US20080268270A1 - High impact polymer interlayers - Google Patents

High impact polymer interlayers Download PDF

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Publication number
US20080268270A1
US20080268270A1 US11/742,547 US74254707A US2008268270A1 US 20080268270 A1 US20080268270 A1 US 20080268270A1 US 74254707 A US74254707 A US 74254707A US 2008268270 A1 US2008268270 A1 US 2008268270A1
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polymer
polymer layer
layer
plasticizer
plasticized thermoplastic
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US11/742,547
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English (en)
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Wenjie Chen
Aristotelis Karagiannis
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Solutia Inc
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Solutia Inc
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Priority to US11/742,547 priority Critical patent/US20080268270A1/en
Assigned to SOLUTIA INC. reassignment SOLUTIA INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KARAGIANNIS, ARISTOTELIS, CHEN, WENJIE
Priority to TW97114517A priority patent/TWI438090B/zh
Priority to RU2009136519/05A priority patent/RU2469869C2/ru
Priority to CN200880014039.1A priority patent/CN101678660B/zh
Priority to PCT/US2008/061690 priority patent/WO2008137367A2/en
Priority to BRPI0810707 priority patent/BRPI0810707A2/pt
Priority to EP08769194.5A priority patent/EP2146848B1/en
Priority to JP2010506548A priority patent/JP2010525967A/ja
Priority to CA 2682963 priority patent/CA2682963A1/en
Priority to MX2009011731A priority patent/MX2009011731A/es
Priority to KR20097023277A priority patent/KR20100016323A/ko
Priority to AU2008247894A priority patent/AU2008247894A1/en
Publication of US20080268270A1 publication Critical patent/US20080268270A1/en
Assigned to CITIBANK, N.A. reassignment CITIBANK, N.A. TERM LOAN PATENT SECURITY AGREEMENT Assignors: CPFILMS INC., FLEXSYS AMERICA L.P., SOLUTIA INC.
Assigned to CITIBANK, N.A. reassignment CITIBANK, N.A. ABL PATENT SECURITY AGREEMENT Assignors: CPFILMS INC., FLEXSYS AMERICA L.P., SOLUTIA INC.
Priority to NO20093093A priority patent/NO20093093L/no
Priority to IL201762A priority patent/IL201762A0/en
Assigned to CPFILMS INC., SOLUTIA INC., FLEXSYS AMERICA L.P. reassignment CPFILMS INC. RELEASE OF ABL SECURITY INTEREST IN PATENTS - REEL/FRAME 022610/0495 Assignors: CITIBANK, N.A.
Assigned to FLEXSYS AMERICA L.P., SOLUTIA INC., CPFILMS INC. reassignment FLEXSYS AMERICA L.P. RELEASE OF TERM LOAN SECURITY INTEREST IN PATENTS - REEL/FRAME 022610/0697 Assignors: CITIBANK, N.A.
Assigned to DEUTSCHE BANK TRUST COMPANY AMERICAS, AS COLLATERAL AGENT reassignment DEUTSCHE BANK TRUST COMPANY AMERICAS, AS COLLATERAL AGENT SECURITY AGREEMENT Assignors: CP FILMS INC., FLEXSYS AMERICA L.P., SOLUTIA INC.
