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WO2025064387A1 - Procédés et dispositifs de pelage pour la séparation de couches intermédiaires multicouches - Google Patents

Procédés et dispositifs de pelage pour la séparation de couches intermédiaires multicouches Download PDF

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Publication number
WO2025064387A1
WO2025064387A1 PCT/US2024/047017 US2024047017W WO2025064387A1 WO 2025064387 A1 WO2025064387 A1 WO 2025064387A1 US 2024047017 W US2024047017 W US 2024047017W WO 2025064387 A1 WO2025064387 A1 WO 2025064387A1
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WO
WIPO (PCT)
Prior art keywords
layer
poly
butyral
vinyl butyral
soft
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/US2024/047017
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English (en)
Inventor
Sungkyun Sohn
Jan Herbert Crommen
Wenjie Chen
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Solutia Inc
Original Assignee
Solutia Inc
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Filing date
Publication date
Application filed by Solutia Inc filed Critical Solutia Inc
Publication of WO2025064387A1 publication Critical patent/WO2025064387A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/02—Separating plastics from other materials
    • 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
    • B32B43/00—Operations specially adapted for layered products and not otherwise provided for, e.g. repairing; Apparatus therefor
    • B32B43/006—Delaminating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/02—Separating plastics from other materials
    • B29B2017/0203—Separating plastics from plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/02—Separating plastics from other materials
    • B29B2017/0213—Specific separating techniques
    • B29B2017/0217—Mechanical separating techniques; devices therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2029/00—Use of polyvinylalcohols, polyvinylethers, polyvinylaldehydes, polyvinylketones or polyvinylketals or derivatives thereof as moulding material
    • B29K2029/14—Polyvinylacetals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3052—Windscreens
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/778—Windows
    • B29L2031/7782—Glazing
    • 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/62—Plastics recycling; Rubber recycling

Definitions

  • U.S. Pat. No. 11 ,518,472 discloses a method for recycling an intermediate film for laminated glass, comprising a step of separating a layer comprising an A layer and a layer comprising a B layer from the intermediate film for laminated glass comprising at least the A layer and the B layer.
  • JP2000331384A identifies as a problem to be solved to easily and thoroughly remove a protective layer stuck on a substrate without leaving shavings, an abrasive material, or the like.
  • U.S. Pat. No. 7,812,061 discloses that used optical discs using a PC resin as a substrate material can be reused as a raw material for a flameretardant polycarbonate resin composition by chemical treatment.
  • U.S. Pat. No. 5,278,282 discloses a method for separating polymers from a physically commingled solid mixture containing a plurality of polymers that comprises dissolving a first one of the polymers in a solvent at a first lower temperature to form a first preferably single phase solution and a remaining solid component.
  • the solid component contains additional polymers which are not soluble to the solvent at the first temperature but which may be soluble at higher temperatures.
  • the method includes subsequently heating the solvent to dissolve additional polymer from the solid component to form subsequent solutions.
  • the polymers are then separated from their respective solution either using flash evaporation techniques when more than one polymer has been dissolved at a single temperature, or conventional techniques for extracting a polymer from a solvent in a solution.
  • U.S. Pat. No. 4,940,187 discloses a set of systematic equipment for recycling raw materials such as: copper, ferrous material, and different plastic materials from waste wires.
  • the equipment includes a classifier for separating the copper and plastic materials, and a wet gravity separator for further separating the different plastic materials having different densities and floating heights in a tank of the gravity separator.
  • EP0425800A1 discloses a method of separating synthetic resin foam from rigid articles by subjecting the article to a deformation treatment, after which any synthetic resin foam still bonding to the articles is removed from the articles by means of scraping members. Also disclosed is a device suitable for such use.
  • U.S. Pat. No. 9,050,739 discloses processing a used golf ball to make the materials of the used golf ball reusable in a new golf ball.
  • the method may include melting a golf ball made of layers each having a different melting point.
  • the materials may be separated by melting the different layers one by one.
  • the method of recycling a golf ball may generally include pulverizing used golf balls made of materials having differing amounts of magnetic additive into particles. The particles may be separated by a magnetic field.
  • JP7166571 B2 discloses a film-shaped member having a first layer on one side of an adhesive layer, and a second layer on the opposite side, which is separated by cutting along the layer with a blade.
  • U.S. Pat. No. 4,775,697 discloses pure polymers, such as polyester used in photographic film and in plastic walls of drink bottles or polycarbonate used in high-quality plastic beverage bottles, separated from thin saran and like coating layers of a multi-layer film or sheet in a dry abrasion process.
  • U.S. Pat. No. 5,162,383 discloses pure polymers, such as polyester used in photographic film and in plastic walls of drink bottles or polycarbonate used in high-quality plastic beverage bottles, separated from thin saran and like coating layers of a multi-layer film or sheet in a wet abrasion process.
  • U.S. Pat. No. 7,244,314 discloses a system for recycling reusable resin mold products recovered from discarded apparatuses.
  • the recycling system includes a crushing system for crushing resin mold products into crushed resinous pieces and packing the same in a bag, a classification system for irradiating a light beam to the resin in the bag and classifying the bags into respective kinds of resins based on a reflected beam therefrom, a cleaning system for separately cleaning the respective kind of crushed resinous pieces taken out of the bag to remove foreign matters adhered onto the surfaces of the crushed resinous pieces therefrom, and a recovery system for recovering the cleaned crushed resinous pieces
  • W02005/103130 discloses a process for the recovery of a polymer from a polymer coating on a support, whereby the coated support is subjected to a high-pressure-water-jet by which at least a portion of the polymer coating is removed from the support and is carried away in the form of an aqueous wash of polymer compound in water, whereafter at least a portion of the polymer compound is recovered from the aqueous wash and is introduced into a process where polymer compound is contacted with a solvent or solvent mixture capable of dissolving the polymer compound, and the polymer is then precipitated from the solvent or solvent mixture in the form of solid polymer particles.
  • WO2021/237306 discloses a recycling process for a laminate and a solution used in such a process.
  • the disclosure is said to find particular application in the removal of an adhered overlay from an underlying substrate material such as plastic.
  • the process includes subjecting the laminate to an impact frictional striking force, thereby substantially separating the substrate layer from the one or more surface layers of the overlay and then washing the substrate layer with a washing solution to remove the remaining surface layers of the overlay and glue from the substrate layer.
  • the washing solution may be an aqueous solution including a surfactant, a solvent and a base.
  • WO2022250944A2 discloses processes for separating a first layer from a remainder of a multilayer interlayer sheet, in which the multilayer sheet is heated, and thereafter the first layer is separated from the remainder of the multilayer interlayer sheet by pulling the first layer and the remainder of the multilayer interlayer sheet in different directions, in a defined orientation.
  • 63/448,707 discloses processes for separating a first layer from a remainder of a tapered multilayer interlayer sheet, in which the tapered multilayer interlayer sheet is heated, and thereafter the first layer is separated from the remainder of the tapered multilayer interlayer sheet by pulling the first layer and the remainder of the tapered multilayer interlayer sheet in different directions, in a defined orientation, without the tapered multilayer interlayer sheet wrinkling or tearing.
  • the multilayer sheet is an acoustic interlayer in which the remainder is a core-skin bilayer with the core layer left exposed, it is difficult to mechanically separate the two layers (the core and the remaining skin), since the weak and flimsy core layer easily gets torn, being unable to survive the mechanical peeling force.
  • the core layer can also be quite sticky, making it difficult to work with. Indeed, it sticks to both the skin layer as well as any other material with which it comes in contact. In some cases, it will tend to preferentially adhere to the skin layer, in other cases it may preferentially adhere to the other material.
  • the invention relates to processes for separating a soft poly(vinyl butyral) layer from a stiff poly(vinyl butyral) layer of a multilayer interlayer, the processes comprising peeling the soft poly(vinyl butyral) layer from the stiff poly(viny I butyral) layer.
  • the invention relates to apparatuses for carrying out the methods of the invention.
