Esterified poly(vinyl acetal) resin compositions, layers, and interlayers having enhanced properties

Patent metadata

Field	Value
Publication number	US-2016289362-A1
Application number	US-201615089565-A
Country	US
Kind code	A1
Filing date	Apr 3, 2016
Priority date	Apr 5, 2015
Publication date	Oct 6, 2016
Grant date	—

Abstract

Resin compositions, layers, and interlayers comprising an acetoacetylized poly(vinyl acetal) resin are provided. Such compositions, layers, and interlayers can exhibit enhanced or optimized properties as compared to non-acetoacetylized poly(vinyl acetal) resins. The acetoacetylized poly(vinyl acetal) resins may be used in a layer or an interlayer for in an architectural application, or the acetoacetylized poly(vinyl acetal) resins may be used in a layer or interlayer, or combined with other layers, to provide an interlayer having good acoustic and other properties.

First claim

What is claimed is:

1 . An acetoacetylized polymer comprising units having the structure:

wherein R′ is hydrogen, a substituted or unsubstituted C 1 to C 12 alkyl, a substituted or unsubstituted C 6 to C 14 aryl, a substituted or unsubstituted C 6 to C 14 alkaryl, or a combination thereof, “x” is from about 52 to about 78 mole %, “y” is from about 26 to about 45 mole %, “z” is from about 0 to about 20 mole %, and “a” is 0 to 45 mole % such that 0≦y−a≦45 mole % and x+y+z=100.

2 . The acetoacetylized polymer of claim 1 , wherein a is from about 5 to about 40 mole %, z is from about 0 to about 15 mole % and y−a 25 mole %.

3 . The acetoacetylized polymer of claim 1 , further comprising an ultraviolet absorber.

4 . The acetoacetylized polymer of claim 1 , further comprising up to 35 wt. % plasticizer.

5 . The acetoacetylized polymer of claim 1 , wherein R′ is a substituted or unsubstituted C 1 to C 12 alkyl.

6 . The acetoacetylized polymer of claim 1 , wherein R′ is n-propyl or iso-propyl or combinations thereof.

7 . The acetoacetylized polymer of claim 1 , wherein the acetoacetylized polymer is made by acetoacetylation of a non-acetoacetylized poly(vinyl acetal) polymer comprising units having the structure:

wherein “x” is from about 52 to about 78 mole %, “y” is from about 26 to about 45 mole %, “z” is from about 0 to about 20 mole %, x+y+z=100 and R′ is a substituted or unsubstituted C 1 to C 12 alkyl, a substituted or unsubstituted C 6 to C 14 aryl, a substituted or unsubstituted C 6 to C 14 alkaryl, or a combination thereof, and wherein the poly(vinyl acetal) polymer has a weight average molecular weight, Mw, of about 120,000 to 170,000 Daltons.

8 . The acetoacetylized polymer of claim 1 , wherein the acetoacetylized polymer is prepared by reactive extrusion and the residence time in the extruder is from 3 to 10 minutes.

9 . The acetoacetylized polymer of claim 7 , wherein the glass transition temperature of the acetoacetylized polymer is less than the glass transition temperature of the non-acetoacetylized polymer, or wherein the loss factor at the glass transition temperature of the acetoacetylized polymer is less than the loss factor at the glass transition temperature of the non-acetoacetylized polymer, or wherein both the glass transition temperature of the acetoacetylized polymer is less than the glass transition temperature of the non-acetoacetylized polymer and the loss factor at the glass transition temperature of the acetoacetylized polymer is less than the loss factor at the glass transition temperature of the non-acetoacetylized polymer.

10 . The acetoacetylized polymer of claim 8 , further comprising an organophosphite thermal stabilizer.

11 . An interlayer comprising:
an acetoacetylized polymer comprising units having the structure:

wherein R′ is hydrogen, a substituted or unsubstituted C 1 to C 12 alkyl, a substituted or unsubstituted C 6 to C 14 aryl, a substituted or unsubstituted C 6 to C 14 alkaryl, or a combination thereof, “x” is from about 52 to about 78 mole %, “y” is from about 26 to about 45 mole %, “z” is from about 0 to about 20 mole %, and “a” is 0 to 45 mole % such that 0≦y−a≦45 mole % and x+y+z=100.

12 . The interlayer of claim 11 , wherein “a” is from about 5 to about 40 mole %, “z” is from about 0 to about 15 mole % and y−a 25 mole %.

13 . The interlayer of claim 11 , wherein the interlayer further comprises up to 75 phr plasticizer.

14 . The interlayer of claim 11 , wherein the interlayer further comprises an ultraviolet absorber, an organophosphite thermal stabilizer or both.

15 . The interlayer of claim 11 , wherein the interlayer comprises a second layer comprising a poly(vinyl acetal resin) and a third layer comprising a poly(vinyl acetal) resin, wherein the first layer is between the second layer and the third layer.

16 . A laminate comprising the interlayer of claim 15 .

17 . A process of making an acetoacetylized polymer, the process comprising the steps of
adding to a mixer or extruder a non-acetoacetylized poly(vinyl acetal) polymer comprising units having the structure:

wherein “x” is from about 52 to about 78 mole %, “y” is from about 26 to about 45 mole %, “z” is from about 0 to about 20 mole %, x+y+z=100 and R′ is a substituted or unsubstituted C 1 to C 12 alkyl, a substituted or unsubstituted C 6 to C 14 aryl, a substituted or unsubstituted C 6 to C 14 alkaryl, or a combination thereof, and wherein the poly(vinyl acetyl) polymer has a weight average molecular weight, Mw, of about 170,000 to 500,000 Daltons;
adding to the mixer or extruder an ester comprising units having the structure:
RO—CO—CH 2 —CO—

wherein R is a substituted or unsubstituted C 1 to C 12 alkyl;
reacting the poly(vinyl acetal) polymer and the ester for a time of from about 2 minutes to about 10 minutes to produce an acetoacetylized poly(vinyl acetal) polymer.

18 . The process of claim 17 , wherein the acetoacetylized poly(vinyl acetal) polymer has a residual hydroxyl level that is less than the residual hydroxyl level of the non-acetoacetylized poly(vinyl acetal) polymer.

19 . The process of claim 17 , wherein the process comprises the step of adding a thermal stabilizer and an ultraviolet absorber to the mixer or extruder, or the step of adding plasticizer to the mixer or extruder, or both the step of adding a thermal stabilizer and an ultraviolet absorber to the mixer or extruder and the step of adding plasticizer to the mixer or extruder.

20 . The process of claim 17 , wherein the ester is an acetoacetate selected from the group consisting of methyl acetoacetate, ethyl acetoacetate, t-butyl acetoacetate, ethyl 2-methyl acetoacetate and ethyl 2-ethyl acetoacetate and combinations thereof.

Assignees

• Solutia Inc

Inventors

• Wade Bruce Edward
• Szydlowski Witold
• Thompson Helen Mackin
• Lu Jun
• D'Errico John Joseph
• Weakley Garry Kenneth
• Carman Jr Howard Smith
• Haldeman Steven V
• Tang Guangxin

Classifications

• B32B27/30

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

• B32B27/08

  of synthetic resin · CPC title

• B32B2419/00

  Buildings or parts thereof · CPC title

• B32B2605/006

  Transparent parts other than made from inorganic glass, e.g. polycarbonate glazings · CPC title

• B32B2571/00

  Protective equipment · CPC title