Assigned to SOLUTIA INC., FLEXSYS AMERICA L.P., CPFILMS INC. reassignment SOLUTIA INC. RELEASE BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: DEUTSCHE BANK TRUST COMPANY AMERICAS, AS COLLATERAL AGENT
Priority to US13/683,552 priority patent/US9248599B2/en
Priority to US14/965,446 priority patent/US20160096347A1/en
Abandoned legal-status Critical Current

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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
    • 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
    • B32B17/1055—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
    • 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
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B29C48/08—Flat, e.g. panels flexible, e.g. films
    • 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
    • B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
    • B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
    • 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
    • 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
    • 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
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/22—Layered products comprising a layer of synthetic resin characterised by the use of special additives using plasticisers
    • 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
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • 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
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • 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
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/306—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
    • 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
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • 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
    • B32B27/42—Layered products comprising a layer of synthetic resin comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/0008—Organic ingredients according to more than one of the "one dot" groups of C08K5/01 - C08K5/59
    • C08K5/0016—Plasticisers
    • 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
    • B32B2419/00—Buildings or parts thereof
    • 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
    • B32B2605/00—Vehicles
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31855—Of addition polymer from unsaturated monomers
    • Y10T428/31909—Next to second addition polymer from unsaturated monomers
    • Y10T428/31913—Monoolefin polymer

Definitions

  • the present invention is in the field of polymer interlayers and multiple layer glass panels comprising polymer interlayers, and, more specifically, the present invention is in the field of polymer interlayers comprising multiple thermoplastic layers.
  • Safety glass often refers to a transparent laminate comprising a poly(vinyl butyral) layer disposed between two layers of glass.
  • Safety glass often is used to provide a transparent barrier in architectural and automotive openings. Its main function is to absorb energy, such as that caused by a blow from an object, without allowing penetration through the opening or the dispersion of shards of glass, thus minimizing damage or injury to the objects or persons within an enclosed area.
  • Safety glass also can be used to provide other beneficial effects, such as to attenuate acoustic noise, reduce UV and/or IR light transmission, and/or enhance the appearance and aesthetic appeal of window openings.
  • Safety glass is particularly desirable in architectural glazing applications that are intended for use in areas prone to hurricane activity.
  • wind-borne debris will be present.
  • windows and doors typically the weakest link in a building's envelope, must be safeguarded from penetration by wind-borne debris, and they must also remain in the place through the remainder of the storm. Therefore, an interlayer that can safeguard a window against significant impacts and remain in the opening during cyclical wind loading even if the glass is cracked is particularly desirable.
  • interlayer If an interlayer is too soft or adhesion to glass is too low, then the interlayer will not have the strength to resist high wind loading after an impact. On the other hand, if the interlayer is too stiff and adhesion to glass is too high, then the interlayer will not have a high level of impact resistance—i.e., the interlayer will have low penetration resistance.
  • interlayer compositions are needed to provide multiple layer safety glass that has high impact resistance and high cyclical wind-loading resistance for, among other things, hurricane protection.
  • the present invention provides multiple poly(vinyl butyral) layer interlayers that can be used in multiple layer glass panel type applications that require a high level of impact protection, for example in hurricane protection applications or in bullet proof glass applications.
  • This effect is achieved by forming a poly(vinyl butyral) interlayer that has a relatively stiff poly(vinyl butyral) inner layer disposed between two relatively soft outer poly(vinyl butyral) layers, where the stiffness difference is achieved by a plasticizer differential that is achieved at least in substantial part by a residual hydroxyl content difference among the poly(vinyl butyral) layers.
  • FIG. 1 represents a schematic cross sectional view of a multiple manifold coextrusion device of the present invention.
  • FIG. 2 is a graph showing the results of a ball drop impact test for three sample interlayer embodiments of the present invention and a control interlayer.
  • the interlayer comprises three poly(vinyl butyral) layers having different plasticizer concentrations that are stably achieved by formulating the poly(vinyl butyral) layers with different levels of residual hydroxyl content.
  • composition of the poly(vinyl butyral) layers is such that net migration of plasticizer from one poly(vinyl butyral) layer to another is negligible or zero, thereby maintaining the plasticizer differential.
  • plasticizer content can be measured as parts per hundred resin parts (phr), on a weight per weight basis. For example, if 30 grams of plasticizer is added to 100 grams of polymer resin, then the plasticizer content of the resulting plasticized polymer would be 30 phr. As used herein throughout, when the plasticizer content of a polymer layer is given, the plasticizer content of that particular layer is determined with reference to the phr of the plasticizer in the melt that was used to produce that particular layer.
  • the plasticizer content can be determined via a wet chemical method in which an appropriate solvent, or a mixture of solvents, is used to extract the plasticizer out of the layer.
