High tg monolithic poly(vinyl acetal) sheet

Patent metadata

Field	Value
Publication number	US-2016159043-A1
Application number	US-201414563025-A
Country	US
Kind code	A1
Filing date	Dec 8, 2014
Priority date	Dec 8, 2014
Publication date	Jun 9, 2016
Grant date	—

Abstract

A polyvinyl acetal poly(vinyl acetal), such as polyvinyl butyral, resin formulation, a method of extruding poly(vinyl acetal) resins, and related materials and products that provide for monolithic poly(vinyl acetal) sheets and glass panes having high Tg of at least 50° C. and high modulus at acceptable rates as indicated by their high melt flow index. This is made possible by a reduction in the amount of plasticizer while using a low molecular weight resin not to exceed 160,000 to obtain a thermoplastic resin having a high melt flow index and high Tg. The articles made with these monolithic interlayer sheets can be used in applications that require good modulus at outdoor temperatures.

First claim

What we claim is:

1 . A monolithic interlayer composition comprising:
(A) poly(vinyl acetal) resin in an amount of at least 60 wt. % based on the weight of the composition; and (B) a plasticizer in an amount of at least 5 parts per one hundred parts of said poly(vinyl acetal) resin;
wherein said interlayer composition has a Tg of at least 46° C. and a melt flow index (“MFI”) of at least 0.65 grams/10 minutes when measured at 190° C. at a load of 2.16 kilograms.

2 . The composition of claim 1 , wherein said composition has a Tg of at least 50° C.

3 . The composition of claim 2 , wherein said composition has a Tg of at least 55° C.

4 . The composition of claim 3 , wherein said composition has a Tg of at least 60° C.

5 . The composition of claim 4 , wherein said composition has a Tg of at least 65° C.

6 . The composition of claim 1 , wherein said composition has an MFI of at least 0.9.

7 . The composition of claim 3 , wherein said composition has an MFI of at least 1.2.

8 . The composition of claim 3 , wherein said composition contains at least 80 wt. % poly(vinyl acetal) resin.

9 . The composition of claim 1 , wherein the weight average molecular weight (Mw) of the poly(vinyl acetal) resin does not exceed 150,000.

10 . The composition of claim 7 , wherein the Mw of the poly(vinyl acetal) resin does not exceed 140,000.

11 . The composition of claim 8 , wherein the Mw of the poly(vinyl acetal) resin does not exceed 130,000.

12 . The composition of claim 1 , wherein the Mw of the poly(vinyl acetal) resin does not exceed 110,000.

13 . The composition of claim 1 , wherein the Mw of the poly(vinyl acetal) resin ranges from 45,000 to 130,000.

14 . The composition of claim 1 , wherein the amount of plasticizer is at least 5 parts per hundred parts of the poly(vinyl acetal) resin.

15 . The composition of claim 11 , wherein the amount of plasticizer is at least 8 parts per hundred parts of the poly(vinyl acetal) resin.

16 . The composition of claim 1 , wherein the Mw of the poly(vinyl acetal) resin does not exceed 140,000 and the amount of plasticizer is at least 8 parts per hundred parts of the poly(vinyl acetal) resin, and the composition has an MFI of at least 0.7.

17 . The composition of claim 1 , wherein the Mw of the poly(vinyl acetal) resin does not exceed 140,000 and the amount of plasticizer ranges from about 8 to 20 parts per hundred parts of the poly(vinyl acetal) resin.

18 . The composition of claim 1 , wherein the Mw of the poly(vinyl acetal) resin does not exceed 150,000, the amount of plasticizer ranges from 5 to 20 parts per hundred parts of the poly(vinyl acetal) resin, the composition has an MFI of at least 0.7, and the poly(vinyl acetal) resin comprises polyvinyl butyral units.

19 . The composition of claim 1 , wherein the poly(vinyl acetal) resin has a hydroxyl group content of 6 wt. % to 35 wt. %.

20 . The composition of claim 1 , wherein the poly(vinyl acetal) resin has a solution viscosity of no more than 120 cps.

21 . The composition of claim 1 , wherein the poly(vinyl acetal) has a vinyl butyral group content of at least 60 wt % and up to 90 wt. % based on the weight of the poly(vinyl acetal).

