CN106164009A - 夹层玻璃用中间膜、卷状体、夹层玻璃、夹层玻璃用中间膜的制造方法、以及卷状体的制造方法 - Google Patents
夹层玻璃用中间膜、卷状体、夹层玻璃、夹层玻璃用中间膜的制造方法、以及卷状体的制造方法 Download PDFInfo
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- CN106164009A CN106164009A CN201580019251.7A CN201580019251A CN106164009A CN 106164009 A CN106164009 A CN 106164009A CN 201580019251 A CN201580019251 A CN 201580019251A CN 106164009 A CN106164009 A CN 106164009A
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- Prior art keywords
- thickness
- intermediate film
- width
- laminated glasses
- laminated
- Prior art date
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- Pending
Links
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/28—Storing of extruded material, e.g. by winding up or stacking
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
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- B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
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- B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B17/10559—Shape of the cross-section
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- B32B17/10596—Surface roughness created by melt fracture
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- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
- B32B17/10761—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing vinyl acetal
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10807—Making laminated safety glass or glazing; Apparatus therefor
- B32B17/10816—Making laminated safety glass or glazing; Apparatus therefor by pressing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
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Abstract
本发明的目的在于,提供预压接时能够发挥高脱气性、且能够制造透明性高的夹层玻璃的夹层玻璃用中间膜、卷状体、夹层玻璃、夹层玻璃用中间膜的制造方法、以及卷状体的制造方法。本发明是在至少一侧的表面具有多个凹部和多个凸部的夹层玻璃用中间膜,将相对于上述夹层玻璃用中间膜的制造时的膜的流动方向正交的同一平面状的方向作为宽度方向,沿着制造时的膜的流动方向遍及3m测定所述宽度方向的中心部的厚度、所述宽度方向的一个端部的厚度和所述宽度方向的另一端部的厚度时,所述宽度方向的中心部的厚度、所述宽度方向的一个端部的厚度和所述宽度方向的另一端部的厚度的最大值与最小值之差分别小于40μm。