  • an appropriate solvent or a mixture of solvents
  • the plasticizer content in phr can be calculated.
  • individual polymer layers can be physically separated from one another before the plasticizer content in each of the polymer layers is measured.
  • a multiple layer interlayer that imparts superior impact resistance and high stiffness characteristics on multiple layer glass panels comprises three polymer layers having different stiffness.
  • the stiffness of the two skin layers can be the same or different.
  • an “interlayer” is any thermoplastic construct that can be used in multiple layer glass applications, such as safety glass in windshields and architectural windows
  • a “multiple layer” interlayer is any interlayer that is formed by combining, usually through laminating processes or coextrusion, two or more individual layers into a single interlayer.
  • a multiple layer interlayer comprises three polymer layers disposed in contact with each other, wherein each polymer layer comprises a thermoplastic polymer, as detailed elsewhere herein.
  • three layer interlayers of the present invention have two outer poly(vinyl butyral) layers and an inner poly(vinyl butyral) layer, with the outer layers having relatively high plasticizer content and low residual hydroxyl content (as detailed elsewhere herein), and the inner layer having a relatively low plasticizer content and high residual hydroxyl content.
  • the compatibility of that plasticizer in poly(vinyl butyral) is largely determined by the residual hydroxyl content or vinyl acetate content.
  • poly(vinyl butyral) with a greater residual hydroxyl content or vinyl acetate content will have different compatibility or capacity with the given plasticizer from poly(vinyl butyral) with a lower residual hydroxyl content and vinyl acetate content.
  • These properties can be used to select the hydroxyl or vinyl acetate content of each poly(vinyl butyral) polymer and formulate each of the polymer layers to allow for the proper plasticizer loading and to stably maintain the difference in plasticizer content between the polymer layers.
  • the plasticizer content of the outer layers are each at least 2 phr, 5 phr, 8 phr, 10 phr, 12 phr, 15 phr, 18 phr, 20 phr, or 25 phr greater than the plasticizer content of the inner polymer layer.
  • the outer layers can have, for example, 10-75 phr plasticizer, while the inner layer can have, for example, 0-50 phr plasticizer.
  • the plasticizer difference between the layers is maintained in the final laminate or coextruded interlayer due to the difference in residual hydroxyl content or vinyl acetate content.
  • residual hydroxyl content refers to the amount of hydroxyl groups remaining as side groups on the polymer chains after processing is complete.
  • poly(vinyl butyral) can be manufactured by hydrolyzing poly(vinyl acetate) to poly(vinyl alcohol), and then reacting the poly(vinyl alcohol) with butyraldehyde to form poly(vinyl butyral).
  • PVOH poly(vinyl alcohol)
  • poly(vinyl butyral) can be manufactured by hydrolyzing poly(vinyl acetate) to poly(vinyl alcohol), and then reacting the poly(vinyl alcohol) with butyraldehyde to form poly(vinyl butyral).
  • butyraldehyde typically will not result in all hydroxyl groups being converted to acetal groups.
  • the residual hydroxyl content of the inner polymer layer can be at least 0.5%, 1.5%, 1.8%, 2.0%, 2.2%, 2.5%, 3.0%, 4.0%, 5.0%, 7.5%, or at least 10% greater than the residual hydroxyl content of the two outer polymer layers.
  • This difference is calculated by subtracting the residual hydroxyl content of the layer with the lower residual hydroxyl content from the residual hydroxyl content of the layer with the greater residual hydroxyl content. For example, if the middle polymer layer has a residual hydroxyl content of 20%, and an outer polymer layer has a residual hydroxyl content of 17%, then the residual hydroxyl content of the middle layer is 3% greater than the residual hydroxyl content of the outer layer.
  • the residual hydroxyl content in poly(vinyl butyral) resin can be controlled by controlling butyraldehyde concentration, reaction times, and other variables in the manufacturing process.
