Multilayer interlayer having sound damping properties over a broad temperature range

Patent metadata

Field	Value
Publication number	US-9460702-B2
Application number	US-201615051222-A
Country	US
Kind code	B2
Filing date	Feb 23, 2016
Priority date	Oct 15, 2014
Publication date	Oct 4, 2016
Grant date	Oct 4, 2016

Abstract

A polymer interlayer having improved sound insulation is disclosed. The polymer interlayer comprises at least one soft layer wherein the soft layer comprises a blend of a first poly(vinyl butyral) resin, a second poly(vinyl butyral) resin and a plasticizer; at least one stiffer layer comprising a third poly(vinyl butyral resin) and a plasticizer, wherein the polymer interlayer has a damping loss factor (η) (as measured by Mechanical Impedance Measurement according to ISO 16940) of at least about 0.16 measured at two or more different temperatures selected from 10° C., 20° C. and 30° C.

First claim

The invention claimed is:

1. A polymer interlayer having improved sound insulation, the polymer interlayer comprising:
at least one soft layer wherein the soft layer comprises a blend of two or more poly(vinyl butyral) resins comprising:
a first poly(vinyl butyral) resin having a first residual hydroxyl content and a first glass transition temperature (T g );
a second poly(vinyl butyral) resin having a second residual hydroxyl content and a second glass transition temperature (T g ),
wherein the difference between the first residual hydroxyl content and the second residual hydroxyl content is at least 1.0 weight percent;
a plasticizer, wherein the first poly(vinyl butyral) resin, the second poly(vinyl butyral) resin and the plasticizer are mixed and melt-extruded to form the at least one soft layer;
at least one stiffer layer comprising a third poly(vinyl butyral) resin having a third residual hydroxyl content; and
a plasticizer,
wherein the difference between the third residual hydroxyl content and at least one of the first residual hydroxyl content and the second residual hydroxyl content is at least 2.5 weight percent.

2. The polymer interlayer of claim 1 , wherein the polymer interlayer has a damping loss factor (η) (as measured by Mechanical Impedance Measurement according to ISO 16940) of at least about 0.12 measured at two or more different temperatures selected from 10° C., 20° C. and 30° C.

3. The polymer interlayer of claim 1 , wherein the difference between the first glass transition temperature (T g ) and the second glass transition temperature (T g ) is at least 4° C.

4. The polymer interlayer of claim 1 , wherein the second poly(vinyl butyral) resin is present in an amount of from about 5 weight percent to about 50 weight percent.

5. The polymer interlayer of claim 1 , wherein each plasticized resin in the soft layer of the polymer interlayer has a glass transition temperature (T g ) less than 20.0° C.

6. The polymer interlayer of claim 1 , wherein the residual hydroxyl content of the third poly(vinyl butyral) resin is the same as the residual hydroxyl content of at least one of the first poly(vinyl butyral) resin or the second poly(vinyl butyral) resin.

7. The polymer interlayer of claim 1 , wherein the difference between the first residual hydroxyl content and the second residual hydroxyl content is at least 4.0 weight percent.

8. The polymer interlayer of claim 1 , wherein the difference between the third residual hydroxyl content and at least one of the first residual hydroxyl content and the second residual hydroxyl content is at least 5.0 weight percent.

9. A polymer interlayer having improved sound insulation, the polymer interlayer comprising:
at least one soft layer wherein the soft layer comprises a blend of two or more poly(vinyl butyral) resins comprising:
a first poly(vinyl butyral) resin having a first residual hydroxyl content and a first glass transition temperature (T g );
a second poly(vinyl butyral) resin having a second residual hydroxyl content and a second glass transition temperature (T g ); and
a first plasticizer in a first amount, wherein the first poly(vinyl butyral) resin, the second poly(vinyl butyral) resin and the first plasticizer are mixed and melt-extruded to form the at least one soft layer;
at least one stiffer layer comprising a third poly(vinyl butyral) resin having a third residual hydroxyl content; and
a second plasticizer in a second amount,
wherein the difference between the first plasticizer amount and the second plasticizer amount is a least 8 phr.

10. The polymer interlayer of claim 9 , wherein each plasticized resin in the soft layer of the polymer interlayer has a glass transition temperature (T g ) less than 20.0° C.

11. The polymer interlayer of claim 9 , wherein the residual hydroxyl content of the third poly(vinyl butyral) resin is the same as the residual hydroxyl content of at least one of the first poly(vinyl butyral) resin or the second poly(vinyl butyral) resin.

12. The polymer interlayer of claim 9 , wherein the difference between the first amount and the second amount of plasticizer is at least 15 phr.

13. The polymer interlayer of claim 9 , wherein the polymer interlayer has a damping loss factor (η) (as measured by Mechanical Impedance Measurement according to ISO 16940) of at least about 0.12 measured at two or more different temperatures selected from 10° C., 20° C. and 30° C.

14. The polymer interlayer of claim 9 , wherein difference between the glass transition temperatures (T g ) of the first poly(vinyl butyral) resin and the second poly(vinyl butyral) resin is at least 4.0° C.

15. A polymer interlayer having improved sound insulation, the polymer interlayer comprising:
at least one soft layer wherein the soft layer comprises a blend of two or more poly(vinyl butyral) resins comprising:
a first poly(vinyl butyral) resin having a first residual hydroxyl content, a first residual acetate content and a first glass transition temperature (T g ),
a second poly(vinyl butyral) resin having a second residual hydroxyl content, a second residual acetate content and a second glass transition temperature (T g ),
wherein the difference between the first residual acetate content and the second residual acetate content is at least 1.5 mol percent,
a plasticizer, wherein the first poly(vinyl butyral) resin, the second poly(vinyl butyral) resin and the plasticizer are mixed and melt-extruded to form the at least one soft layer;
at least one stiffer layer comprising a third poly(vinyl butyral) resin having a third residual hydroxyl content and a third residual acetate content; and
a plasticizer,
wherein each plasticized resin in the soft layer of the polymer interlayer has a glass transition temperature (T g ) less than 20.0° C.

16. The polymer interlayer of claim 15 , wherein the polymer interlayer has a damping loss factor (η) (as measured by Mechanical Impedance Measurement according to ISO 16940) of at least about 0.12 measured at two or more different temperatures selected from 10° C., 20° C. and 30° C.

17. The polymer interlayer of claim 15 , wherein the residual acetate content of the third poly(vinyl butyral) resin is the same as the residual acetate content of at least one of the first poly(vinyl butyral) resin or the second poly(vinyl butyral) resin.

18. The polymer interlayer of claim 15 , wherein the difference between the glass transition temperatures (T g ) of the first poly(vinyl butyral) resin and the second poly(vinyl butyral) resin is at least 2.0° C.

19. The polymer interlayer of claim 15 , wherein the difference between the first residual acetate content and the second residual acetate content is at least 2.0 mol percent.

20. The polymer interlayer of claim 15 , wherein the residual hydroxyl content of the first poly(vinyl butyral) resin is the same as the residual hydroxyl content of the second poly(vinyl butyral) resin.

Assignees

• Solutia Inc

Inventors

• Lu Jun

Classifications

• B32B2250/02

  2 layers · CPC title

• B32B27/30

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

• B32B7/02

  Physical, chemical or physicochemical properties · CPC title

• B32B2250/24

  All layers being polymeric · CPC title

• B32B2307/102

  Insulating · CPC title