Description
技术领域
本发明涉及预压接时能够发挥高脱气性、且能够制造透明性高的夹层玻璃的夹层玻璃用中间膜、卷状体、夹层玻璃、夹层玻璃用中间膜的制造方法、以及卷状体的制造方法。
背景技术
在2片玻璃板之间夹持含有可塑化聚乙烯醇缩丁醛的夹层玻璃用中间膜并使其相互粘接而得到的夹层玻璃在汽车、飞机、建筑物等的窗玻璃中广泛使用。
关于夹层玻璃的制造方法,进行以下方法:例如,将从卷状体卷出的夹层玻璃用中间膜切成适当大小,将该夹层玻璃用中间膜夹在至少2片玻璃板之间而得到层叠体,将该层叠体放入橡胶袋中减压抽吸,对玻璃板与中间膜之间残留的空气进行脱气的同时进行预压接,接着,例如在高压釜内加热加压从而进行正式压接的方法(橡胶袋法);用输送机输送至少在2片玻璃板之间层叠有夹层玻璃用中间膜的层叠体,同时使该层叠体通过加热区从而加热到一定的温度后,通过夹辊将玻璃与中间膜之间残留的空气捋出并除去,同时使之热压接,使层叠体的中间膜与玻璃间的空气减少而进行预压接,并在所得层叠体间的空气减少的状态下,在高压釜内于高温高压下使之正式粘接的方法(夹辊法)等。(例如,专利文献1。)
在此,为了得到透明性高的夹层玻璃,在上述夹层玻璃的制造工序中,在预压接时将玻璃与夹层玻璃用中间膜层叠时的脱气性是重要的。以确保夹层玻璃制造时的脱气性为目的,通常在夹层玻璃用中间膜的至少一个表面形成微细的凹凸。
然而,以往的夹层玻璃用中间膜虽然在表面具有微细的凹凸,但存在预压接工序中的脱气不充分,得到的夹层玻璃的透明性差的问题。尤其在制造建筑用的大型的夹层玻璃的情况下,容易发生脱气不良。
现有技术文献
专利文献
专利文献1:日本特开平8-26789号公报
发明内容
发明要解决的问题
本发明鉴于上述现状,目的在于提供预压接时能够发挥高脱气性、且能够制造透明性高的夹层玻璃的夹层玻璃用中间膜、卷状体、夹层玻璃、夹层玻璃用中间膜的制造方法、以及卷状体的制造方法。
用于解决问题的手段
本发明为一种夹层玻璃用中间膜,其是在至少一侧的表面具有多个凹部和多个凸部的夹层玻璃用中间膜,将相对于上述夹层玻璃用中间膜的制造时的膜的流动方向正交的同一平面状的方向作为宽度方向,沿着制造时的膜的流动方向遍及3m测定所述宽度方向的中心部的厚度、所述宽度方向的一个端部的厚度和所述宽度方向的另一端部的厚度时,所述宽度方向的中心部的厚度、所述宽度方向的一个端部的厚度和所述宽度方向的另一端部的厚度的最大值与最小值之差分别小于40μm。
以下详细描述本发明。
本发明人等对于在以往的夹层玻璃用中间膜中,尽管在表面具有微细的凹凸,预压接工序中的脱气仍不充分的原因进行了研究。其结果发现,由于在夹层玻璃用中间膜的流动方向上存在厚度偏差,因此在预压接时的压力施加方式产生不均是脱气不良的原因。
即,在夹层玻璃用中间膜的制造中,由挤出机挤出原料树脂组合物并成形。此时的挤出速度等挤出条件按照均匀的方式设定,但实际上挤出条件有波动,该变动成为所得到的夹层玻璃用中间膜的厚度的偏差而体现。另外,认为在夹层玻璃用中间膜的表面实施压花加工的情况下,边施加温度边使膜通过压花辊间,此时的压花辊的偏心也成为所得到的夹层玻璃用中间膜的厚度偏差的原因。
本发明人等经过更深入研究的结果发现,具有多个凹部和多个凸部的夹层玻璃用中间膜中,将相对于该夹层玻璃用中间膜的制造时的膜的流动方向正交的同一平面状的方向设为宽度方向,沿着制造时的膜的流动方向遍及3m测定宽度方向的中心部的厚度、宽度方向的一个端部的厚度和宽度方向的另一端部的厚度时,宽度方向的中心部的厚度、宽度方向的一个端部的厚度和宽度方向的另一端部的厚度的偏差分别设为小于40μm,由此可以提供预压接时能发挥高脱气性、且能够制造透明性高的夹层玻璃的夹层玻璃用中间膜,从而完成本发明。
本发明的夹层玻璃用中间膜将相对于夹层玻璃用中间膜的制造时的膜的流动方向正交的同一平面状的方向作为宽度方向,沿着制造时的膜的流动方向遍及3m测定该宽度方向的中心部的厚度、宽度方向的一个端部的厚度和宽度方向的另一端部的厚度时,宽度方向的中心部的厚度、宽度方向的一个端部的厚度和宽度方向的另一端部的厚度的最大值与最小值之差分别小于40μm。由此,预压接时能够发挥高脱气性,能够制造透明性高的夹层玻璃。需要说明的是,在此设为“3m”是由于,特别是在制造建筑用的大型夹层玻璃的情况下,如果在3m的长度上的厚度偏差小,则能够切实地防止脱气不良。上述宽度方向的中心部的厚度、宽度方向的一个端部的厚度和宽度方向的另一端部的厚度的最大值与最小值之差优选分别为39μm以下,更优选为30μm以下,进一步优选为25μm以下,特别优选为15μm以下。