  • the residual hydroxyl content of the layers is as follows: middle layer less than 30% and outer layers less than 28%; middle layer less than 25% and outer layers less than 23%; middle layer less than 23% and outer layers less than 21%; middle layer less than 21% and outer layers less than 19%; middle layer less than 21% and outer layer less than 17%; middle layer less than 21% and out layer less than 15%; middle layer less than 21% and out layer less than 12%; middle layer less than 20% and outer layers less than 17%; middle layer less than 18% and outer layers less than 15%; and middle layer less than 15% and outer layers less than 12%.
  • any suitable values given in the paragraph, above, for the difference in hydroxyl content between the layers can be used.
  • tensile break stress, or tensile strength, of a polymer layer is defined and measured according to the method described in JIS K6771.
  • the polymer layers have a tensile break stress according to the following, wherein the middle polymer layer in the following list is the polymer layer with the lower plasticizer content: middle polymer layer greater than 135 kilograms per square centimeter and outer polymer layers less than 120 kilograms per square centimeter; middle polymer layer greater than 150 kilograms per square centimeter and outer polymer layers less than 135 kilograms per square centimeter; middle polymer layer greater than 165 kilograms per square centimeter and outer polymer layers less than 150 kilograms per square centimeter; middle polymer layer greater than 180 kilograms per square centimeter and outer polymer layers less than 165 kilograms per square centimeter; or middle polymer layer greater than 350 kilograms per square centimeter and outer polymer layer less than 100 kilograms per square centimeter; or in general the two polymer layers differ
  • two adjacent polymer layers of the present invention have the differing plasticizer content and residual hydroxyl content, as described above, and each further has a residual acetate content of less than 5 mole %, less than 4 mole %, less than 3 mole %, less than 2 mole %, or less than 1 mole %.
  • These residual acetate concentrations can be combined with the residual hydroxyl contents given above, in any combination, to form polymer layers of the present invention having the described differences in plasticizer content and residual hydroxyl content while having little to no residual acetate content.
  • the outer two layers can have the same or different compositions.
  • one outer polymer layer can have a 10 phr plasticizer difference with the middle polymer layer, while the second outer polymer layer can have a 20 phr plasticizer difference with the middle polymer layer.
  • Such a difference would be useful, for example and without limitation, in embodiments in which the two rigid glazing substrates between which the multiple layer interlayer is being laminated are different or have different surface treatments.
  • interlayers having more than three layers.
  • any of the three polymer layers in the three layer embodiment can be substituted with multiple thinner polymer layers that together have the approximate thickness of the single polymer layer.
  • a modifying agent such as an ultraviolet light absorber
  • polymer films as described below, can also be added, as desired.
  • a polymer film can be added between the middle polymer layer and an outer polymer layer in the three layer embodiment to provide a desired function, such as infrared blocking.
  • Interlayers of the present invention can have, for example, 4, 5, 6, or up to 10 individual layers.
  • interlayers of the present invention can be incorporated into the interlayers of the present invention.
  • polymer films such as polyesters like poly(ethylene terephthalate) having a metallized layer, an infrared reflecting stack, or other performance layer deposited thereon, can be included between any two layers of polymer layers of the present invention.
  • additional layers of thermoplastics such as poly(vinyl butyral), polyester films, primer layers, and hardcoat layers can be added to the multiple layer interlayers of the present invention according to the desired result and the particular application.
  • the present invention also includes methods of manufacturing an interlayer, comprising the steps of forming a first polymer layer, a second polymer layer, and a third polymer layer, wherein the three polymer layers have compositions according to the three layer embodiments as described elsewhere herein, and laminating the three polymer layers together to form the interlayer.
  • the present invention also includes multiple layer glass panels, such as windshields and architectural windows and doors, comprising a multiple layer interlayer of the present invention.
  • multiple layer glazing panels having plastics, such as acrylics, or other suitable materials in place of the glass panels.
  • 4,799,745) and can comprise, for example, one or more Angstroms-thick metal layers and one or more (for example two) sequentially deposited, optically cooperating dielectric layers.
