Multiple layer interlayers having a gradient region

• US 7,842,395 B2
• Filed: 11/01/2006
• Issued: 11/30/2010
• Est. Priority Date: 11/01/2006
• Status: Active Grant

• Current Assignee: Solutia Incorporated (Eastman Chemical Company)
• Original Assignee: Solutia Incorporated (Eastman Chemical Company)
• Inventors: Wardak, Marcin, Karagiannis, Aristotelis, D'Errico, John Joseph, Lu, Jun, Bourcier, David Paul, Matis, Gary, Smith, Andrew Neil
• Primary Examiner(s): NAKARANI, DHIRAJLAL S
• Application Number:
  US11/555,678
• Publication Number:
  US 20080102280A1
• Time in Patent Office: 1,490 Days
• Field of Search: 428/436, 428/437, 428/525, 264/173.16
• US Class Current: 428/525
• CPC Class Codes: B32B 17/10339 Specific parts of the laminated safety glass or glazing being colored or tinted tinted glass sheet B32B17/1011; tinted interlayer B32B17/10651
• CPC Class Codes: B32B 17/10761 containing vinyl acetal
• CPC Class Codes: B32B 27/30 comprising vinyl (co)polymers; comprising acrylic (co)polymers
• CPC Class Codes: Y10T 428/31504 Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/31511 Of epoxy ether
• CPC Class Codes: Y10T 428/31627 Next to aldehyde or ketone condensation product
• CPC Class Codes: Y10T 428/3163 Next to acetal of polymerized unsaturated alcohol [e.g., formal butyral, etc.]
• CPC Class Codes: Y10T 428/31942 Of aldehyde or ketone condensation product
• CPC Class Codes: Y10T 428/31946 Next to second aldehyde or ketone condensation product

Abstract

The present invention provides multiple layer interlayers that can be used in multiple layer glass panel type applications to reduce the amount of sound transmitted through the panel while also providing a colored region within a gradient region. The acoustic effect can be achieved by using two or more polymer sheets having differing compositions that have been combined into a single multiple layer interlayer, and the gradient region effect is achieved by forming a colored region in one or more gradient regions of the individual layers.

Claims

1. A poly(vinyl butyral) interlayer comprising:

a single poly(vinyl butyral) sheet, including;

a first plasticized poly(vinyl butyral) layer having a first gradient region and a first clear region;

a second plasticized poly(vinyl butyral) layer having a second gradient region and a second clear region;

a third plasticized poly(vinyl butyral) layer having a third gradient region and a third clear region;

wherein the amount of plasticizer in said second layer is at least 10 parts per hundred greater than the amount of plasticizer in said first layer, and wherein said first layer and said second layer each have a residual acetate content of less than 5 mol percent;

wherein the amount of plasticizer in said second layer is at least 10 parts per hundred greater than the amount of plasticizer in said third layer, and wherein said third layer and said second layer each have a residual acetate content of less than 5 mol percent;

wherein at least one of said first gradient region, said second gradient region and said third gradient region has a colored region; and

,

wherein said colored region has a total alkaline titer that is at least 4 titers less than the total alkaline titer of the clear region of the layer in which it is formed.

2. The interlayer of claim 1, wherein said colored region has a total alkaline titer that is at least 8 titers less than the total alkaline titer of the clear region of the layer in which it is formed.

3. The interlayer of claim 1, wherein said colored region incorporates an epoxy compound.

4. The interlayer of claim 3, wherein said colored region epoxy compound is an epoxy resin.

5. The interlayer of claim 4, wherein said epoxy resin is selected from the group consisting of an epoxide or diepoxide of poly(oxypropylene) glycol.

6. The interlayer of claim 1, wherein said first gradient region, said second gradient region and said third gradient region have a ratio of the height of said gradient region, in the layer in which it is formed, to the height of the clear region below it of greater than 0.25.

7. The interlayer of claim 6, wherein said first gradient region, said second gradient region and said third gradient region have said ratio of the height of said gradient region, in the layer in which it is formed, to the height of the clear region below it of greater than 0.4.