本说明书中夹层玻璃用中间膜的制造时的流动方向是指在制造夹层玻璃用中间膜时,由挤出机挤出原料树脂组合物的方向。
需要说明的是,夹层玻璃用中间膜的制造时的流动方向可以通过例如以下方法进行确认。即,可以通过如下方式确认:将夹层玻璃用中间膜在140℃的恒温槽中保管30分钟后,膜的平行方向和垂直方向的收缩率大的方向为流动方向。除此以外,还可以通过该夹层玻璃用中间膜的卷状体的卷取方向来确认。这是由于,夹层玻璃用中间膜的卷状体沿着夹层玻璃用中间膜制造时的膜的流动方向卷取,所以卷状体的巻取方向与夹层玻璃用中间膜制造时的膜的流动方向相同。
使用图1更具体地说明测定本发明中的夹层玻璃用中间膜的宽度方向的中心部的厚度、宽度方向的一个端部的厚度和宽度方向的另一端部的厚度的方法。图1(a)中,首先由卷状体2拉出夹层玻璃用中间膜1。此时,拉出方向为夹层玻璃用中间膜的制造的流动方向,相对于该流动方向正交的同一平面状的方向为宽度方向。
拉出的夹层玻璃用中间膜沿流动方向在3m以上的位置切断,得到3m×膜幅(通常为1m)的试验用样品3(图1(b))。试验用样品3在20℃、30%RH以下的条件下以平面状放置,保养24小时后,供测定。保养后,测定试验用样品3的宽度方向的中心部的厚度、宽度方向的一个端部的厚度和宽度方向的另一端部的厚度。厚度的测定在20℃、30%RH以下的条件下进行。图1(b)中,在试验用样品3上示出沿着宽度方向的中心部的虚线41、沿着宽度方向的端部的虚线42、43。需要说明的是,作为宽度方向的端部,优选选择从端部向宽度方向的中心部进入相当于夹层玻璃用中间膜的宽度的5%的长度的位置。厚度的测定沿着这些虚线41、42、43使用千分尺(例如,安立电气公司制、KG601B型广泛围电子千分尺等),以1.5m/分钟连续地进行。
根据所得到的夹层玻璃用中间膜的宽度方向的中心部的厚度、宽度方向的一个端部的厚度和宽度方向的另一端部的厚度的数据,分别算出厚度的最大值与最小值之差。
本发明的夹层玻璃用中间膜优选包含热塑性树脂。
作为上述热塑性树脂,可以举出例如:聚偏二氟乙烯、聚四氟乙烯、偏二氟乙烯-六氟丙烯共聚物、聚三氟乙烯、丙烯腈-丁二烯-苯乙烯共聚物、聚酯、聚醚、聚酰胺、聚碳酸酯、聚丙烯酸酯、聚甲基丙烯酸酯、聚氯乙烯、聚乙烯、聚丙烯、聚苯乙烯、聚乙烯醇缩醛、乙烯-乙酸乙烯酯共聚物等。其中,聚乙烯醇缩醛是适宜的。
上述聚乙烯醇缩醛可以通过例如用醛将聚乙烯醇(PVA)缩醛化来制造。上述聚乙烯醇缩醛优选为聚乙烯醇的缩醛化物。PVA的皂化度一般为70~99.9摩尔%的范围内。
为了得到上述聚乙烯醇缩醛的PVA的聚合度优选为200以上、更优选为500以上、进一步优选为1700以上、特别优选为2000以上、优选为5000以下、更优选为4000以下、更进一步优选为3000以下、进一步优选小于3000、特别优选为2800以下。上述聚乙烯醇缩醛优选为通过将聚合度为上述下限以上和上述上限以下的PVA缩醛化而得到的聚乙烯醇缩醛。若上述聚合度为上述下限以上,则夹层玻璃的耐贯通性进一步变高。若上述聚合度为上述上限以下,则中间膜的成形变得容易。
PVA的聚合度表示平均聚合度。该平均聚合度通过依据JIS K6726“聚乙烯醇试验方法”的方法求出。作为上述醛,通常适合使用碳数为1~10的醛。作为上述碳数为1~10的醛,可以举出例如:甲醛、乙醛、丙醛、正丁基醛、异丁基醛、正戊醛、2-乙基丁醛、正己醛、正辛醛、正壬醛、正癸醛和苯甲醛等。其中,优选正丁醛、正己醛或正戊醛,更优选正丁醛。上述醛可以仅使用1种,也可以同时使用2种以上。
上述聚乙烯醇缩醛优选为聚乙烯醇缩丁醛。通过使用聚乙烯醇缩丁醛,中间膜相对于夹层玻璃部件的耐候性等变得更高。
本发明的夹层玻璃用中间膜优选含有增塑剂。
作为上述增塑剂,只要是通常用于夹层玻璃用中间膜的增塑剂就没有特别限定,可以举出例如:一元有机酸酯、多元有机酸酯等有机增塑剂;有机磷酸化合物、有机亚磷酸化合物等磷酸增塑剂等。