  • Fig. 1 is a schematic of the mechanical separation for an acoustic trilayers interlayer, including the peeling of the core layer of a core-skin bilayer.
  • Fig. 2 is a schematic illustration of the orientation of each layer while being separated.
  • the invention relates to processes for separating a soft poly(vinyl butyral) layer from a stiff poly(vi nyl butyral) layer of a multilayer interlayer, the processes comprising peeling the soft poly(vinyl butyral) layer from the stiff poly(vi nyl butyral) layer.
  • the invention further comprises a preliminary step of trimming the multilayer interlayer such that a width of the multilayer interlayer is less than 50 mm, and a thickness of the soft poly(vinyl butyral) layer is from about 0.05 mm to about 0.3 mm.
  • the multilayer interlayer varies in thickness across a surface of the multilayer interlayer.
  • the stiff poly(vinyl butyral) layer comprises poly(vinyl butyral) having a weight average molecular weight from about 70,000 to about 225,000, or from 90,000 to 200,000.
  • the soft poly(vinyl butyral) layer comprises poly(vinyl butyral) having a weight average molecular weight from about 130,000 to about 600,000, or from 150,000 to 500,000.
  • the soft poly(vinyl butyral) layer comprises a poly(vinyl butyral) polymer having a polydispersity Index (Mw/Mn) from about 2 to about 4.5, or from 2.5 to 4.0.
  • Mw/Mn polydispersity Index
  • the soft poly(vinyl butyral) layer has a number average molecular weight (Mn) higher than about 65,000 g/mole.
  • the soft poly(vinyl butyral) layer has a poly(vinyl acetate) content less than 3 wt%.
  • a thickness of the stiff poly(vinyl butyral) layer is at least 1 .0 times, or at least 1 .5 times, a thickness of the soft poly(vi nyl butyral) layer.
  • the stiff poly(vinyl butyral) layer comprises a plasticized poly(vinyl butyral) polymer which exhibits a 90° peel adhesion value, when laminated to glass, of from about 20 N/cm to about 70 N/cm.
  • the soft poly(vinyl butyral) layer comprises a plasticized poly(vinyl butyral) polymer which exhibits a 90° peel adhesion value, when laminated to glass, of from about 3 N/cm to about 18 N/cm.
  • a difference in a 90° peel adhesion value between the soft poly(vinyl butyral) layer and the stiff poly(vinyl butyral) layer, when laminated to glass is at least 10 N/cm, or at least 15 N/cm.
  • a difference in a 90° peel adhesion value between the stiff PVB and soft PVB when in contact is at least about 10 N/cm, at 25% relative humidity and 21 ° C.
  • the soft poly(vinyl butyral) layer comprises poly(vinyl butyral) having a shear storage modulus at 20°C from about 0.1 MPa to about 18 MPa.
  • the stiff poly(vinyl butyral) layer comprises poly(vinyl butyral) having a shear storage modulus at 20°C from about 20 MPa to about 600 MPa.
  • a difference between a shear storage modulus at 20°C of the soft poly(vinyl butyral) layer and the stiff poly(vinyl butyral) layer is at least 10 MPa.
  • the soft poly(vinyl butyral) layer comprises a poly(vinyl butyral) polymer having a residual hydroxyl content from about 8% to about 13.5%.
  • the stiff poly(vinyl butyral) layer comprises poly(vinyl butyral) having a weight average molecular weight from about 70,000 to 225,000.
  • the process includes the use of spreader rollers to ensure the interlayer is flat.
  • the process includes the use of annealing to help eliminate wrinkles.
  • substantially all of the soft poly(vinyl butyral) layer is removed from the stiff poly(vinyl butyral) layer such that FT-IR results show substantially no residue of the soft poly(vinyl butyral) layer.
  • the invention relates to processes of separating a soft poly(vinyl butyral) layer from a stiff poly(vinyl butyral) layer of a multilayer interlayer, the process comprising peeling the soft po ly (vinyl butyral) layer from the stiff poly(viny I butyral) layer.
  • the processes may further comprise a preliminary step of trimming the multilayer interlayer such that a width of the multilayer interlayer is less than 50 mm, and a thickness of the soft poly(vinyl butyral) layer is from about 0.05 mm to about 0.3 mm.
  • the multilayer interlayer may vary somewhat in thickness across a surface of the multilayer interlayer.
  • the stiff poly(vinyl butyral) layer comprises poly(vinyl butyral) having a weight average molecular weight from about 70,000 to about 225,000, or from about 90,000 to about 200,000.
  • the soft poly(vinyl butyral) layer comprises poly(vinyl butyral) having a weight average molecular weight from about 130,000 to about 600,000, or from about 150,000 to about 500,000.
  • the soft poly (vinyl butyral) layer may comprise a poly(vinyl butyral) polymer having a polydispersity Index (Mw/Mn) from about 2 to about 4.5, or from about 2.5 to about 4.0. It may be advantageous also that the soft poly(viny I butyral) layer has a number average molecular weight (Mn) higher than about 65,000 g/mole.
  • the soft poly(vinyl butyral) layer has a poly(vinyl acetate) content less than 3 wt%, or less than 2.5 wt%.
  • the invention thus relates to a process for mechanically separating a poly(viny I butyral) (PVB) core-skin bi-layer into a core layer and a skin layer, which can be reused in core layer extrusion processes and skin layer extrusion processes, respectively.
  • the PVB core-skin bi-layer used in the processes of this invention may be generated as a result of mechanically separating one of the skin layers from an acoustic PVB sheet composed of a skin-core-skin tri-layer, as depicted in Figure 1 .
  • the core layer properties useful to enable such a mechanical separation process are also described.
  • the invention relates to processes for separating a soft poly(vinyl butyral) layer from a stiff poly(vinyl butyral) layer of a multilayer interlayer, the process comprising peeling the soft poly(vinyl butyral) layer from the poly(vinyl butyral) stiff layer.
  • the step of peeling is not particularly limited, although as noted, the soft, sticky nature of the core layer may make it difficult to work with.
  • the invention thus involves separating the soft poly(vinyl butyral) layer from the stiff poly(vinyl butyral) layer of the multilayer interlayer sheet by pulling the soft layer and the stiff layer of the multilayer interlayer sheet in different directions.
  • an angle a defined by the skin layer to be separated and the multilayer sheet at the separation point may be equal to or greater than an angle p defined by the multilayer interlayer and the soft layer at the separation point, during the process, which may be continuous.
  • These angles are illustrated in Figure 2.
  • the invention relates also to defining an angle y, defined by the skin layer and the core layer at the separation point, and it may be advantageous that the following formulas be satisfied: a ⁇ 180°
  • the orientation described may be maintained during the continuous process.
  • the multilayer interlayer may be interleaved with a film such as polyethylene prior to separation.
  • the process may be achieved, for example, in 3 steps.
  • the bi-layer may be interleaved with another film and wound on a roll.
  • the interleaved core-skin bilayer roll may be unwound, slit to a pre-determined width, 1 -inch for instance, then re-wound into multiple rolls having the narrower width.
  • the roll from the second step may be unwound, the interleaving separated from the bi-layer, and then the core layer mechanically peeled from the skin layer, followed by collecting the recovered core layer and the skin layer, respectively.
  • the bi-layer may be interleaved while wound on a roll. This interleaving step may be accomplished by unwinding the multilayer interlayer and adhering the other film to the core layer side of the multilayer interlayer, and rewinding the multilayer interlayer onto a roll.
  • the core layer of the multilayer interlayer tends to be soft and sticky and thus will readily adhere to the other film, for example polyethylene.
  • Other film materials that may be used for the other film include films or coated films such as release liners and the like.
  • the interleaved core-skin bi-layer roll may then be unwound, slit to a pre-determined width, 1 -inch for instance, then re-wound into multiple rolls having the narrower width.
  • This optional step may be used, if needed, to trim the interlayer such that the width of the trimmed interlayer is suited for the following process of peeling.