  • the metal layer(s) may optionally be electrically resistance heated for defrosting or defogging of any associated glass layers.
  • An additional type of polymer film that can be used with the present invention which is described in U.S. Pat. No. 6,797,396, comprises a multitude of nonmetallic layers that function to reflect infrared radiation without creating interference that can be caused by metallic layers.
  • the polymer film layer in some embodiments, is optically transparent (i.e. objects adjacent one side of the layer can be comfortably seen by the eye of a particular observer looking through the layer from the other side), and usually has a greater, in some embodiments significantly greater, tensile modulus regardless of composition than that of any adjacent polymer layer.
  • the polymer film layer comprises a thermoplastic material.
  • thermoplastic materials having suitable properties are nylons, polyurethanes, acrylics, polycarbonates, polyolefins such as polypropylene, cellulose acetates and triacetates, vinyl chloride polymers and copolymers and the like.
  • the polymer film layer comprises materials such as re-stretched thermoplastic films having the noted properties, which include polyesters, for example poly(ethylene terephthalate) and copoly(ethylene terephthalate) (PETG).
  • PET poly(ethylene terephthalate)
  • poly(ethylene terephthalate) is used, and, in various embodiments, the poly(ethylene terephthalate) has been biaxially stretched to improve strength, and has been heat stabilized to provide low shrinkage characteristics when subjected to elevated temperatures (e.g. less than 2% shrinkage in both directions after 30 minutes at 150° C.).
  • Poly(ethylene terephthalate) film that can be used with the present invention are disclosed in published European Application No. 0157030.
  • Polymer films of the present invention can also include a hardcoat and/or and antifog layer, as are known in the art.
  • a “polymer layer” means any thermoplastic polymer composition formed by any suitable method into a thin layer that is suitable alone, or in stacks of more than one layer, for use as an interlayer that provides adequate penetration resistance and glass retention properties to laminated glazing panels. Plasticized poly(vinyl butyral) is most commonly used to form polymer layers.
  • the polymer layer can comprise any suitable polymer, and, in a preferred embodiment, the polymer layer comprises poly(vinyl butyral).
  • the polymer layer comprises poly(vinyl butyral).
  • the polymer component consists of or consists essentially of poly(vinyl butyral).
  • any of the variations in additives disclosed herein can be used with the polymer layer having a polymer consisting of or consisting essentially of poly(vinyl butyral).
  • the polymer layer comprises a polymer based on partially acetalized poly(vinyl alcohol)s.
  • the polymer layer comprises a polymer selected from the group consisting of poly(vinyl butyral), polyurethane, polyvinyl chloride, poly(ethylene vinyl acetate), combinations thereof, and the like.
  • the polymer layer comprises plasticized poly(vinyl butyral).
  • the polymer layer comprises poly(vinyl butyral) and one or more other polymers. Other polymers having a proper plasticizing capacity can also be used.
  • the poly(vinyl butyral) can be produced by known acetalization processes that involve reacting poly(vinyl alcohol) with butyraldehyde in the presence of an acid catalyst, followed by neutralization of the catalyst, separation, stabilization, and drying of the resin, with the understanding that in various embodiments, residual hydroxyl content will be controlled, as described elsewhere herein.
  • the polymer layer comprises poly(vinyl butyral) having a molecular weight greater than 30,000, 40,000, 50,000, 55,000, 60,000, 65,000, 70,000, 120,000, 250,000, or 350,000 grams per mole (g/mole or Daltons).
  • Small quantities of a dialdehyde or trialdehyde can also be added during the acetalization step to increase molecular weight to greater than 350 Daltons (see, for example, U.S. Pat. Nos. 4,874,814; 4,814,529; and 4,654,179).
  • the term “molecular weight” means the weight average molecular weight.
  • those additional, conventional polymer layers can comprise 20 to 60, 25 to 60, 20 to 80, or 10 to 70 parts plasticizer per one hundred parts of resin (phr). Of course other quantities can be used as is appropriate for the particular application.