作为上述有机增塑剂,可举出例如:二-2-乙基己酸三乙二醇酯、二-2-乙基丁酸三乙二醇酯、二正庚酸三乙二醇酯、二-2-乙基己酸四乙二醇酯、二-2-乙基丁酸四乙二醇酯、二正庚酸四乙二醇酯、二-2-乙基己酸二乙二醇酯、二-2-乙基丁酸二乙二醇酯、二正庚酸二乙二醇酯等。其中,优选含有二-2-乙基己酸三乙二醇酯、二-2-乙基丁酸三乙二醇酯、或二正庚酸三乙二醇酯,更优选含有二-2-乙基己酸三乙二醇酯。
本发明的夹层玻璃用中间膜中,增塑剂相对于上述热塑性树脂的含量没有特别限定。相对于上述热塑性树脂100质量份,上述增塑剂的含量优选为25质量份以上、更优选为30质量份以上、进一步优选为35质量份以上、优选为80质量份以下、更优选为60质量份以下、进一步优选为50质量份以下。若上述增塑剂的含量为上述下限以上,则夹层玻璃的耐贯通性进一步提高。若上述增塑剂的含量为上述上限以下,则中间膜的透明性进一步提高。
本发明的夹层玻璃用中间膜优选含有粘接力调节剂。
作为上述粘接力调节剂,适合使用例如碱金属盐或碱土金属盐。作为上述粘接力调节剂,可以举出例如:钾、钠、镁等的盐。
作为构成上述盐的酸,可举出例如:辛酸、己酸、2-乙基丁酸、丁酸、乙酸、甲酸等羧酸的有机酸,或盐酸、硝酸等无机酸。
本发明的夹层玻璃用中间膜根据需要可以含有抗氧化剂、光稳定剂、作为粘接力调节剂的改性硅油、阻燃剂、抗静电剂、耐湿剂、热射线反射剂、热射线吸收剂、防粘连剂、抗静电剂、包含颜料或染料的着色剂等添加剂。
本发明的夹层玻璃用中间膜可以为仅由1层树脂膜构成的单层结构,也可以为层叠了2层以上的树脂层的多层结构。
本发明的夹层玻璃用中间膜为多层结构的情况下,通过具有第1的树脂层和第2树脂层作为2层以上的树脂层,且第1的树脂层与第2树脂层具有不同性质,由此可以提供具有仅1层难以实现的各种性能的夹层玻璃用中间膜。
本发明的夹层玻璃用中间膜为多层结构的情况下,可举出例如如下具有优异的隔音性的夹层玻璃用中间膜(以下,也称为“隔音中间膜”。),其为了提高夹层玻璃的隔音性,将上述第1的树脂层作为保护层,将上述第2树脂层作为隔音层,用2个保护层夹持隔音层。
以下,对该隔音中间膜更具体地进行说明。
上述隔音中间膜中,上述隔音层具有赋予隔音性的作用。
上述隔音层优选含有聚乙烯醇缩醛X和增塑剂。
上述聚乙烯醇缩醛X可以通过用醛将聚乙烯醇缩醛化来制备。上述聚乙烯醇缩醛X优选为聚乙烯醇的缩醛化物。上述聚乙烯醇通常通过将聚乙酸乙烯酯皂化而得到。
上述聚乙烯醇的聚合度的优选下限为200、优选上限为5000。通过将上述聚乙烯醇的聚合度设为200以上,可以提高所得隔音中间膜的耐贯通性,通过设为5000以下,可以确保隔音层的成形性。上述聚乙烯醇的聚合度的更优选下限为500,更优选上限为4000。
用于将上述聚乙烯醇缩醛化的醛的碳数的优选下限为4,优选上限为6。通过将醛的碳数设为4以上,可以稳定含有充分量的增塑剂,可以发挥优异的隔音性能。另外,可以防止增塑剂的渗出。通过将醛的碳数设为6以下,容易合成聚乙烯醇缩醛X,可以确保生产率。
作为上述碳数为4~6的醛,可以是直链状的醛,也可以是支链状的醛,可举出例如正丁醛,正戊醛等。
上述聚乙烯醇缩醛X的羟基量的优选上限为30摩尔%。通过将上述聚乙烯醇缩醛X的羟基量设为30摩尔%以下,可以含有发挥隔音性所必要的量的增塑剂,可以防止增塑剂的渗出。上述聚乙烯醇缩醛X的羟基量的更优选上限为28摩尔%、进一步优选上限为26摩尔%、特别优选上限为24摩尔%、优选下限为10摩尔%、更优选下限为15摩尔%、进一步优选下限为20摩尔%。
上述聚乙烯醇缩醛X的羟基量是将羟基键合的亚乙基量除以主链的亚乙基总量而求得的摩尔分率以百分率(摩尔%)表示的值。上述羟基键合的亚乙基量可以通过例如依据JIS K6728“聚乙烯醇缩丁醛试验方法”的方法,上述聚乙烯醇缩醛X的羟基键合的亚乙基量从而求得。
上述聚乙烯醇缩醛X的缩醛基量的优选下限为60摩尔%、优选上限为85摩尔%。通过将上述聚乙烯醇缩醛X的缩醛基量设为60摩尔%以上,可以含有提高隔音层的疏水性、发挥隔音性所必要的量的增塑剂,可以防止增塑剂的渗出、白化。通过将上述聚乙烯醇缩醛X的缩醛基量设为85摩尔%以下,容易合成聚乙烯醇缩醛X,可以确保生产率。上述缩醛基量可以通过依据JIS K6728“聚乙烯醇缩丁醛试验方法”的方法测定上述聚乙烯醇缩醛X的缩醛基键合的亚乙基量从而求得。