  • the roll from the second step may be unwound, the interleaving separated from the bi-layer, and the core layer mechanically peeled from the skin layer, followed by collecting the recovered core layer and the skin layer, respectively.
  • the core layer has a polydispersity index (PDI), that is Mw/Mn, larger than 4.5, the core layer tends to be crumbly, non-elastic, and strongly adheres to the skin layer, making peeling difficult.
  • PDI polydispersity index
  • the core has a number average molecular weight (Mn) that may be higher than 65,000 g/mole, and/or a po ly (vinyl acetate) content no greater than 3 wt%, so that the core layer is not crumbly and is sufficiently elastic, and does not strongly adhere to the skin, making it almost impossible to mechanically peel off from the skin layer.
  • Mn number average molecular weight
  • po ly (vinyl acetate) content no greater than 3 wt%
  • multilayer interlayers having at least a soft layer and a stiff layer are separated such that at least a portion of the soft layer is removed from the stiff layer.
  • the multilayer interlayers are typically bilayers, although the invention is not so limited so long as the soft and stiff layers are present, as described herein.
  • the soft and stiff layers are also described herein as the core and skin layers, respectively.
  • the layers described comprise poly(vinyl butyral) polymers, which may each be the reaction product of a single reaction, or a blend of reaction products of different reactions. Indeed, when blended, it may be difficult or impossible to distinguish between a single polymer and a blend of polymers.
  • a poly(vinyl butyral) polymer and its properties may refer to a single polymer which is a single reaction product, a blend of two or more polymers having these properties, or a blend of several polymers in which the resulting blend has the stated properties.
  • a multilayer interlayer typically a bilayer resulting from a skin layer having been separated from an acoustic trilayer leaving the core layer exposed, is separated into two layers, a soft poly(vinyl butyral) layer and a stiff poly(vinyl butyral) layer.
  • stiff poly(vinyl butyral) refers to a poly(vinyl butyral) resin, or a blend of poly(vinyl butyral) resins, that is demonstrably stiffer than the “soft poly(vinyl butyral),” typically forming a skin or stiff layer of a multilayer poly(vinyl butyral) multilayer sheet, as further described herein.
  • soft poly(vinyl butyral) refers to a poly(vinyl butyral) resin, or a blend of poly(vinyl butyral) resins, that is demonstrably softer than the “stiff poly(vinyl butyral),” typically forming a core or soft layer of a multilayer poly(vinyl butyral) multilayer sheet, as further described herein.
  • the soft or core poly(vinyl butyral) layer is typically sandwiched between two stiff or skin poly(vinyl butyral) layers to form a multilayer poly(viny I butyral) multilayer sheet, from which one skin layer may thereafter be removed prior to the processes of the present invention, or as a precursor step of the present invention.
  • the bilayers separated according to the invention may result from processes disclosed and claimed in WO2022250944A2, the relevant disclosure of which is incorporated herein by reference in its entirety, in which a first or skin layer is separated from a remainder of a multilayer interlayer sheet, for example from the core and skin layer of an acoustic trilayer interlayer.
  • the multilayer sheet may be heated, and thereafter the first (skin) layer separated from the remainder of the multilayer interlayer sheet by pulling the first layer and the remainder of the multilayer interlayer sheet in different directions, resulting in a core-skin bilayer.
  • Any other suitable method may likewise be used to obtain the multilayers (bilayers) that are separated according to the present invention.
  • multilayer and multiple layers mean an interlayer having more than one layer, and multilayer and multiple-layer may be used interchangeably.
  • the layers of the interlayer are generally produced by mixing a polymer resin such as poly(vinyl butyral) with one or more plasticizers and melt processing the mix into a sheet by any applicable process or method known to one of skill in the art, including, but not limited to, extrusion, with the layers being combined by processes such as co-extrusion or lamination. Other additional ingredients may optionally be added for various other purposes.
  • the interlayer sheet is formed, it is typically collected and rolled for transportation and storage and for later use in the multiple layer glass panel, as discussed below.
  • the two stiff (or outer or skin) layers may comprise poly(vinyl butyral) (“PVB”) resin with a plasticizer or mixture of plasticizers, while the softer (inner or core) layers may comprise the same or different PVB resin or a different thermoplastic material with the same or different plasticizer and/or mixture of plasticizers.
  • PVB poly(vinyl butyral)
  • the stiff or skin layers and the soft or core layer(s) of the multilayered interlayer sheets may be comprised of the same thermoplastic material or different thermoplastic materials and the same or different plasticizer or plasticizers. Either or both layers may include additional additives as known in the art, as desired.
  • the core or soft layer of the multilayer interlayer is understood to be responsible for the acoustic properties of an acoustic trilayer, and comprises soft poly(vinyl butyral), that is poly(vinyl butyral) (PVB) that is softer than the skin or stiff PVB, which is stiffer than the soft PVB.
  • the soft poly (vinyl butyral) may have a residual hydroxyl content from about 5% to about 15%, or from 8% to 12%, or from about 9% to 11 %, or as described elsewhere herein.
  • the stiff poly(vinyl butyral) may have a residual hydroxyl content of from about 12% to about 30%, or from 15% to about 25%, or from 18% to 22%.
  • these multilayered interlayer sheets may comprise in order: a polymer layer (skin layer) comprising a stiff plasticized poly(vinyl butyral) resin; a second polymer layer (core layer) comprising a soft plasticized poly(vinyl butyral) resin, or a blend thereof having the same or different residual hydroxyl content; and optionally a third polymer layer (skin layer) comprising stiff plasticized poly(viny I butyral) resin.
  • This optional skin layer is removed prior to the processes of the invention, or incorporated in aspects where a skin layer is removed prior to and such that a core layer is exposed.
  • the core polymer layer is thus disposed adjacent a skin layer. If there are three or more layers, the second polymer layer may be disposed between the first polymer layer and the third polymer layer, resulting in two skin layers and a central core layer.
  • the thickness of each of the outer layers can be at least about 4, at least about 5, at least about 6, at least about 7 mils and/or not more than about 15, not more than about 13, not more than about 12, not more than about 10, not more than about 9, not more than about 8 mils, or can be in the range of from about 2 to about 15, about 3 to about 13, or about 4 to about 10 mils.
  • these layers can have a combined thickness of at least about 9, at least about 13, at least about 15, at least about 16, at least about 18, at least about 20, at least about 23, at least about 25, at least about 26, at least about 28, or at least about 30 mils, and/or not more than about 73, not more than about 60, not more than about 50, not more than about 45, not more than about 40, not more than about 35 mils, or in the range of from about 9 to about 70 mils, about 13 to about 40 mils, or about 25 to about 35 mils.
  • the ratio of the thickness of one of the outer layers to one of the inner layers in a multiple layer interlayer can be at least about 1 .4:1 , at least about 1 .5:1 , at least about 1 .8:1 , at least about 2:1 , at least about 2.5:1 , at least about 2.75:1 , at least about 3:1 , at least about 3.25:1 , at least about 3.5:1 , at least about 3.75:1 , or at least about 4:1 .
  • the interlayer is a three-layer interlayer having an inner core layer disposed between a pair of outer skin layers, the ratio of the thickness of one of the skin layers to the thickness of the core layer may fall within one or more of the ranges above.
  • the ratio of the combined thickness of the outer layers to the inner layer can be at least about 2.25:1 , at least about 2.4:1 , at least about 2.5:1 , at least about 2.8:1 , at least about 3:1 , at least about 3.5:1 , at least about 4:1 , at least about 4.5:1 , at least about 5:1 , at least about 5.5:1 , at least about 6:1 , at least about 6.5:1 , or at least about 7:1 and/or not more than about 30:1 , not more than about 20:1 , not more than about 15:1 , not more than about 10:1 , not more than about 9:1 , or not more than about 8:1 .
  • Multiple layer interlayers as described herein can comprise generally flat interlayers having substantially the same thickness along the length, or longest dimension, and/or width, or second longest dimension, of the sheet.