22 . The composition of claim 1 , wherein the amount of plasticizer is at least 5 parts and up to 30 parts per hundred parts of the poly(vinyl acetal).

23 . The composition of claim 1 , wherein the amount of plasticizer is up to 20 parts per hundred parts of the poly(vinyl acetal) and has an MFI of at least 0.7.

24 . The composition of claim 23 , wherein the amount of plasticizer is up to 18 parts per hundred parts of the poly(vinyl acetal) and has an MFI of at least 2.

25 . The composition of claim 17 , wherein said composition comprises a monolithic interlayer sheet.

26 . The composition of claim 25 , wherein said sheet has a thickness of at least 5 mils.

27 . The composition of claim 25 , wherein said sheet has a modulus E′ at 40° C. of at least 400,000,000 pascals.

28 . The method of claim 25 , wherein the sheet has a modulus E′ at 50° C. of at least 10,000,000 pascals.

29 . The composition of claim 25 , wherein said sheet is laminated between:
(A) a layer of glass and a polymer film, and wherein said polymer film is not a poly(vinyl acetal) resin; or (B) two layers of glass.

30 . The composition of claim 29 , wherein the sheet has a thickness of at least 5 mils.

31 . A monolithic interlayer composition comprising:
(A) poly(vinyl acetal) resin having a weight average molecular weight (Mw) of 160,000 or less, and (B) a plasticizer in an amount of at least 5 parts per one hundred parts of said poly(vinyl acetal) resin;
wherein said interlayer composition has a Tg of at least 46.0° C.

32 . The composition of claim 31 , wherein said composition has a Tg of at least 50° C.

33 . The composition of claim 31 , wherein said composition has a Tg of at least 55° C.

34 . The composition of claim 31 , wherein said composition has a Tg of at least 60° C.

35 . The composition of claim 31 , wherein said composition has an MFI of at least 0.65.

36 . The composition of claim 35 , wherein said composition has a melt flow index of at least 1 gram/10 minutes at 190° C. and under a load of 2.16 kg.

37 . The composition of claim 35 , wherein said composition contains at least 70 wt. % poly(vinyl acetal) resin.

38 . The composition of claim 31 , wherein the weight average molecular weight (Mw) of the poly(vinyl acetal) resin does not exceed 150,000.

39 . The composition of claim 38 , wherein the Mw of the poly(vinyl acetal) resin does not exceed 130,000.

40 . The composition of claim 31 , wherein the Mw of the poly(vinyl acetal) resin does not exceed 110,000.

41 . The composition of claim 31 , wherein the amount of plasticizer is from 5 to 23 parts per hundred parts of the poly(vinyl acetal) resin.

42 . The composition of claim 41 , wherein the amount of plasticizer is 8 to less than 20 parts per hundred parts of the poly(vinyl acetal) resin.

43 . The composition of claim 31 , wherein the molecular weight of the poly(vinyl acetal) resin does not exceed 140,000, the amount of plasticizer is from 2 to 18 parts per hundred parts of the poly(vinyl acetal) resin, the poly(vinyl acetal) resin comprises polyvinyl butyral units, and the amount of poly(vinyl acetal) resin is at least 80 wt % based on the weight of the composition.

44 . The composition of claim 31 , wherein the weight average molecular weight (Mw) of the poly(vinyl acetal) resin does not exceed 150,000, the amount of plasticizer ranges from 5 to 18 parts per hundred parts of the poly(vinyl acetal) resin, a melt flow index of at least 0.65 gram/10 minutes at 190° C. and under a load of 2.16 kg, and the poly(vinyl acetal) resin comprises polyvinyl butyral units.

45 . The composition of claim 44 , wherein the poly(vinyl acetal) resin has a hydroxyl group content of 14 wt. % to 23 wt. %.

46 . The composition of claim 31 , wherein the poly(vinyl acetal)

Assignees

• Solutia Inc

Inventors

• Karagiannis Aristotelis
• Szlosek Megan L
• Farhoudi Yalda

Classifications

• B32B17/10761 Primary

  containing vinyl acetal · CPC title

• B32B27/30

  comprising vinyl {(co)polymers; comprising acrylic (co)polymers} · CPC title

• B29L2011/00

  Optical elements, e.g. lenses, prisms · CPC title

• B29C47/0004

  Operations & Transport · mapped topic

• B29C47/0847

  Operations & Transport · mapped topic