上述聚乙烯醇缩醛X的乙酰基量的优选下限为0.1摩尔%,优选上限为30摩尔%。通过将上述聚乙烯醇缩醛X的乙酰基量设为0.1摩尔%以上,可以含有发挥隔音性所必要的量的增塑剂,可以防止渗出。另外,通过将上述聚乙烯醇缩醛X的乙酰基量设为30摩尔%以下,可以提高隔音层的疏水性,防止白化。上述乙酰基量的更优选下限为1摩尔%、进一步优选下限为5摩尔%、特别优选下限为8摩尔%、更优选上限为25摩尔%、进一步优选上限为20摩尔%。上述乙酰基量是将从主链的亚乙基总量中减去缩醛基键合的亚乙基量和羟基键合的亚乙基量后的值除以主链的亚乙基总量而求得的摩尔分率以百分率(摩尔%)表示的值。
尤其从使上述隔音层容易地含有发挥隔音性所必要的量的增塑剂出发,上述聚乙烯醇缩醛X优选为上述乙酰基量为8摩尔%以上的聚乙烯醇缩醛、或者上述乙酰基量不足8摩尔%并且缩醛基量为68摩尔%以上的聚乙烯醇缩醛。
上述隔音层中的增塑剂的含量相对于100质量份上述聚乙烯醇缩醛X的优选下限为45质量份、优选上限为80质量份。通过将上述增塑剂的含量设为45质量份以上,可发挥高隔音性,通过设为80质量份以下,可以防止发生增塑剂的渗出而夹层玻璃用中间膜的透明性、粘接性降低。上述增塑剂的含量的更优选下限为50质量份、进一步优选下限为55质量份、更优选上限为75质量份、进一步优选上限为70质量份。
上述隔音层的厚度的优选下限为50μm。通过将上述隔音层的厚度设为50μm以上,可以发挥充分的隔音性。上述隔音层的厚度的更优选下限为70μm、进一步优选下限为80μm。需要说明的是,上限为没有特别限定,但是若考虑作为夹层玻璃用中间膜的厚度,则优选上限为150μm。
上述保护层具有防止隔音层所含大量的增塑剂渗出而夹层玻璃用中间膜与玻璃的粘接性降低的作用,还有赋予夹层玻璃用中间膜耐贯通性的作用。
上述保护层优选含有例如聚乙烯醇缩醛Y和增塑剂,更优选含有比聚乙烯醇缩醛X的羟基量更大的聚乙烯醇缩醛Y和增塑剂。
上述聚乙烯醇缩醛Y可以通过用醛将聚乙烯醇缩醛化来制备。上述聚乙烯醇缩醛Y优选为聚乙烯醇的缩醛化物。
上述聚乙烯醇通常通过将聚乙酸乙烯酯皂化而得到。另外,上述聚乙烯醇的聚合度的优选下限为200、优选上限为5000。通过将上述聚乙烯醇的聚合度设为200以上,可以提高夹层玻璃用中间膜的耐贯通性,通过设为5000以下,可以确保保护层的成形性。上述聚乙烯醇的聚合度的更优选下限为500、更优选上限为4000。
用于将上述聚乙烯醇缩醛化的醛的碳数的优选下限为3、优选上限为4。通过将醛的碳数设为3以上,夹层玻璃用中间膜的耐贯通性变高。通过将醛的碳数设为4以下,聚乙烯醇缩醛Y的生产率提高。
作为上述碳数为3~4的醛,可以是直链状的醛,也可以是支链状的醛,可举出例如正丁醛等。
上述聚乙烯醇缩醛Y的羟基量的优选上限为33摩尔%、优选下限为28摩尔%。通过将上述聚乙烯醇缩醛Y的羟基量设为33摩尔%以下,可以防止夹层玻璃用中间膜的白化。通过将上述聚乙烯醇缩醛Y的羟基量设为28摩尔%以上,夹层玻璃用中间膜的耐贯通性变高。
上述聚乙烯醇缩醛Y的缩醛基量的优选下限为60摩尔%、优选上限为80摩尔%。通过将上述缩醛基量设为60摩尔%以上,可以含有发挥充分的耐贯通性所必要的量的增塑剂。通过将上述缩醛基量设为80摩尔%以下,可以确保上述保护层与玻璃的粘接力。上述缩醛基量的更优选下限为65摩尔%、更优选上限为69摩尔%。
上述聚乙烯醇缩醛Y的乙酰基量的优选上限为7摩尔%。通过将上述聚乙烯醇缩醛Y的乙酰基量设为7摩尔%以下,可以提高保护层的疏水性,防止白化。上述乙酰基量的更优选上限为2摩尔%、优选下限为0.1摩尔%。需要说明的是,聚乙烯醇缩醛Y的羟基量、缩醛基量、和乙酰基量可以用与聚乙烯醇缩醛X相同的方法测定。
上述保护层中的增塑剂的含量相对于100质量份上述聚乙烯醇缩醛Y的优选下限为20质量份、优选上限为45质量份。通过将上述增塑剂的含量设为20质量份以上,可以确保耐贯通性,通过设为45质量份以下,可以防止增塑剂的渗出,防止夹层玻璃用中间膜的透明性和粘接性的降低。上述增塑剂的含量的更优选下限为30质量份、进一步优选下限为35质量份、更优选上限为43质量份、进一步优选上限为41质量份。从进一步提高夹层玻璃的隔音性出发,上述保护层中增塑剂的含量优选少于上述隔音层中增塑剂的含量。
从进一步提高夹层玻璃的隔音性出发,聚乙烯醇缩醛Y的羟基量优选大于聚乙烯醇缩醛X的羟基量,更优选大1摩尔%以上,进一步优选大5摩尔%以上,特别优选大8摩尔%以上。通过调整聚乙烯醇缩醛X和聚乙烯醇缩醛Y的羟基量,可以控制上述隔音层和上述保护层中增塑剂的含量,上述隔音层的玻璃化转变温度变低。其结果是,夹层玻璃的隔音性进一步提高。