  • the multiple layer interlayers of the present invention can be tapered, or wedge-shaped, interlayers that comprise at least one tapered zone having a wedge-shaped profile.
  • Tapered interlayers may have a changing thickness profile along at least a portion of the length and/or width of the sheet, such that, for example, at least one edge of the interlayer has a thickness greater than the other.
  • the interlayer is a tapered interlayer, at least 1 , at least 2, at least 3, or more of the individual resin layers may include at least one tapered zone.
  • Tapered interlayers may be particularly useful in, for example, heads-up display (HUD) panels in automotive and aircraft applications.
  • HUD heads-up display
  • plasticizer refers generally to a molecule or blend of molecules, as further described herein, that plasticizes a polymer at lower plasticizer content, specifically poly(vinyl butyral), thereby softening it.
  • plasticizers are added to the polymer resin to form polymer layers or interlayers.
  • Plasticizers are generally added to the polymer resin to increase the flexibility and durability of the resultant polymer interlayer. Plasticizers function by embedding themselves between chains of polymers, spacing them apart (increasing the “free volume”) and thus significantly lowering the glass transition temperature (T g ) of the polymer resin, making the material softer.
  • the amount of plasticizer in the interlayer can be adjusted to affect the glass transition temperature (T g ).
  • the glass transition temperature (T g ) is the temperature that marks the transition from the glassy state of the interlayer to the rubbery state. In general, higher amounts of plasticizer loading can result in lower T g .
  • the inner core layer i.e., the soft layer
  • the outer skin layers e.g., the stiff layer
  • Contemplated plasticizers include, but are not limited to, esters of a polybasic acid, a polyhydric alcohol, triethylene glycol di-(2-ethylbutyrate), triethylene glycol di-(2-ethylhexonate) (known as “3-GEH”), triethylene glycol diheptanoate, tetraethylene glycol diheptanoate, dihexyl adipate, dioctyl adipate, hexyl cyclohexyladipate, mixtures of heptyl and nonyl adipates, diisononyl adipate, heptylnonyl adipate, dibutyl sebacate, and polymeric plasticizers such as oil-modified sebacic alkyds and mixtures of phosphates and adipates, and mixtures and combinations thereof.
  • esters of a polybasic acid a polyhydric alcohol
  • 3-GEH is particularly preferred.
  • suitable plasticizers can include, but are not limited to, tetraethylene glycol di-(2-ethylhexanoate) (“4-GEH”), di(butoxyethyl) adipate, and bis(2-(2-butoxyethoxy)ethyl) adipate, dioctyl sebacate, nonylphenyl tetraethylene glycol, and mixtures thereof.
  • 4-GEH tetraethylene glycol di-(2-ethylhexanoate)
  • di(butoxyethyl) adipate di(butoxyethyl) adipate
  • bis(2-(2-butoxyethoxy)ethyl) adipate dioctyl sebacate
  • nonylphenyl tetraethylene glycol and mixtures thereof.
  • suitable plasticizers may include blends of two or more distinct plasticizers, including but not limited to those plasticizers described above.
  • plasticizers may be formed from aromatic groups, such polyadipates, epoxides, phthalates, terephthalates, benzoates, toluates, mellitates and other specialty plasticizers.
  • Further examples include, but are not limited to, dipropylene glycol dibenzoate, tripropylene glycol dibenzoate, polypropylene glycol dibenzoate, isodecyl benzoate, 2-ethylhexyl benzoate, diethylene glycol benzoate, propylene glycol dibenzoate, 2,2,4-trimethyl-1 ,3-pentanediol dibenzoate, 2,2,4-trimethyl-1 ,3- pentanediol benzoate isobutyrate, 1 ,3-butanediol dibenzoate, diethylene glycol di-o-toluate, triethylene glycol di-o-toluate, dipropylene glycol di-o-toluate, 1 ,2- octyl dibenzoate, tri-2-ethylhexyl trimellitate, di-2-ethylhexyl terephthalate, bisphenol A bis(2-ethylhexaonate), eth
  • the plasticizer content of the polymer interlayers of this application are measured in 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, the plasticizer content of the resulting plasticized polymer would be 30 phr.
  • the plasticizer content of a polymer layer is given in this application, the plasticizer content of the particular layer is determined in reference to the phr of the plasticizer in the melt that was used to produce that particular layer.
  • the high rigidity interlayer comprises a layer having a plasticizer content of less than about 35 phr and less than about 30 phr.
  • one or more polymer layers described herein can have a total plasticizer content of at least about 20 phr, at least about 25 phr, at least about 30 phr, at least about 35 phr, at least about 38 phr, at least about 40 phr, at least about 45 phr, at least about 50 phr, at least about 55 phr, at least about 60 phr, at least about 65 phr, at least about 67 phr, at least about 70 phr, at least about 75 phr of one or more plasticizers.
  • the polymer layer may also include not more than about 100 phr, not more than about 85 phr, not more than 80 phr, not more than about 75 phr, not more than about 70 phr, not more than about 65 phr, not more than about 60 phr, not more than about 55 phr, not more than about 50 phr, not more than about 45 phr, not more than about 40 phr, not more than about 38 phr, not more than about 35 phr, or not more than about 30 phr of one or more plasticizers.
  • the total plasticizer content of at least one polymer layer can be in the range of from about 20 to about 40 phr, about 20 to about 38 phr, or about 25 to about 35 phr. In other embodiments, the total plasticizer content of at least one polymer layer can be in the range of from about 38 to about 90 phr, about 40 to about 85 phr, or about 50 to 70 phr.
  • the interlayer includes a multiple layer interlayer
  • two or more polymer layers within the interlayer may have substantially the same plasticizer content and/or at least one of the polymer layers may have a plasticizer content different from one or more of the other polymer layers.
  • the interlayer includes two or more polymer layers having different plasticizer contents, the two layers may be adjacent to one another.
  • the difference in plasticizer content between adjacent polymer layers can be at least about 1 , at least about 2, at least about 5, at least about 7, at least about 10, at least about 20, at least about 30, at least about 35 phr and/or not more than about 80, not more than about 55, not more than about 50, or not more than about 45 phr, or in the range of from about 1 to about 60 phr, about 10 to about 50 phr, or about 30 to 45 phr.
  • At least two of the polymer layers of the interlayer may have similar plasticizer contents falling for example, within 10, within 5, within 2, or within 1 phr of each other, while at least two of the polymer layers may have plasticizer contents differing from one another according to the above ranges.
  • one or more polymer layers or interlayers described herein may include a blend of two or more plasticizers including, for example, two or more of the plasticizers listed above.
  • the total plasticizer content of the polymer layer and the difference in total plasticizer content between adjacent polymer layers may fall within one or more of the ranges above.
  • the interlayer is a multiple layer interlayer
  • one or more than one of the polymer layers may include two or more plasticizers.
  • at least one of the polymer layers including a blend of plasticizers may have a glass transition temperature higher than that of conventional plasticized polymer layer. This may provide, in some cases, additional stiffness to layer which can be used, for example, as an outer “skin” layer in a multiple layer interlayer.
  • the amount of plasticizer in the soft or core poly(vinyl butyral) or a blend of soft poly(vinyl butyral), may be, for example, from about 50 phr to about 150 phr, or from 55 phr to 120 phr, or from 60 to 100 phr.
  • the stiff poly(vinyl butyral) contained in the plasticized poly(vinyl butyral) multilayer sheet comprises from about 25 phr to about 50 phr plasticizer, or from 30 phr to 45 phr, or from 32 to 42 phr.
  • the plasticized poly(vinyl butyral) multilayer sheet may comprise triethylene glycol bis(2-ethylhexanoate) present as a plasticizer.
  • the plasticized poly(vinyl butyral) multilayer sheet may further comprise dihexyladipate or bis(2- ethylhexyl)adipate or another convenient substance such as BenzoflexTM 9-88 benzoate ester as a plasticizer.
