominal thicknesses of 0.38 mm, 0.76 mm, and 1.52 mm; multi-ply layups are used to achieve total interlayer thicknesses up to 3.04 mm for impact-rated or overhead configurations. Roll widths commonly extend to 3210 mm, with narrower slit widths available for automated cutting and layup lines. The polymer sheet has a density of approximately 1.07 g/cm³ and a refractive index near 1.48 at 589 nm. The interlayer is intended for use with clear float, low-iron, heat-strengthened, and tempered glass; however, the visual benefit is only fully realised when low-iron glass is specified because iron absorption in conventional float glass dominates transmitted colour.
Unopened rolls are stored in their original moisture-barrier packaging at 10–25 °C and below 70 % RH. Exposure to temperatures above 30 °C accelerates plasticiser migration and can produce blocking between film layers. Opened roll stock intended for lamination is conditioned in a clean layup room at 20–25 °C and 25–35 % RH for not less than 24 h before assembly, depending on roll diameter and packaging integrity. Karl Fischer moisture content of the sheet is controlled to 0.35–0.55 %; values above 0.60 % increase the probability of autoclave bubbles at edge regions, while values below 0.30 % can reduce glass adhesion below the accepted pummel adhesion range described in ISO 12543-2. Production facilities using twin-roll de-airing lines monitor sheet moisture at the unwind station because ambient humidity above 60 % RH can shift the surface moisture of conditioned film within 20–30 min.
Cold roll stock below 10 °C increases sheet stiffness and can produce unwind curl or mis-tracking. Before use, cold rolls are allowed to equilibrate in the lamination hall until surface temperature reaches at least 18 °C; forced heating above 35 °C is not used because non-uniform plasticiser distribution can create local tack differences. Cut sheet stored too long in an uncontrolled room is returned to the conditioned area after 30 min unless assembled immediately. In high-humidity plants, layup areas above 55 % RH require desiccant dehumidification or a climate-controlled layup line.
On a flat-glass lamination line equipped with a horizontal infrared preheating furnace and a hydraulic nip roller, the glass–interlayer stack is heated to a glass surface temperature of 60–70 °C before initial de-airing. The nip roller station is set to produce continuous edge contact without squeezing the interlayer below its nominal thickness. After de-airing, the stack is transferred to an autoclave operating at 10–13 bar and 130–140 °C with a hold time of 60–120 min depending on glass make-up and load size. Heating and cooling ramps are maintained below 2 °C/min; pressure is held until the load reaches 50 °C during cooling. When the autoclave hold temperature falls below 125 °C under full pressure, incomplete PVB flow can leave visible air channels at glass edges; when the temperature exceeds 145 °C, edge flow can occur and the PVB may squeeze out beyond the glass edge. In UltraClear laminates these defects are more detectable because the low-yellowness formulation reduces background colour that would otherwise mask small bubbles and haze bands. The permissible autoclave deviation is therefore kept within ±5 °C on production lines that process visible-edge balustrades and point-supported facades.
The primary differentiation is measured by yellowness index rather than total transmittance alone. In a 6 mm low-iron glass / 1.52 mm UltraClear / 6 mm low-iron glass laminate, batch-averaged visible light transmittance is approximately 90 % under ISO 9050 spectral conditions, while the same glass stack with a standard architectural PVB typically falls in the 88–89 % range. The more significant difference is yellowness index: UltraClear targets ≤1.0 under ASTM E313-20, whereas standard PVB may shift to 1.0–2.0 depending on plasticiser stabiliser package and glass iron content. Haze measured by ASTM D1003 remains below 0.5 % for clean, correctly stored UltraClear film; entrapped moisture or surface contamination can raise this above 1.0 % even when the interlayer itself is within specification.
| Property | Test method | Trosifol UltraClear | Trosifol Clear reference |
|---|---|---|---|
| Visible light transmittance | ISO 9050 | ≥ 90 % | 88–89 % |
| Yellowness index | ASTM E313-20 | ≤ 1.0 | 1.0–2.0 |
| Haze | ASTM D1003 | ≤ 0.5 % | 0.5–1.0 % |
The low yellowness does not indicate a UV-transparent interlayer. Trosifol UltraClear absorbs the UV edge below 380 nm; measured UV transmittance is below 1 % in the 300–380 nm band under ISO 9050 unless the glass is specifically selected as UV-transmitting. This characteristic is relevant for museum and display-case specifications where both colour neutrality and UV screening are required. Compared with Trosifol Clear, the UltraClear grade reduces yellowness index by up to 1.0 unit in identical glass stacks. The difference is achieved through raw PVB resin and plasticiser selection that lowers short-wavelength absorption rather than through glass selection alone.
Mechanical properties of the UltraClear grade remain inside the conventional plasticised PVB envelope governed by ISO 12543-2. At 23 °C, film tensile strength is not less than 20 MPa and elongation at break not less than 250 % when measured according to ISO 527-3. The interlayer is viscoelastic: under slow static load it exhibits low shear resistance, while under high-rate impact it stiffens and contributes to glass retention. This rate dependence is not unique to UltraClear, and the product is not a substitute for ionoplast or structural interlayers in applications requiring high post-breakage residual stiffness or elevated shear modulus. Designers should not attribute structural superiority to the optical grade; laminated glass conformance is evaluated at the finished-product level under EN 14449, ANSI Z97.1, or CPSC 16 CFR 1201 depending on jurisdiction. For balustrades and overhead glazing, the end-product test result governs the required interlayer thickness; the low-yellowness formulation does not reduce the required interlayer thickness.
Incoming sheet inspection uses laser thickness gauges and optical density sensors at the slitting line. Thickness tolerance for 0.76 mm film is ±0.025 mm, and width tolerance for standard roll stock is ±2 mm. The PVB sheet is cut with an overhang of 1–2 mm beyond the glass edge; overhang below 1 mm can produce edge starvation during autoclave flow, while overhang above 5 mm can produce squeeze-out and sealant contamination. Surface roughness is controlled to permit de-airing during nip rolling; excessively smooth film from overwinding or high storage temperature can close the de-airing channels and produce edge bubbles. Glass substrates are washed with demineralised water at conductivity below 20 µS/cm and dried with filtered air. Residual glass surface contamination from cutting oils or fingerprints can lower pummel adhesion below 3 units and appears as local haze after autoclaving. UltraClear will make such defects more visible because the interlayer does not add enough colour to mask them.
PVB interlayers are edge-deleted to 2–5 mm from the glass edge before autoclaving so that the subsequent structural silicone bond is not contaminated by plasticised polymer. Bonding standards such as ASTM C1401 require a clean glass surface for silicone adhesion; residual PVB film or plasticiser migration can delay moisture-cure silicone crosslinking and reduce joint strength. The low-yellowness formulation of UltraClear does not alter this requirement, but it does make edge clouding and plasticiser staining more visible against white ceramic frit and low-iron polished edges. Amine-containing sealants and incompatible edge coatings are specifically avoided because amine components can accelerate edge haze formation in PVB. For visible-edge balustrades, fabricators should maintain edge deletion width at not less than 3 mm and verify sealant compatibility by adhesion testing under ASTM C1401 using production glass and the exact edge profile; published data for this specific configuration is limited when non-silicone or hybrid sealant chemistries are substituted. The product is not specified for structural silicone applications without completed compatibility testing; the interlayer alone does not provide a glazing seal.