  • the plasticizer has a hydrocarbon segment of fewer than 20, fewer than 15, fewer than 12, or fewer than 10 carbon atoms.
  • Plasticizers used in the polymer layers of the present invention can include esters of a polybasic acid or a polyhydric alcohol, among others.
  • Suitable plasticizers include, for example, triethylene glycol di-(2-ethylbutyrate), triethylene glycol di-(2-ethylhexanoate), triethylene glycol diheptanoate, tetraethylene glycol diheptanoate, dihexyl adipate, dioctyl adipate, hexyl cyclohexyladipate, mixtures of heptyl and nonyl adipates, diisononyl adipate, heptylnonyl adipate, dibutyl sebacate, polymeric plasticizers such as the oil-modified sebacic alkyds, and mixtures of phosphates and adipates such as disclosed in U
  • plasticizers that can be used are mixed adipates made from C 4 to C 9 alkyl alcohols and cyclo C 4 to C 10 alcohols, as disclosed in U.S. Pat. No. 5,013,779, and C 6 to C 8 adipate esters, such as hexyl adipate.
  • the plasticizer is triethylene glycol di-(2-ethylhexanoate).
  • Adhesion control agents can also be included in the polymer layers of the present invention to impart the desired adhesiveness. These agents can be incorporated into the outer layers in a three polymer layer embodiment, for example. Any of the ACAs disclosed in U.S. Pat. No. 5,728,472 can be used. Additionally, residual sodium acetate and/or potassium acetate can be adjusted by varying the amount of the associated hydroxide used in acid neutralization.
  • polymer layers of the present invention comprise, in addition to sodium acetate, magnesium bis(2-ethyl butyrate)(chemical abstracts number 79992-76-0). The magnesium salt can be included in an amount effective to control adhesion of the polymer layer to glass.
  • Additives may be incorporated into the polymer layer to enhance its performance in a final product.
  • additives include, but are not limited to, plasticizers, dyes, pigments, stabilizers (e.g., ultraviolet stabilizers), antioxidants, flame retardants, other IR absorbers, anti-block agents, combinations of the foregoing additives, and the like, as are known in the art.
  • Agents that selectively absorb light in the visible or near infrared spectrum can be added to any of the appropriate polymer layers.
  • Agents that can be used include dyes and pigments such as indium tin oxide, antimony tin oxide, or lanthanum hexaboride (LaB 6 ).
  • Any suitable method can be used to produce the polymer layers and the multiple layer interlayers of the present invention. Details of suitable processes for making poly(vinyl butyral) are known to those skilled in the art (see, for example, U.S. Pat. Nos. 2,282,057 and 2,282,026). In one embodiment, the solvent method described in Vinyl Acetal Polymers, in Encyclopedia of Polymer Science & Technology, 3 rd edition, Volume 8, pages 381-399, by B. E. Wade (2003) can be used. In another embodiment, the aqueous method described therein can be used. Poly(vinyl butyral) is commercially available in various forms from, for example, Solutia Inc., St. Louis, Mo. as ButvarTM resin.
  • resin refers to the polymeric (for example poly(vinyl butyral)) component that is removed from the mixture that results from the acid catalysis and subsequent neutralization of the polymeric precursors. Resin will generally have other components in addition to the polymer, for example poly(vinyl butyral), such as acetates, salts, and alcohols.
  • melt refers to a mixture of resin with a plasticizer and, optionally, other additives.
  • One exemplary method of forming a poly(vinyl butyral) layer comprises extruding molten poly(vinyl butyral) comprising resin, plasticizer, and additives and then forcing the melt through a sheet die (for example, a die having an opening that is substantially greater in one dimension than in a perpendicular dimension).
  • Another exemplary method of forming a poly(vinyl butyral) layer comprises casting a melt from a die onto a roller, solidifying the resin, and subsequently removing the solidified resin as a sheet.
  • the surface texture at either or both sides of the layer may be controlled by adjusting the surfaces of the die opening to control melt fracture or by providing texture at the roller surface.