  • plasticizer may be selected from one or more of esters of a polybasic acid or a polyhydric alcohol.
  • the plasticizer may be selected from one or more of: triethylene glycol bis(2-ethylhexanoate), tetraethylene glycol bis(2-ethylhexanoate), triethylene glycol bis(2-ethylbutyrate), triethylene glycol diheptanoate, tetraethylene glycol diheptanoate, dihexyl adipate, bis(2-ethylhexyl)adipate, bis(2-ethoxyethyl)adipate, dioctyl adipate, hexyl cyclohexyladipate, diisononyl adipate, heptylnonyl adipate, dibutyl sebacate, polymeric adipates, a soybean oil, or an epoxidized soybean oil.
  • the interlayer may comprise about 30 to about 60 phr (parts per hundred parts resin) total plasticizer. While the total plasticizer content is indicated above, the plasticizer content in the stiff layer(s) or soft layer(s) can be different from the total plasticizer content. In addition, the stiff layer(s) and soft layer(s) can have different plasticizer contents, as each respective layer's plasticizer content at the equilibrium state is determined at least in part by its respective residual hydroxyl content.
  • the amount of plasticizer in the stiff poly(vinyl butyral) or soft poly(vinyl butyral)s may be from about 20 phr to about 60 phr, or from 25 phr to 50 phr, or from 30 to 45 phr.
  • the skin or stiff layer of the multilayer interlayer sheet may comprise a PVB polymer having a Tg, for example, from about 20°C to about 45°C, or from 25°C to 40°C, or from 28°C to 35°C.
  • the Tg of the stiff po ly (vinyl butyral) may be at least about 20°C or at least 25°C, or at least 28°C, up to about 45°C, or up to 40°C, or up to 35°C.
  • the soft or core layer of the multilayer interlayer sheet may comprise a PVB polymer having a Tg, for example, from about - 15°C to about 45°C, or from -10°C to 30°C, or from -8°C to 25°C.
  • the Tg of the soft poly(vinyl butyral) may be at least about -15°C or at least -10°C, or at least -8°C, up to about 45°C, or up to 30°C, or up to 20°C.
  • the Tg of the core or soft layer may be at least 12°C lower, or at least 15°C lower, or at least 20°C lower, or at least 30° lower than the Tg of the stiff layer.
  • the polymer interlayer has at least two different glass transition temperatures (T g ) and the difference between the at least two different glass transition temperatures (T g ) is at least 5 e C.
  • the glass transition temperatures of one or more polymer layers may be different when measured alone or as part of a multiple layer interlayer.
  • the interlayer can include at least one polymer layer having a glass transition temperature, outside of an interlayer, of at least about 33, at least about 34, at least about 35, at least about 36, at least about 37, at least about 38, at least about 39, at least about 40, at least about 41 , at least about 42, at least about 43, at least about 44, at least about 45, or at least about 46°C.
  • the same layer may have a glass transition temperature within the polymer layer of at least about 34, at least about 35, at least about 36, at least about 37, at least about 38, at least about 39, at least about 40, at least about 41 , at least about 42, at least about 43, at least about 44, at least about 45, at least about 46, or at least about 47°C.
  • At least one other polymer layer of the multiple layer interlayer can have a glass transition temperature less than 30°C and may, for example, have a glass transition temperature of not more than about 25, not more than about 20, not more than about 15, not more than about 10, not more than about 9, not more than about 8, not more than about 7, not more than about 6, not more than about 5, not more than about 4, not more than about 3, not more than about 2, not more than about 1 , not more than about 0, not more than about -1 , not more than about -2°C, or not more than about -5°C, measured when the interlayer is not part of an interlayer.
  • the same polymer layer may have a glass transition temperature of not more than about 25, not more than about 20, not more than about 15, not more than about 10, not more than about 9, not more than about 8, not more than about 7, not more than about 6, not more than about 5, not more than about 4, not more than about 3, not more than about 2, not more than about 1 , or not more than about 0°C, when measured outside of the interlayer.
  • the difference between the glass transition temperatures of two polymer layers, typically adjacent polymer layers within an interlayer can be at least about 5, at least about 10, at least about 15, at least about 20, at least about 25, at least about 30, at least about 35, at least about 40, or at least about 45°C, while in other embodiments, two or more polymer layers can have a glass transition temperature within about 5, about 3, about 2, or about 1 °C of each other.
  • the lower glass transition temperature layer has a lower stiffness than the higher glass transition temperature layer or layers in an interlayer and may be located between higher glass transition temperature polymer layers in the final interlayer construction.
  • PVB layers according to the invention are further characterized by their peel adhesion properties, with respect to one another and with respect to other materials they may come in contact with.
  • the stiff PVB as described herein can exhibit a 90° peel adhesion value, when laminated to glass, of at least about 20 N/cm, at least about 25 N/cm, at least about 30 N/cm, at least about 35 N/cm, at least about 40 N/cm, at least about 45 N/cm, or at least about 50 N/cm at 25% relative humidity and 21 °C.
  • the stiff PVB as described herein can exhibit a 90° peel adhesion value, when laminated to glass, of from about 20 N/cm to about 70 N/cm, or from 25 N/cm to 65 N/cm, or from 30 N/cm to 60 N/cm.
  • the soft PVB as described herein can exhibit a 90° peel adhesion, when laminated to glass, of at least about 2 N/cm, at least about 3 N/cm, at least about 4 N/cm, up to about 20 N/cm, or up to 18 N/cm, or up to 15 N/cm, at 25% relative humidity and 21 °C.
  • the soft PVB as described herein can exhibit a 90° peel adhesion value, when laminated to glass, of from about 2 N/cm to about 20 N/cm, or from 3 N/cm to 18 N/cm, or from 4 N/cm to 15 N/cm.
  • the stiff PVB as described herein can exhibit a 90° peel adhesion to the soft PVB of at least about 8, at least about 10, at least about 15, at least about 20, at least about 25, at least about 30 at least about 35 or at least about 40 N/cm at 25% relative humidity and 21 °C.
  • the layers and interlayers according to embodiments of the present invention may exhibit such a peel adhesion while having an average moisture content of at least about 0.2%, or at least 0.25%, or at least 0.3%, or at least 0.35% or at least 0.4%, measured by Karl-Fisher Titration according to ASTM E203.
  • the 90° peel adhesion to glass values described herein may be determined according to the following procedure, including the lamination/autoclaving described.
  • the peel adhesion values of the stiff PVB to the soft PVB are determined according to the following, without of course first laminating/autoclaving the film to glass.
  • peel Adhesion To measure the bond strength between the plasticized PVB layer and glass, adhesion-coated aluminum foil is initially conditioned at 105°C for 30 min. Special peel adhesion laminates containing the PVB interlayer to be tested are then prepared using standard laminating techniques by substituting the conditioned aluminum foil for one glass piece of a standard double glass layered laminate. The thickness of the plasticized PVB layer in the laminate being tested is standardized at 30 mils (0.76 mil). More specifically, the coated foil is assembled to one side of the polymeric laminate with the adhesive next to the PVB layer and a test glass layer assembled to the other side of the PVB laminate. After two such laminates are assembled, they are placed with the foil faces in face-to-face contact and passed through deairing rolls.
  • the laminates are then placed singly, with foil down, in a circulating air oven at 100 °C for 5 minutes.
  • the hot laminates are then assembled, rerolled as before and autoclaved at 290 °F (143 °C) at 185 psi (1275k Pa).
  • a 4 cm wide cut through the foil and polymeric laminate is made using a special double wheeled cutter.
  • the glass at one end of the laminate is then scored and broken.
  • the outside edge of the aluminum foil and polymer laminate on each side of the 4 cm strip is cut at the glass break. At least three samples of a particular common polymeric laminate are tested per reported value.
  • a standard laminate to be used for moisture analysis is prepared from the same polymeric laminate piece.
  • the samples Prior to conducting the actual peel test, the samples are conditioned at (21 °C) overnight.