另外,从夹层玻璃的隔音性进一步提高出发,相对于100质量份上述隔音层中的聚乙烯醇缩醛X的增塑剂的含量(以下,也称含量X。)优选多于相对于100质量份上述保护层中的聚乙烯醇缩醛Y的增塑剂的含量(以下,也称含量Y。),更优选多5质量份以上,进一步优选多15质量份以上,特别优选多20质量份以上。通过调整含量X和含量Y,上述隔音层的玻璃化转变温度变低。其结果是,夹层玻璃的隔音性进一步提高。
作为上述保护层的厚度的优选下限为200μm、优选上限为1000μm。通过将上述保护层的厚度设为200μm以上,可以确保耐贯通性。
上述保护层的厚度的更优选下限为300μm、更优选上限为700μm。
作为制造上述隔音中间膜的方法没有特别限定,例如,可以举出将上述隔音层和保护层通过挤出法、压延法、冲压法等通常的制膜法制膜为片状后进行层叠的方法等。
本发明的夹层玻璃用中间膜的制造方法没有特别限定,可以通过将原料树脂组合物由挤出机挤出并成形的方法来制造。在此,通过控制挤出成形时的条件,可以得到所述宽度方向的中心部的厚度、宽度方向的一个端部的厚度和宽度方向的另一端部的厚度的最大值与最小值之差分别小于40μm的夹层玻璃用中间膜。另外,作为对夹层玻璃用中间膜的表面实施压花加工的方法,使用压花辊的方法中难以得到满足所述宽度方向的膨胀率和流动方向的收缩率的夹层玻璃用中间膜,因此优选采用通过对挤出机的模具的口模的形状进行改进来赋予凹凸的唇形法。
具体地,将原料树脂组合物使用挤出机从模具挤出的挤出工序中,通过将挤出机的吐出压变动设为±5kg/cm2以下,并将模具的温度变动设为±20℃以下,可以得到所述宽度方向的中心部的厚度、宽度方向的一个端部的厚度和宽度方向的另一端部的厚度的最大值与最小值之差分别小于40μm的夹层玻璃用中间膜。
具有将原料树脂组合物使用挤出机从模具挤出的挤出工序,将上述挤出工序中的挤出机的吐出压变动设为±5kg/cm2以下,并将模具的温度变动设为±20℃以下的夹层玻璃用中间膜的制造方法也是本发明之一。
使用挤出机将上述原料树脂组合物从模具挤出而得的夹层玻璃用中间膜可以沿制造时的膜的流动方向卷取而成为卷状,供夹层玻璃的制造。
将本发明的夹层玻璃用中间膜沿着夹层玻璃用中间膜的制造时的膜的流动方向卷取而成的卷状体也是本发明之一。
具有使用挤出机将原料树脂组合物从模具挤出的挤出工序、和将上述被挤出的夹层玻璃用中间膜沿着挤出方向卷取成卷状的卷取工序,将上述挤出工序中的挤出机的吐出压变动设为±5kg/cm2以下,并将模的温度变动设为±20℃以下的卷状体的制造方法也是本发明之一。
本发明的夹层玻璃用中间膜层叠于一对玻璃板之间夹层玻璃也是本发明之一。
上述玻璃板可以使用通常所用的透明板玻璃。例如,可以举出浮法板玻璃、抛光板玻璃、模塑板玻璃(molded plate glass)、丝网玻璃、夹丝板玻璃、着色的平板玻璃、热射线吸收玻璃、热射线反射玻璃、生玻璃等无机玻璃。另外,也可以使用在玻璃的表面形成了紫外线遮蔽涂层的紫外线遮蔽玻璃。此外,也可以使用聚对苯二甲酸乙二醇酯、聚碳酸酯、聚丙烯酸酯等有机塑料板。
作为上述玻璃板,也可使用2种以上的玻璃板。例如,可举出在透明浮法板玻璃和生玻璃这样的着色的玻璃板之间层叠了本发明的夹层玻璃用中间膜的夹层玻璃。另外,作为上述玻璃板,也可使用2种以上厚度不同的玻璃板。
发明效果
根据本发明,可以提供预压接时能够发挥高脱气性且能够制造透明性高的夹层玻璃的夹层玻璃用中间膜、卷状体、夹层玻璃、夹层玻璃用中间膜的制造方法、以及卷状体的制造方法。
附图说明
图1是说明测定夹层玻璃用中间膜的宽度方向的中心部的厚度、宽度方向的一个端部的厚度和宽度方向的另一端部的厚度的方法的示意图。
具体实施方式
以下举实施例对本发明的方案进行更具体的说明,但本发明不仅限于这些实施例。
(实施例1)
相对于聚乙烯醇缩丁醛(羟基的含量30摩尔%、乙酰基化度1摩尔%、缩丁醛化度69摩尔%、平均聚合度1700)100质量份,添加作为增塑剂的二-2-乙基己酸三乙二醇酯(3GO)40质量份、作为紫外线屏蔽剂的2-(2’-羟基-3’-叔丁基-5-甲基苯基)-5-氯苯并三唑(BASF公司制、“Tinuvin326”)0.5质量份、作为抗氧化剂的2,6-二叔丁基-对甲酚(BHT)0.5质量份,用混合辊充分地混炼,得到树脂组合物。
