Blends of poly(vinyl acetal) resins for compositions, layers, and interlayers having enhanced optical properties

Patent metadata

Field	Value
Publication number	US-2016160022-A1
Application number	US-201414562829-A
Country	US
Kind code	A1
Filing date	Dec 8, 2014
Priority date	Dec 8, 2014
Publication date	Jun 9, 2016
Grant date	—

Abstract

Resin compositions, layers, and interlayers comprising two or more poly(vinyl acetal) resins and at least one blending agent or haze reducing agent are provided. Such compositions, layers, and interlayers exhibit enhanced optical properties while retaining other properties, such as impact resistance and acoustic performance.

First claim

What is claimed is:

1 . An interlayer comprising:
a resin layer comprising— a first poly(vinyl acetal) resin; a second poly(vinyl acetal) resin having a residual hydroxyl content that is at least 2 weight percent different than the residual hydroxyl content of said first poly(vinyl acetal) resin, wherein each of said first and said second poly(vinyl acetal) resins is present in said resin layer in an amount of at least 10 weight percent, based on the total weight of said first and said second poly(vinyl acetal) resins; and a blending agent comprising one moiety that is more compatible with said first poly(vinyl acetal) resin than with said second poly(vinyl acetal) resin and a second moiety that is more compatible with the second poly(vinyl acetal) resin than with said first poly(vinyl acetal) resin, wherein said blending agent is present in said resin layer in an amount of at least 0.5 weight percent, based on the total weight of said resin layer.

2 . The interlayer of claim 1 , wherein said blending agent has an HLB value of not more than 16.

3 . The interlayer of claim 1 , wherein said blending agent is selected from the group consisting of glycols and glycol ethers.

4 . The interlayer of claim 1 , wherein said resin layer further comprises at least one plasticizer present in an amount in the range of from at least 10 parts per hundred resin (phr) to less than 50 phr and wherein the glass transition temperature of said resin layer is in the range of from 26 to 70° C.

5 . The interlayer of claim 1 , wherein said resin layer further comprises at least one plasticizer present in an amount in the range of at least 10 phr to not more than about 90 phr, and wherein the glass transition temperature of said resin layer is less than 25° C.

6 . The interlayer of claim 1 , wherein said resin layer further comprises a third poly(vinyl acetal) resin, wherein each of said first, second, and third poly(vinyl acetal) resins are present in said resin layer in an amount of at least 5 weight percent, based on the total weight of said first, second, and third poly(vinyl acetal) resins.

7 . The interlayer of claim 1 , further comprising a second resin layer adjacent to said resin layer, wherein said second resin layer comprises another poly(vinyl acetal) resin, wherein the glass transition temperature of said resin layer is at least 5° C. lower than the glass transition temperature of said second resin layer.

8 . The interlayer of claim 1 , wherein said interlayer has a haze value of less than 5 percent.

9 . A multiple layer panel comprising said interlayer of claim 1 and at least one rigid substrate.

10 . An interlayer comprising:
a first resin layer comprising a first poly(vinyl acetal) resin and a plasticizer; a second resin layer adjacent to said first resin layer, wherein said second resin layer comprises a blend of two poly(vinyl acetal) resins and at least one blending agent, wherein one of said blend of two poly(vinyl acetal) resins has a residual hydroxyl content that is at least 2 weight percent higher or lower than the residual hydroxyl content of said first poly(vinyl acetal) resin and/or wherein said one of said blend of two poly(vinyl acetal) resins has a residual acetate content that is at least 2 weight percent higher or lower than the residual acetate content of said first poly(vinyl acetal) resin, wherein the other of said blend of two poly(vinyl acetal) resins has a residual hydroxyl content that is within 2 weight percent of the residual hydroxyl content of said first poly(vinyl acetal) resin, wherein each of said one and said other of said blend of two poly(vinyl acetal) resins is present in said second resin layer in an amount of at least 5 weight percent, based on the combined weight of resins in said second resin layer, and wherein said interlayer has a haze value of less than 5 percent.

11 . The interlayer of claim 10 , wherein said blending agent comprises at least a first moiety and a second moiety, wherein said first moiety is more compatible with said one of said blend of two poly(vinyl acetal) resins than with said other of said blend of two poly(vinyl acetal) resins, and said second moiety is more compatible with said other of said blend of two poly(vinyl acetal) resins than with said one of said blend of two poly(vinyl acetal) resins, and wherein said blending agent is present in said second resin layer in an amount of at least 0.5 weight percent, based on the total weight of said second resin layer.

12 . The interlayer of claim 10 , wherein said second resin layer further comprises at least one plasticizer present in said second resin layer in an amount of at least about 10 parts per hundred resin (phr).

13 . The interlayer of claim 10 , wherein the difference between the glass transition temperature of said first resin layer and the glass transition temperature of said second resin layer is at least 5° C.

14 . The interlayer of claim 10 , wherein said one of said blend of two poly(vinyl acetal) resins in said second resin layer has a residual hydroxyl content of not more than 15 weight percent and wherein said second resin layer has a single glass transition temperature of less than 25° C.

15 . The interlayer of claim 1 , wherein said first poly(vinyl acetal) resin and each of said one and said other of said blend of two poly(vinyl acetal) resins comprise at least 50 weight percent of residues of n-butyraldehyde, based on the total weight of aldehyde residues of said first poly(vinyl acetal) resin, said one of said blend of two poly(vinyl acetal) resins, or said other of said blend of two poly(vinyl acetal) resins, and wherein said other of said blend of two poly(vinyl acetal) resins has a residual hydroxyl content of at least 16 weight percent.

16 . A method of making an interlayer, said method comprising:
(a) providing a first poly(vinyl acetal) resin; (b) providing a second poly(vinyl acetal) resin having a residual hydroxyl content that is at least 2 weight percent higher or lower than said first poly(vinyl acetal) resin; (c) blending said first and said second poly(vinyl acetal) resins with at least one blending agent to provide a blended resin composition, wherein said blended resin composition includes at least 10 weight percent of each of said first and said second poly(vinyl acetal) resins, based on the total weight of resins in said blended composition; and (d) forming a resin layer from said blended resin composition, wherein said interlayer has a haze value of less than 5 percent.

17 . The method of claim 16 , wherein said blending agent is present in said blended resin composition in an amount of at least about 0.5 weight percent, based on the total weight of said blended resin composition, and wherein said blending agent has an HLB value of less than 10.

18 . The method of claim 16 , wherein at least one of said first poly(vinyl acetal) resin and said second poly(vinyl acetal) resin has a residual hydroxyl content of less than 15 weight percent, wherein said resin layer has a single glass transition temperature of less than 25° C.

19 . The method of claim 16 , wherein said forming of step (d) comprises combining said blended composition with at least one plasticizer to form said resin layer, wherein said plasticizer is present in said resin layer in an amount of at least about 10 phr, and wherein said interlayer has a loss factor at 20° C. of at least 0.10.

20 . The method of claim 19 , further comprising adding another resin layer to said resin

Assignees

• Solutia Inc

Inventors

• Lu Jun

Classifications

• B32B37/24

  with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate (B32B37/15 takes precedence) · CPC title

• B32B2551/00

  Optical elements · CPC title

• B32B27/30

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

• B32B2307/40

  having particular optical properties · CPC title

• B32B2250/02

  2 layers · CPC title