Thermoplastic resin compositions suitable for use in transparent laminates

• US 7,763,360 B2
• Filed: 10/31/2005
• Issued: 07/27/2010
• Est. Priority Date: 10/29/2004
• Status: Active Grant

• Current Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Original Assignee: E. I. du Pont de Nemours and Company (Corteva, Inc.)
• Inventors: Bennison, Stephen J., Anderson, Jerrel C., Pesek, Steven C., Smith, C. Anthony, Samuels, Sam L., Paul, John W.
• Primary Examiner(s): Wu; David
• Assistant Examiner(s): BERNSHTEYN, MICHAEL
• Application Number:
  US11/263,015
• Publication Number:
  US 20060182983A1
• Time in Patent Office: 1,730 Days
• Field of Search: 526/317.1, 524/556, 428/192, 428/215, 428/426, 428/500, 428/441, 428/522, 428/461
• US Class Current: 428/500
• CPC Class Codes: B32B 17/10036 comprising two outer glass sheets
• CPC Class Codes: B32B 17/10743 containing acrylate (co)polymers or salts thereof
• CPC Class Codes: B32B 17/10834 using a fluid
• CPC Class Codes: B32B 17/10871 in combination with particular heat treatment
• CPC Class Codes: B32B 17/1099 After-treatment of the layered product, e.g. cooling
• CPC Class Codes: C08F 210/02 Ethene
• CPC Class Codes: C08F 220/04 Acids; Metal salts or ammonium salts thereof
• CPC Class Codes: C08F 8/44 Preparation of metal salts or ammonium salts
• CPC Class Codes: C08J 2323/08 Copolymers of ethene C08J2323/16 takes precedence
• CPC Class Codes: C08J 5/18 Manufacture of films or sheets
• CPC Class Codes: Y10T 428/24777 Edge feature
• CPC Class Codes: Y10T 428/31645 Next to addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31692 Next to addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31855 Of addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31935 Ester, halide or nitrile of addition polymer

Abstract

The present invention is an improved polymeric resin composition comprising or consisting essentially of from about 70 wt % to about 79 wt % units derived from ethylene and from about 21 wt % to about 30 wt % units derived from an α, β-unsaturated carboxylic acid having from 3 to 8 carbons. Resins of the present invention are particularly suitable for preparing transparent laminates useful as glazing elements that provide a greater measure of safety than non-laminated glazing elements. Laminates of the present invention have 3% haze or less without the addition of amines.

Claims

1. A laminate article comprising at least one transparent interlayer, wherein the transparent interlayer is obtained from a resin composition consisting essentially of copolymerized units of ethylene and from 20 to 23 wt % of copolymerized units of a carboxylic acid monomer selected from acrylic acid or methacrylic acid, wherein 20% to 35% of the acid groups are neutralized;

and the resin has a melt index of about 60 g/10 min or less prior to neutralization, and wherein the laminate article has a haze of 3% or less after heating to a temperature of at least 120°

C. and cooling to 40°

C. at a rate of less than 1°

C./min; and

further wherein the peel strength of the laminate article is from 16 to 47 lbs/inch when measured at an angle of 90°

at a peel rate of 1 inch/min, provided that the transparent interlayer is an extruded sheet having a moisture level of 0.066 wt % or less; and

further wherein said transparent interlayer has an adhesion to glass of at least 200 J/m², when measured by Double-Cantilever Beam testing; and

said transparent interlayer has an impact toughness of at least 300 J/m², when measured according to ASTM 1822.

2. The laminate article of claim 1, wherein the resin has a melt index of about 55 g/10 min or less prior to neutralization.

3. The laminate article of claim 1, wherein the resin has a melt index of about 50 g/10 min or less prior to neutralization.

4. The laminate article of claim 1, wherein the resin has a melt index of about 35 g/10 min or less prior to neutralization.

5. The laminate article of claim 1, wherein the resin has a melt index of about 2.5 g/10 min or less after neutralization.

6. The laminate article of claim 1, wherein the resin has a melt index of about 1.5 g/10 min or less after neutralization.

7. The laminate article of claim 1, wherein the transparent interlayer has a thickness of from about 0.38 to about 2.60 mm.

8. The laminate article of claim 1, further comprising at least one additional layer selected from the group consisting of ionomeric interlayers having from 15 to 20 wt % acid before neutralization;

EVA copolymer interlayers;

polyurethane interlayers;

polyvinyl chloride polymer interlayers;

PVB interlayers;

adhesive layers; and

rigid structural layers.

9. The laminate article of claim 8, comprising a rigid structural layer that is a layer of glass.

10. An application comprising the laminate article of claim 1, said application selected from the group consisting of windows;

windshields;

sidelites;

structural support units; and

other architectural units.

11. The application of claim 10, wherein a building comprises the window;

an automobile, a plane, or a train comprises the windshield or the sidelite;

stairs, a floor, a wall, or a partition comprises the structural support unit;

or a ceiling comprises the other architectural unit.