通过挤出机挤出所得到的树脂组合物,得到宽度为100cm的单层的夹层玻璃用中间膜,卷成卷状。此时,作为唇形模具使用唇的间隙为1.2mm的模具,将挤出机的吐出压变动设为±3kg/cm2以下,并将模具的温度变动设为±10℃以下。
(实施例2~8、比较例1~5)
除了将挤出机的吐出压变动设为±5kg/cm2以下、并将模具的温度变动设为±20℃以下的范围而改变挤出条件以外,与实施例1同样地得到夹层玻璃用中间膜。
(实施例9)
(保护层用树脂组合物的制备)
相对于聚乙烯醇缩丁醛树脂(羟基的含量30摩尔%、乙酰基化度1摩尔%、缩丁醛化度69摩尔%、平均聚合度1700)100重量份,添加作为增塑剂的二-2-乙基己酸三乙二醇酯(3GO)40重量份、作为紫外线屏蔽剂的2-(2’-羟基-3’-叔丁基-5-甲基苯基)-5-氯苯并三唑(BASF公司制、“Tinuvin326”)0.5重量份、作为抗氧化剂的2,6-二叔丁基-对甲酚(BHT)0.5重量份,用混合辊充分混炼,得到保护层树脂组合物。
(隔音层用树脂组合物的制备)
相对于聚乙烯醇缩丁醛树脂(羟基的含量23摩尔%、乙酰基化度12摩尔%、缩丁醛化度65摩尔%、平均聚合度2300)100重量份,添加作为增塑剂的二-2-乙基己酸三乙二醇酯(3GO)60重量份,用混合辊充分混炼,得到隔音层用树脂组合物。
(夹层玻璃用中间膜的制作)
通过将隔音层用树脂组合物和保护层用树脂组合物共挤出,得到宽度为100cm且在厚度方向上依次层叠有保护层(厚度350μm)、隔音层(厚度100μm)、保护层(厚度350μm)的三层结构的夹层玻璃用中间膜,卷成卷状。此时,作为唇形模具使用唇的间隙为1.2mm的模具,将挤出机的吐出压变动设为±3kg/cm2以下,并将模具的温度变动设为±10℃以下。
(实施例10)
除了将挤出机的吐出压变动设为±5kg/cm2以下、并将模具的温度变动设为±20℃以下的范围而改变挤出条件以外,与实施例9同样地得到夹层玻璃用中间膜。
(评价)
对于实施例和比较例中得到的夹层玻璃用中间膜,通过以下方法进行评价。
结果示于表1。
(1)夹层玻璃用中间膜的厚度的流动方向的偏差的评价
通过图1所示方法,评价夹层玻璃用中间膜的厚度的流动方法的偏差。
首先从卷状体拉出夹层玻璃用中间膜,沿流动方向在3m以上的位置切断,得到3m×1m的试验用样品。将试验用样品在20℃、30%RH以下的条件下以平面状放置,保养24小时后,供测定。
对于保养后的试验用样品,沿着图1的沿宽度方向的中心部的虚线41、沿宽度方向的端部(从各端部向宽度方向的中心部进入夹层玻璃用中间膜的宽度的5%的长度的位置)的虚线42、43,使用千分尺(安立电气公司制、KG601B型广泛围电子千分尺),以1.5m/分钟连续地测量夹层玻璃用中间膜的厚度。需要说明的是,测定在20℃、30%RH以下的条件下进行。
根据所得到的夹层玻璃用中间膜的宽度方向的中心部的厚度、宽度方向的一个端部的厚度和宽度方向的另一端部的厚度的数据,分别算出厚度的最大值与最小值之差。
(2)预压接时的脱气性的评价
将2片透明的前玻璃板(纵100cm×横50cm×厚2mm)作为1组,准备6组透明的前玻璃板。在厚度的流动方向的偏差的评价中将所得到的3m×1m的试验用样品切分成6个1m×0.5m。需要说明的是,切分时,使试验用样品的3m的方向与切分样品的1m的方向平行。将切分的6个试验用样品片分别用上述6组透明的前玻璃板夹持,得到6组层叠体。在加热烘箱内按照层叠体的温度(预压接温度)成为50~70℃的方式加热所得到的层叠体,输送到夹辊(基于气缸的夹压厚度5kg/cm2、线速度5m/分钟)间,进行预压接。
使用雾度计(东京电色公司制、TC-H3DP)JIS-K7105测定预压接后的层叠体的总光线透过率。6组层叠体的平均的总光线透过率为60%以上的情况评价为“○○”,50%以上且小于60%的情况评价为“○”,40%以上且小于50%的情况评价为“△”,小于40%的情况评价为“×”。
【表1】
产业上的可利用性
根据本发明,可以提供预压接时能够发挥高脱气性、且能够制造透明性高的夹层玻璃的夹层玻璃用中间膜、卷状体、夹层玻璃、夹层玻璃用中间膜的制造方法、以及卷状体的制造方法。
附图标记说明
1 夹层玻璃用中间膜
2 卷状体
3 试验用样品
41 沿着试验用样品3上的宽度方向的中心部的虚线
42、43 沿着试验用样品3上的宽度方向的端部的虚线