8. The interlayer of claim 1, wherein the amount of plasticizer in said second layer is at least 15 parts per hundred greater than the amount of plasticizer in said first layer, and wherein the amount of plasticizer in said second layer is at east 15 parts per hundred greater than the amount of plasticizer in said third layer.

9. The interlayer of claim 1, wherein said second layer has a residual hydroxyl content per weight percentage that is at least 2% lower than the residual hydroxyl content per weight percentage of said first layer.

10. The interlayer of claim 1, wherein said second layer has a residual hydroxyl content per weight percentage that is at least 4% lower than the residual hydroxyl content per weight percentage of said first polymer layer.

11. The interlayer of claim 1, wherein said second layer has a residual hydroxyl content per weight percentage that is at least 8% lower than the residual hydroxyl content per weight percentage of said first polymer layer.

12. The interlayer of claim 1, wherein said second layer has a residual hydroxyl content per weight percentage of less than 17.0% and said first polymer layer has a residual hydroxyl content per weight percentage of less than 20%.

13. The interlayer of claim 1, wherein said first layer and said second layer each have a residual acetate content of less than 3 mol percent.

14. The interlayer of claim 1, wherein said first layer and said second layer each have a residual acetate content of less than 1 mol percent.

15. The interlayer of claim 1, wherein said colored region is said entire gradient region.

16. The interlayer of claim 1, wherein said colored region is a subportion of said gradient region.

17. The polymer interlayer of claim 1, wherein said first gradient region has a colored region.

18. The interlayer of claim 1, wherein said second gradient region has a colored region.

19. The interlayer of claim 1, wherein said first gradient region and said second gradient region each have a colored region.

20. The interlayer of claim 1, wherein said third gradient region has a colored region.

21. The interlayer of claim 1, wherein said third gradient region and said second gradient region each have a colored region.

22. The interlayer of claim 1, wherein said first, second and third gradient region each have a colored region.

23. A multiple layer glazing panel comprising a poly(vinyl butyral) interlayer comprising:

a single poly(vinyl butyral) sheet, including;

a first plasticized poly(vinyl butyral) layer having a first gradient region and a first clear region;

a second plasticized poly(vinyl butyral) layer having a second gradient region and a second clear region;

a third plasticized poly(vinyl butyral) layer having a third gradient region and a third clear region;

wherein the amount of plasticizer in said second layer is at least 10 parts per hundred greater than the amount of plasticizer in said first layer, and wherein said first layer and said second layer each have a residual acetate content of less than 5 mol percent;

wherein the amount of plasticizer in said second layer is at least 10 parts per hundred greater than the amount of plasticizer in said third layer, and wherein said third layer and said second layer each have a residual acetate content of less than 5 mol percent;

wherein at least one of said first gradient region, said second gradient region and said third gradient region comprises has a colored region; and

,

wherein said colored region has a total alkaline titer that is at least 4 titers less than the total alkaline titer of the clear region of the layer in which it is formed.

24. A method of making a multiple layer interlayer, comprising:

coextruding a first plasticized poly(vinyl butyral) melt to form a first layer having a first gradient region and a first clear region; and

a second plasticized polyvinyl butyral) melt to form a second layer having a second gradient region and a second clear region; and

a third plasticized poly(vinyl butyral) melt to form a third layer having a third gradient layer and a third clear region;

wherein said second layer is between said first layer and said third layer;

wherein the amount of plasticizer in said second layer is at least 10 parts per hundred greater than the amount of plasticizer in said first layer, and wherein said first layer and said second layer each have a residual acetate content of less than 5 mol percent;

wherein the amount of plasticizer in said second layer is at least 10 parts per hundred greater than the amount of plasticizer in said third layer, and wherein said third layer and said second layer each have a residual acetate content of less than 5 mol percent;

wherein at least one of said first gradient region, said second gradient region and said third gradient region has a colored region; and

,

wherein said colored region has a total alkaline titer that is at least 4 titers less than the total alkaline titer of the clear region of the layer in which it is formed.