  • the layer texture can be configured to include spaced projections that define a temporary surface irregularity to facilitate the de-airing of the layer during lamination processes after which the elevated temperatures and pressures of the laminating process cause the projections to melt into the layer, thereby resulting in a smooth finish.
  • Manufacture of the interlayers of the present invention can be by any suitable process, for example, by lamination of individual layers or through coextrusion.
  • Lamination of individual layers can be performed by combining separately produced layers and then applying sufficient heat and pressure to tack the layers together to form a “prelaminate,” thereby allowing the handling of the layers as a unit, with final adhesion occurring later when the interlayer is laminated between rigid glazing substrates.
  • individual layers can be assembled and positioned between rigid glazing substrates without any prior tacking, and the complete multiple layer glazing can be laminated in a single step.
  • the preferred method of producing interlayers of the present invention is through the simultaneous coextrusion of multiple, for example three, polymer layers.
  • coextrusion of multiple melts results in multiple polymer layers being formed together as one interlayer.
  • Multiple layer interlayers of the present invention are preferably coextruded using a multiple manifold coextrusion device such as the one shown in FIG. 1 .
  • an extrusion device has a first die manifold 12 , a second die manifold 14 , and a third die manifold 16 .
  • the device shown in FIG. 1 operates by simultaneously extruding polymer melts from each manifold ( 12 , 14 , 16 ) toward the extrusion opening 20 , where the multiple layer interlayer is extruded as a composite of three individual polymer layers. Layer thickness can be varied by adjusting the distance between the die lips at the extrusion opening 20 .
  • a “polymer layer” includes layers that are produced individually and layers that are coextruded.
  • an interlayer that is produced by coextruding three melts will have three individual “polymer layers” just as will an interlayer that is produced by laminating three individually produced polymer layers into a single interlayer.
  • the interlayers of the present invention can have total thicknesses of 0.1 to 3 millimeters, 0.2 to 2.5 millimeters, 0.25 to 1.75 millimeters, and 0.3 to 1.5 millimeters (mm).
  • the individual polymer layers of a multiple layer interlayer can have, for example, approximately equal thicknesses that, when added together, result in the total thickness ranges given above.
  • the thicknesses of the layers can be different, and can still add to the total thicknesses given above.
  • the parameters for the polymer layer described above apply as well to any layer in a multiple layer construct of the present invention that is a poly(vinyl butyral) type layer.
  • the clarity of a polymer layer, and particularly a poly(vinyl butyral) layer can be determined by measuring the haze value, which is a quantification of the amount of light scattered away from the direction of the incident beam in passing through the layer.
  • the percent haze can be measured according to the following technique.
  • An apparatus for measuring the amount of haze a Hazemeter, Model D25, which is available from Hunter Associates (Reston, Va.), can be used in accordance with ASTM D1003-61 (Re-approved 1977)-Procedure A, using Illuminant C, at an observer angle of 2 degrees.
  • percent haze is less than 5%, less than 3%, and less than 1%.
  • the visible transmittance can be quantified using a UV-Vis-NIR spectrophotometer such as the Lambda 900 made by Perkin Elmer Corp. by methods described in international standard ISO 9050:1990.
  • the transmittance through a polymer layer of the present invention is at least 60%, at least 70%, or at least 80%.
  • Pummel adhesion can be measured according to the following technique, and where “pummel” is referred to herein to quantify adhesion of a polymer layer to glass, the following technique is used to determine pummel.
  • Two-ply glass laminate samples are prepared with standard autoclave lamination conditions. The laminates are cooled to about ⁇ 18° C. (0° F.) and manually pummeled with a hammer to break the glass. All broken glass that is not adhered to the poly(vinyl butyral) layer is then removed, and the amount of glass left adhered to the poly(vinyl butyral) layer is visually compared with a set of standards.
  • the standards correspond to a scale in which varying degrees of glass remain adhered to the poly(vinyl butyral) layer.