  • the sample of glass, foil and polymer laminate are clamped in testing grips of an Instron peel tester (crosshead speed of 5 in (12.7 cm) per min.) and a direct recorded measurement made of the force necessary to separate the polymer laminate from the glass. The average of the various recorded peaks is the value for the sample.
  • a stiff/soft/stiff trilayer or a stiff/soft bilayer sample are cut to a rectangular strip.
  • the surface layers are adhered to a piece of tape of a corresponding size.
  • the initial separation of the soft/core layers is carried out manually at one end of the strip to facilitate the mounting of the layer to the sample holder of the peel tester.
  • the strip can then be peeled apart at the stiff/soft interface in a 180 degree peel test by a peel testing apparatus.
  • the peel adhesion properties described are significant, since the core and skin material both exhibit stickiness to various materials, while the core layer is even stickier than the skin layer. Similarly, the two layers also exhibit a peel adhesion value when in the same film which value affects the ability to neatly separate the two layers.
  • the core and skin layers of the multilayers separated according to the invention are further characterized as having a different shear storage modulus.
  • the soft poly(vinyl butyral) layer comprises poly(vinyl butyral) having a shear modulus at 20 °C from about 0.01 MPa to about 20 MPa, or from about 0.1 to about 18 MPa, or from or from about 0.15 to about 15 MPa.
  • the stiff poly(vinyl butyral) layer comprises poly(vinyl butyral) having a shear modulus at 20 °C from about 20 MPa to about 600 MPa, or from about 28 to about 450 MPa, or from about 30 to about 400 MPa.
  • This property is likewise significant, since it indicates among other things the tendency of the layers to remain intact, or put another way, the likelihood the materials will tear. Because of the differences in shear modulus just described, the soft layer is indeed susceptible to tearing, making it difficult to remove the layer intact.
  • the glass transition temperature (Tg) and Shear Modulus as described herein can be determined by dynamical mechanical thermal analysis (DMTA) in shear mode.
  • the Tg is then determined by the position of the tan delta peak on the temperature scale in °C and the tan delta peak value is referred as tan delta or peak tan delta.
  • tan delta peak tan delta
  • tan 6 peak tan 6
  • peak tan 6 may be used interchangeably.
  • PVB residual hydroxyl content
  • PVB poly(vinyl alcohol)
  • residual hydroxyl content refers to the amount of hydroxyl groups remaining as side groups on the chains of the polymer after processing is complete.
  • PVB can be manufactured by hydrolyzing poly(vinyl acetate) to poly(vinyl alcohol), and then reacting the poly(vinyl alcohol) with butyraldehyde to form PVB. In the process of hydrolyzing the poly(vinyl acetate), typically not all the acetate side groups are converted to hydroxyl groups.
  • the reaction with butyraldehyde typically will not result in all the hydroxyl groups being converted into acetal groups. Consequently, in any finished PVB, there will typically be residual acetate groups (such as vinyl acetate groups) and residual hydroxyl groups (such as vinyl hydroxyl groups) as side groups on the polymer chain.
  • residual acetate groups such as vinyl acetate groups
  • residual hydroxyl groups such as vinyl hydroxyl groups
  • the residual hydroxyl content of a polymer can be regulated by controlling the reaction times and reactant concentrations, among other variables in the polymer manufacturing process. When utilized as a parameter herein, the residual hydroxyl content is measured on a wt. % basis per ASTM D-1396.
  • the difference between the residual hydroxyl content of the soft poly(vinyl butyral) and the residual hydroxyl content of the stiff poly(vinyl butyral) is at least 6%, or at least 5%, or at least 4%, or from 4% to 8%, or from 5% to 10%, or as further described herein.
  • the residual hydroxyl contents of the poly(vinyl butyral) resins for stiff (skin) layer(s) and soft (core) layer(s) may be different.
  • the resin for the core layer(s) for example, can comprise about 9 to about 18 weight percent (wt. %) residual hydroxyl groups calculated as PVOH, about 9 to about 16 wt. % residual hydroxyl groups calculated as PVOH, or about 9 to about 14 wt. % residual hydroxyl groups calculated as PVOH.
  • the resin for the skin layer(s) for example, can comprise about 13 to about 35 weight percent (wt. %) residual hydroxyl groups calculated as PVOH, about 13 to about 30 wt.
  • % residual hydroxyl groups calculated as PVOH or about 15 to about 22 wt. % residual hydroxyl groups calculated as PVOH; and, for certain embodiments, about 17.25 to about 22.25 wt. residual hydroxyl groups calculated as PVOH, or as described elsewhere herein
  • the poly(vinyl butyral) resin comprises about 8 to about 35 wt. % (wt. %) residual hydroxyl groups calculated as PVOH, about 13 to about 30 wt. % residual hydroxyl groups calculated as PVOH, about 8 to about 22 wt. % residual hydroxyl groups calculated as PVOH, or about 15 to about 22 wt. % residual hydroxyl groups calculated as PVOH; and for some of the high rigidity interlayers disclosed herein, for one or more of the layers, the poly(vinyl butyral) resin comprises greater than about 19 wt. % residual hydroxyl groups calculated as PVOH, greater than about 20 wt. % residual hydroxyl groups calculated as PVOH, greater than about 20.4 wt. % residual hydroxyl groups calculated as PVOH, and greater than about 21 wt. % residual hydroxyl groups calculated as PVOH.
  • the poly (vi ny I butyral) resin used in at least one polymer layer of an interlayer may include a poly(vinyl butyral) resin that has a residual hydroxyl content of at least about 18, at least about 18.5, at least about 18.7, at least about 19, at least about 19.5, at least about 20, at least about 20.5, at least about 21 , at least about 21 .5, at least about 22, at least about 22.5 wt. % and/or not more than about 30, not more than about 29, not more than about 28, not more than about 27, not more than about 26, not more than about 25, not more than about 24, not more than about 23, or not more than about 22 wt. %, measured as described above.
  • one or more other polymer layers in the interlayers described herein may include another poly(vinyl butyral) resin that has a lower residual hydroxyl content.
  • at least one polymer layer of the interlayer can include a poly(vinyl butyral) resin having a residual hydroxyl content of at least about 8, at least about 8.5, at least about 9, at least about 9.5, at least about 10, at least about 10.5, at least about 1 1 , at least about 11 .5, at least about 12, at least about 13 wt. % and/or not more than about 16, not more than about 15, not more than about 14, not more than about 13.5, not more than about 13, not more than about 12, or not more than about 1 1 .5 wt. %, measured as described above.
  • the soft or core poly(vinyl butyral) or blend of soft poly(vinyl butyral)s may have a residual hydroxyl content, as further described herein, from about 5% to about 15%.
  • the residual hydroxyl content of the soft poly(vinyl butyral) may be from about 7% to about 13, or from 8% to 12%, or as described elsewhere herein.
  • the stiff poly(vinyl butyral) or blend of stiff poly(vinyl butyral)s may have a residual hydroxyl content, as further described herein, from about 12 % to about 28%.
  • the residual hydroxyl content of the stiff poly(vinyl butyral) may be from about 15% to about 25%, or from 18% to 20%, or as described elsewhere herein.
  • the residual hydroxyl content of the first stiff poly(vinyl butyral resin) is typically the same as the residual hydroxyl content of the second stiff poly (vinyl butyral resin) and typically differs from that in the core poly(vinyl butyral resin).
  • the difference between the core residual hydroxyl content and the skin residual hydroxyl content is at least 4.0 weight percent, or at least 5 weight percent, or at least 6.0 weight percent.
  • the core poly(vinyl butyral) resin is present in an amount of from about 2 weight percent to about 45 weight percent, or from about 5 weight percent to about 40 weight percent.
  • the soft poly(vinyl butyral) or blend of soft poly(vinyl butyral)s may have a residual acetate content, as further described herein, from about 0% to about 18%, or from 0.5% to 10%.
  • the residual acetate content may be less than 10%, or less than 5%, or less than 2%, or less than 1 %, or as further described herein.