Claims (6)
1.一种夹层玻璃用中间膜,其特征在于,是在至少一侧的表面具有多个凹部和多个凸部的夹层玻璃用中间膜,
将相对于所述夹层玻璃用中间膜的制造时的膜的流动方向正交的同一平面状的方向作为宽度方向,沿着制造时的膜的流动方向遍及3m测定所述宽度方向的中心部的厚度、所述宽度方向的一个端部的厚度和所述宽度方向的另一端部的厚度时,所述宽度方向的中心部的厚度、所述宽度方向的一个端部的厚度和所述宽度方向的另一端部的厚度的最大值与最小值之差分别小于40μm。
2.如权利要求1所述的夹层玻璃用中间膜,其特征在于,将相对于所述夹层玻璃用中间膜的制造时的膜的流动方向正交的同一平面状的方向作为宽度方向,沿着制造时的膜的流动方向遍及3m测定所述宽度方向的中心部的厚度、所述宽度方向的一个端部的厚度和所述宽度方向的另一端部的厚度时,所述宽度方向的中心部的厚度、所述宽度方向的一个端部的厚度和所述宽度方向的另一端部的厚度的最大值与最小值之差分别为30μm以下。
3.一种卷状体,其特征在于,是将权利要求1或2所述的夹层玻璃用中间膜沿着夹层玻璃用中间膜的制造时的膜的流动方向卷取而成的。
4.一种夹层玻璃,其特征在于,权利要求1或2所述的夹层玻璃用中间膜层叠于一对玻璃板之间。
5.一种夹层玻璃用中间膜的制造方法,其特征在于,是权利要求1或2所述的夹层玻璃用中间膜的制造方法,
具有使用挤出机从模具挤出原料树脂组合物的挤出工序,
将所述挤出工序中的挤出机的吐出压变动设为±5kg/cm2以下,且将模具的温度变动设为±20℃以下。
6.一种卷状体的制造方法,其特征在于,是权利要求3所述的卷状体的制造方法,
具有使用挤出机从模具挤出原料树脂组合物的挤出工序、和将所述被挤出的夹层玻璃用中间膜沿着挤出方向卷取成卷状的卷取工序,
将所述挤出工序中的挤出机的吐出压变动设为±5kg/cm2以下,且将模具的温度变动设为±20℃以下。
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KR102066796B1 (ko) | 2018-07-06 | 2020-01-15 | 에스케이씨 주식회사 | 유리접합필름의 패턴 제조방법 및 이를 포함하는 전사장치 |
JPWO2020137851A1 (ja) * | 2018-12-28 | 2021-11-04 | 積水化学工業株式会社 | 合わせガラス用中間膜、ロール体及び合わせガラスの製造方法 |
KR102237613B1 (ko) | 2019-07-23 | 2021-04-07 | 에스케이씨 주식회사 | 접합용 필름 및 이를 포함하는 광투과 적층체 |
KR102254665B1 (ko) | 2019-09-19 | 2021-05-20 | 에스케이씨 주식회사 | 접합용 필름 및 이를 포함하는 광투과 적층체 |
KR102254664B1 (ko) | 2019-09-19 | 2021-05-20 | 에스케이씨 주식회사 | 접합용 필름 및 이를 포함하는 광투과 적층체 |
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JP2020125238A (ja) | 2020-08-20 |
RU2700387C2 (ru) | 2019-09-16 |
JPWO2016052615A1 (ja) | 2017-07-13 |
EP3202735A1 (en) | 2017-08-09 |
JP6966180B2 (ja) | 2021-11-10 |
KR20170066279A (ko) | 2017-06-14 |
WO2016052615A1 (ja) | 2016-04-07 |
EP3202735A4 (en) | 2018-04-18 |
RU2017114990A3 (zh) | 2019-05-07 |
TW201711844A (en) | 2017-04-01 |
MX2017003744A (es) | 2017-06-30 |
RU2017114990A (ru) | 2018-11-02 |
US20170165938A1 (en) | 2017-06-15 |
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