  • Poly(vinyl butyral) layers of the present invention can have, for example, a pummel value of between 2 and 10.
  • Tensile break stress can be determined for a polymer layer according to the procedure described in JIS K6771.
  • Impact testing is carried out using a staircase method “ball drop” test to determine the impact resistance of the laminated glass panel comprising the interlayer.
  • a 2,268 gram steel ball is dropped vertically onto a horizontally positioned, 30.5 cm ⁇ 30.5 cm size of the sample panel to be tested.
  • Impact performance is measured as the Mean Break Height (MBH), which is calculated as the ball drop height at which 50% of the samples would hold the ball and 50% would allow penetration.
  • MBH Mean Break Height
  • Examples of the poly(vinyl butyral) multiple layer interlayers having improved impact resistance are listed in Table 1.
  • the impact resistance shown as the Mean Break Height (MBH) in the unit of meters, is illustrated in FIG. 2 .
  • each sample interlayer has a total thickness of 0.64 millimeters (25 mil) comprising a first layer and a third layer each having 16% residual hydroxyl content and a thickness of 0.10 millimeters (4 mils) with a second layer having 18.5% residual hydroxyl content and a thickness of 0.43 millimeters (17 mils) between and in contact with the first layer and the third layer.
  • Table 1 provides the phr of the plasticizer triethylene glycol di-(2-ethylhexanoate) (3GEH) formulated with the resin.
  • the tested multiple layer interlayer embodiments of the present invention demonstrate a higher impact performance at 0.64 millimeter total layer thickness (25 mil), compared with a conventional, single layer interlayer having a thickness of 0.76 millimeters (30 mil).
  • the stiffness of two sample multiple layer interlayers of the present invention are measured as the Flexural Modulus of a laminated glass panel comprising the sample interlayers.
  • the same thickness of glass is used for both samples and the comparative interlayer, which is 3 millimeters in the present invention. Results are shown in Table 2.
  • each sample three layer interlayer has the thicknesses and residual hydroxyl content given in the table, with the first and third outer layers of each having 25 phr of plasticizer triethylene glycol di-(2-ethylhexanoate) (3GEH) formulated with the resin, and the second, inner layer of each having 18 phr of that same plasticizer formulated with the resin.
  • the “Comp” interlayer is a Saflex “Storm” product that is commercially available from Solutia Inc.
  • any of the ranges, values, or characteristics given for any single component of the present invention can be used interchangeably with any ranges, values, or characteristics given for any of the other components of the invention, where compatible, to form an embodiment having defined values for each of the components, as given herein throughout.
  • a polymer layer can be formed comprising residual acetate content in any of the ranges given in addition to any of the ranges given for plasticizer, where appropriate, to form many permutations that are within the scope of the present invention but that would be cumbersome to list.

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MX2009011731A MX2009011731A (es) 2007-04-30 2008-04-25 Capas intermedias de polimero de alto impacto.
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BRPI0810707 BRPI0810707A2 (pt) 2007-04-30 2008-04-25 Intercamadas poliméricas de alto impacto.
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IL201762A0 (en) 2010-06-16
TWI438090B (zh) 2014-05-21
KR20100016323A (ko) 2010-02-12
CN101678660A (zh) 2010-03-24
US20130075949A1 (en) 2013-03-28
AU2008247894A1 (en) 2008-11-13
CA2682963A1 (en) 2008-11-13
EP2146848B1 (en) 2019-09-11
CN101678660B (zh) 2015-12-02
EP2146848A2 (en) 2010-01-27
NO20093093L (no) 2010-01-29
US20160096347A1 (en) 2016-04-07
BRPI0810707A2 (pt) 2014-10-21
RU2469869C2 (ru) 2012-12-20
US9248599B2 (en) 2016-02-02
TW200906620A (en) 2009-02-16
WO2008137367A3 (en) 2009-10-08
RU2009136519A (ru) 2011-06-10
MX2009011731A (es) 2009-12-18
JP2010525967A (ja) 2010-07-29

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