  • the stiff poly ( vi ny I butyral) or blend of stiff poly(vinyl butyral)s may have a residual acetate content, as further described herein , from about 0% to about 18%.
  • the residual acetate content of the stiff poly(vinyl butyral) may be less than 10%, or less than 5%, or less than 2%, or less than 1%, or as further described herein.
  • the residual hydroxyl content of the soft layer can be the same as, greater than, or less than the residual hydroxyl content of the resin in the stiff layer.
  • the soft resin, or skin resin, or both of these resins may comprise less than 30 wt.% residual ester groups, less than 25 wt.% residual ester groups, less than 20 wt.%, less than 15 wt.%, less than 13 wt.%, less than 10 wt.%, less than 7 wt.%, less than 5 wt.%, or less than 1 wt.% residual ester groups calculated as polyvinyl ester, e.g., acetate, with the balance being an acetal, such as butyraldehyde acetal, but optionally being other acetal groups, such as an isobutyraldehyde acetal group, a 2-ethyl hexanal acetal group, or a mix of any two of buty
  • the resin for the core layer(s) or for the skin layer(s) or for both the skin layer(s) and core layer(s) can also comprise less than 20 wt. % residual ester groups, less than 15 wt. %, less than 13 wt. %, less than 11 wt. %, less than 9 wt. %, less than 7 wt. %, less than 5 wt. %, or less than 1 wt.
  • % residual ester groups calculated as polyvinyl ester, e.g., acetate, with the balance being an acetal, preferably butyraldehyde acetal, but optionally including other acetal groups in a minor amount, for example, a 2-ethyl hexanal group (see, for example, U.S. Pat. No. 5,137,954, the entire disclosure of which is incorporated herein by reference).
  • the multilayered interlayers used in the processes of the invention may comprise: a skin or still polymer layer comprising plasticized poly(vinyl butyral) having a weight average molecular weight (Mw) of less than about 140,000 amu, or less than 150,000 or less than 200,000, or less than 250,000; a core polymer layer comprising plasticized poly(vinyl butyral) having a weight average molecular weight of greater than about 200,000 amu, or greater than 225,000, or greater than 250,000, or greater than 275,000.
  • Mw weight average molecular weight
  • the skin or stiff polymer layer comprising plasticized poly(vinyl butyral) having a weight average molecular weight (Mw) of from about 60,000 to 250,000, or from 70,000 to 225,000, or from 100,000 to 200,000.
  • the core polymer layer may comprise plasticized poly(vinyl butyral) having a weight average molecular weight of from about 150,000 amu to 600,000, or from 200,000 to 500,000, or from 250,000 to 400,000.
  • molecular weight refers to weight average molecular weight (Mw).
  • Mw weight average molecular weight
  • suitable PVB resins will generally be in the range of from about 50,000 to about 600,000, about 70,000 to about 450,000, or about 100,000 to about 425,000 atomic mass units.
  • the extruded interlayer formed from plasticized PVB resin can be prepared with systems known to those skilled in the art by extrusion through a conventional sheeting die having cooled die lips, i.e. by forcing molten polymer through a horizontally long, vertically narrow die opening substantially conforming in length and width to that of the sheet being formed therein.
  • multiple layer interlayers may be coextruded using a multiple manifold coextrusion device such as that disclosed in U.S. Pat. Publn. No. 2008/0254302, the relevant disclosure of which is incorporated herein by reference.
  • a multiple manifold coextrusion device such as that disclosed in U.S. Pat. Publn. No. 2008/0254302, the relevant disclosure of which is incorporated herein by reference.
  • Such a device has a first die manifold, a second die manifold, and a third die manifold.
  • the device operates by simultaneously extruding polymer melts from each manifold toward the extrusion opening, 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.
  • Melt fracture may be controlled though control of the composition of the melts, the temperature of the die lips or lands at the extrusion opening, or through control of the rate and method of cooling of the extruded interlayer, which can be, for example, immersed in a cooling bath soon after extrusion.
  • the desired film having a rough surface and a smooth surface on opposite sides may be obtained using the separation techniques described herein.
  • Conventional multilayer interlayers such as a tri-layer acoustic interlayer typically contain a soft core layer consisting of a single poly(vinyl butyral) (“PVB”) resin having a low residual hydroxyl content and a high amount of a conventional plasticizer, and two stiff skin layers having significantly higher residual hydroxyl content (see, for example U.S. Patents 5,340,654, 5,190,826, and 7,510,771 ).
  • the isolated soft poly(vinyl butyral) may be recycled to form the core layer of a trilayer acoustic interlayer, or the soft poly(vinyl butyral) and plasticizer varnish may be used directly to form a soft poly(vinyl butyral) layer without first separating the two.
  • the residual hydroxyl content in the PVB core resin and the amount of the plasticizer are optimized such that the interlayer provides optimal sound insulation property under ambient conditions for multiple layer glass panels such as windshields and windows installed on vehicles and buildings.
  • the multilayer interlayer sheet comprises a multilayer PVB interlayer, for example having a skin/core/skin cross-section.
  • a multilayer PVB interlayer for example having a skin/core/skin cross-section.
  • the PVB resin may be produced by known acetalization processes by reacting polyvinyl alcohol (“PVOH”) with butyraldehyde in the presence of an acid catalyst, separation, stabilization, and drying of the resin.
  • PVOH polyvinyl alcohol
  • Such acetalization processes are disclosed, for example, in U.S. Pat. Nos. 2,282,057 and 2,282,026 and Vinyl Acetal Polymers, in Encyclopedia of Polymer Science & Technology, 3rd edition, Volume 8, pages 381 -399, by B.E. Wade (2003), the entire disclosures of which are incorporated herein by reference.
  • the resin is commercially available in various forms, for example, as Butvar® Resin from Solatia Inc., a wholly owned subsidiary of Eastman Chemical Company.
  • ACAs adhesion control agents
  • Contemplated ACAs include, but are not limited to, magnesium carboxylates/salts.
  • contemplated ACAs may also include those ACAs disclosed in U.S. Patent 5,728,472, incorporated by reference herein in its entirety, such as residual sodium acetate, potassium acetate, magnesium bis(2-ethyl butyrate), and/or magnesium bis(2-ethylhexanoate).
  • additives may be incorporated into the interlayer to enhance its performance in a final product and impart certain additional properties to the interlayer.
  • additives include, but are not limited to, dyes, pigments, stabilizers (e.g., ultraviolet stabilizers), antioxidants, anti-blocking agents, flame retardants, IR absorbers or blockers (e.g., indium tin oxide, antimony tin oxide, lanthanum hexaboride (LaB 6 ) and cesium tungsten oxide), processing aides, flow enhancing additives, lubricants, impact modifiers, nucleating agents, thermal stabilizers, UV absorbers, UV stabilizers, dispersants, surfactants, chelating agents, coupling agents, adhesives, primers, reinforcement additives, and fillers, among other additives known to those of ordinary skill in the art.
  • ACAs adhesion control agents
  • the interlayer can comprise about 0.003 to about 0.15 parts ACAs per 100 parts resin; about 0.01 to about 0.10 parts ACAs per 100 parts resin; and about 0.01 to about 0.04 parts ACAs per 100 parts resin.
  • ACAs include, but are not limited to, the ACAs disclosed in U.S. Patent No.
  • additives may be incorporated into the interlayer to enhance its performance in a final product and impart certain additional properties to the interlayer.
  • additives include, but are not limited to, dyes, pigments, stabilizers (e.g., ultraviolet stabilizers), antioxidants, antiblocking agents, flame retardants, IR absorbers or blockers (e.g., indium tin oxide, antimony tin oxide, lanthanum hexaboride (LaB 6 ) and cesium tungsten oxide), processing aides, flow enhancing additives, lubricants, impact modifiers, nucleating agents, thermal stabilizers, UV absorbers, dispersants, surfactants, chelating agents, coupling agents, adhesives, primers, reinforcement additives, and fillers, among other additives known to those of ordinary skill in the art.
  • a range stated to be 0 to 10 is intended to disclose all whole numbers between 0 and 10 such as, for example 1 , 2, 3, 4, etc., all fractional numbers between 0 and 10, for example 1 .5, 2.3, 4.57, 6.1113, etc., and the endpoints 0 and 10.
  • the term “and/or”, when used in a list of two or more items, means that any one of the listed items can be employed by itself, or any combination of two or more of the listed items can be employed.
  • the composition can contain A alone; B alone; C alone; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination.
  • An acoustic PVB skin-core-skin tri-layer sheet had been mechanically separated into a skin layer and a core-skin bi-layer, as disclosed in the application.
  • the thickness of the core layer in the bi-layer was 0.114 mm.
  • the number average molecular weight, Mn, and the weight average molecular weight, Mw, of the core layer are 75,000 g/mole, and 300,000 g/mole, respectively.
  • the poly(vinyl acetate) (PVAc) content in the core resin is 1 .0 wt%.
  • the core-skin bi-layer was interleaved with a polyethylene as it is wound to a roll on a winding device.
  • the interleaved bi-layer was then unwound, slit to 25.4 mm width each, and wound again as multiple rolls with a narrower width. [00158] The roll was then unwound mechanically, the interleaving separated from the bi-layer, then the elastic core layer was mechanically peeled off from the skin layer, followed by collecting the recovered core layer and the skin layer, respectively.
  • Example 2
  • An acoustic PVB skin-core-skin tri-layer sheet had been mechanically separated into a skin layer and a core-skin bi-layer, as disclosed previously.
  • the thickness of the core layer in the bi-layer was 0.114 mm.
  • the number average molecular weight, Mn, and the weight average molecular weight, Mw, of the core layer were 100,000 g/mole, and 290,000 g/mole, respectively.
  • the poly(vinyl acetate) (PVAc) content in the core resin was 1 .5 wt%.
  • the core-skin bi-layer had been interleaved with a polyethylene as it was wound to a roll on a winding device. The interleaved bi-layer was then unwound, slit to 25.4 mm width each, and wound again as multiple rolls with narrower width.
  • the roll was unwound, interleaving separated from the bi-layer, then the elastic core layer was mechanically peeled off from the skin layer, followed by collecting the recovered core layer and the skin layer, respectively.
  • An acoustic PVB skin-core-skin tri-layer sheet had been mechanically separated into a skin layer and a core-skin bi-layer, as disclosed previously.
  • the thickness of the core layer in the bi-layer was 0.114 mm.
  • the number average molecular weight, Mn, and the weight average molecular weight, Mw, of the core layer were 130,000 g/mole, and 300,000 g/mole, respectively.
  • the poly(vinyl acetate) (PVAc) content in the core resin was 1 .5 wt%.
  • the core-skin bi-layer was interleaved with a polyethylene film as it was wound to a roll on a winding device. The interleaved bi-layer was then unwound, slit to 38.1 mm width each, and wound again as multiple rolls with narrower width.
  • An acoustic PVB skin-core-skin tri-layer sheet had been mechanically separated into a skin layer and a core-skin bi-layer, as disclosed previously.
  • the thickness of the core layer in the bi-layer was 0.228 mm.
  • the number average molecular weight, Mn, and the weight average molecular weight, Mw, of the core layer were 75,000 g/mole, and 300,000 g/mole, respectively.
  • the poly(vinyl acetate) (PVAc) content in the core resin was 1 .0 wt%.
  • the core-skin bi-layer was interleaved with a polyethylene film as it was wound to a roll on a winding device. The interleaved bi-layer was then unwound, slit to 50.8 mm width each, and wound again as multiple rolls with narrower width.
  • the roll was unwound, interleaving separated from the bi-layer, then the elastic core layer was mechanically peeled off from the skin layer, followed by collecting the recovered core layer and the skin layer, respectively.
  • An acoustic PVB skin-core-skin tri-layer sheet had been mechanically separated into a skin layer and a core-skin bi-layer, as disclosed previously.
  • the thickness of the core layer in the bi-layer was 0.114 mm.
  • the number average molecular weight, Mn, and the weight average molecular weight, Mw, of the core layer were 100,000 g/mole, and 290,000 g/mole, respectively.
  • the poly(vinyl acetate) (PVAc) content in the core resin was 1 .5 wt%.
  • the core-skin bi-layer was interleaved with a polyethylene as it was wound to a roll on a winding device. The interleaved bi-layer was then unwound, slit to 76.2 mm width each, and wound again as multiple rolls with narrower width.
  • the roll was unwound, and the interleaving separated from the bi- layer.
  • the elastic core layer was mechanically peeled off from the skin layer, it tore very easily. Because the core layer is elastic, it tends to stretch rather than be pulled apart, if the width is too wide, making it difficult to stabilize the separation process.
  • An acoustic PVB skin-core-skin tri-layer sheet had been mechanically separated into a skin layer and a core-skin bi-layer, as disclosed previously.
  • the thickness of the core layer in the bi-layer was 0.114 mm.
  • the number average molecular weight, Mn, and the weight average molecular weight, Mw, of the core layer were 55,000 g/mole, and 280,000 g/mole, respectively.
  • the poly(vinyl acetate) (PVAc) content in the core resin was 1 .0 wt%.
  • the core-skin bi-layer was interleaved with a polyethylene film as it was wound to a roll on a winding device. The interleaved bi-layer was then unwound, slit to 25.4 mm width each, and wound again as multiple rolls with narrower width.
  • An acoustic PVB skin-core-skin tri-layer sheet had been mechanically separated into a skin layer and a core-skin bi-layer, as disclosed previously.
  • the thickness of the core layer in the bi-layer was 0.114 mm.
  • the number average molecular weight, Mn, and the weight average molecular weight, Mw, of the core layer were 110,000 g/mole, and 290,000 g/mole, respectively.
  • the poly(vinyl acetate) (PVAc) content in the core resin was 1 1 wt%.
  • the core-skin bi-layer was interleaved with a polyethylene film as it was wound to a roll on a winding device.
  • the interleaved bi-layer was then unwound, slit to 25.4 mm width each, and wound again as multiple rolls with narrower width. [00170] The roll is unwound and the interleaving was separated from the bi-layer. Because of the PDI value of 2.6 (290,000/110,000), that is, the Mw/Mn, the core was crumbly, non-elastic, and strongly adhered to the skin, making it almost impossible to mechanically peel off from the skin layer.
  • An acoustic PVB skin-core-skin tri-layer sheet had been mechanically separated into a skin layer and a core-skin bi-layer, as disclosed previously.
  • the thickness of the core layer in the bi-layer was 0.114 mm.
  • the number average molecular weight, Mn, and the weight average molecular weight, Mw, of the core layer were 130,000 g/mole, and 300,000 g/mole, respectively.
  • the poly(vinyl acetate) (PVAc) content in the core resin was 13 wt%.
  • the core-skin bi-layer was interleaved with a polyethylene film as it was wound to a roll on a winding device. The interleaved bi-layer was then unwound, slit to 25.4 mm width each, and wound again as multiple rolls with narrower width.
  • the roll was unwound and the interleaving was separated from the bi-layer. Because of the PDI value of 2.3 (300,000/130,000), that is, the Mw/Mn, the core was crumbly, non-elastic, and strongly adhered to the skin, making it almost impossible to mechanically peel off from the skin layer.

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  • Engineering & Computer Science (AREA)
  • Environmental & Geological Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

Sont divulgués des procédés de séparation d'une couche de poly(vinylbutyral) souple à partir d'une couche de poly(vinylbutyral) rigide d'une couche intermédiaire multicouche, comprenant le pelage de la couche souple à partir de la couche rigide.
PCT/US2024/047017 2023-09-19 2024-09-17 Procédés et dispositifs de pelage pour la séparation de couches intermédiaires multicouches Pending WO2025064387A1 (fr)

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US63/583,672 2023-09-19

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