Low distortion interlayer

• US 9,096,037 B2
• Filed: 06/10/2013
• Issued: 08/04/2015
• Est. Priority Date: 02/22/2005
• Status: Active Grant

• Current Assignee: Solutia Incorporated (Eastman Chemical Company)
• Original Assignee: Solutia Incorporated (Eastman Chemical Company)
• Inventors: Yacovone, Vincent J.
• Primary Examiner(s): KHAN, TAHSEEN
• Application Number:
  US13/913,841
• Publication Number:
  US 20130273318A1
• Time in Patent Office: 785 Days
• Field of Search: 428/141, 156/60, 156/219, 264/293
• US Class Current: 1/1
• CPC Class Codes: B29C 59/005 characterised by the choice of material
• CPC Class Codes: B29C 59/04 using rollers or endless belts
• CPC Class Codes: B29D 7/01 Films or sheets
• CPC Class Codes: B29K 2029/00 Use of polyvinylalcohols, polyvinylethers, polyvinylaldehydes, polyvinylketones or polyvinylketals or derivatives thereof as moulding material
• CPC Class Codes: B29L 2007/002 Panels; Plates; Sheets
• CPC Class Codes: B32B 17/10005 laminated safety glass or glazing
• CPC Class Codes: B32B 17/10036 comprising two outer glass sheets
• 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 17/10449 Wavelength selective transmission
• CPC Class Codes: B32B 17/10577 Surface roughness
• CPC Class Codes: B32B 17/10587 created by embossing
• CPC Class Codes: B32B 17/10761 containing vinyl acetal
• CPC Class Codes: B32B 17/10889 shaping the sheets, e.g. by using a mould B32B17/10816 takes precedence
• CPC Class Codes: B32B 17/10935 as a preformed layer, e.g. formed by extrusion
• CPC Class Codes: B32B 2307/42 Polarizing, birefringent, filtering
• CPC Class Codes: B32B 2367/00 Polyesters, e.g. PET, i.e. polyethylene terephthalate
• CPC Class Codes: B32B 2457/20 Displays, e.g. liquid crystal displays, plasma displays
• CPC Class Codes: B32B 2551/00 Optical elements
• CPC Class Codes: B32B 37/182 one or more of the layers being plastic
• CPC Class Codes: B32B 37/24 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 Class Codes: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 156/1039 : Surface deformation only of sandwich or lamina [e.g., embossed panels]
• CPC Class Codes: Y10T 428/24355 : Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]

Abstract

The present invention is in the field of multiple layer glass panels comprising a polymer sheet having desirable surface properties, and more specifically, the present invention is in the field of multiple layer glass panels comprising poly(vinyl butyral) having a finished surface of relatively low waviness and high roughness disposed in contact with poly(ethylene terephthalate) and/or other poly(vinyl butyral) type layers.

Claims

1. A polymer interlayer, comprising:

a first polymer sheet comprising poly(vinyl butyral) and a plasticizer; and

a second polymer sheet adjacent to said first polymer sheet, wherein said second polymer sheet comprises poly(vinyl butyral) and a plasticizer;

wherein at least one of said first polymer sheet and said second polymer sheet is an embossed polymer sheet comprising a first embossed surface having an R_z value of at least 20 micrometers, a waviness index of less than 20,000 square micrometers, and a permanence of less than 85 percent

wherein said embossed polymer sheet comprising said first embossed surface is prepared by a method comprising the steps of;

forming a polymer layer comprising poly(vinyl butyral) and a plasticizer;

wherein said polymer layer has a first surface and a second surface, wherein said first surface has a waviness index of less than 20,000 square micrometers and an R_z value of less than 20 micrometers, and

embossing said polymer layer on said first surface with a roughness pattern to produce said embossed surface, wherein said embossed surface has a waviness index of less than 20,000 square micrometers, an R_z value of at least 20 micrometers, and a permanence of less than 85 percent.

2. The interlayer of claim 1, wherein said polymer interlayer is not disposed in contact with any other polymer layer.

3. The interlayer claim 1, wherein said R_z value of said first embossed surface is at least 30 micrometers.

4. The interlayer of claim 1, wherein said R_z value of said first embossed surface is at least 35 micrometers.

5. The interlayer of claim 1, wherein said embossed polymer sheet has a second embossed surface with having a waviness index of less than 20,000 square micrometers, an R_z value of at least 20 micrometers, and a permanence of between 10 and 95 percent.

6. The interlayer of claim 1, wherein said R_z value is at least 45 micrometers.

7. The interlayer of claim 1, wherein said R_z value is at least 55 micrometers.

8. The interlayer of claim 1, wherein said permanence is between 30 and 50 percent.

9. The interlayer of claim 1, wherein said permanence is less than 50 percent.

10. The interlayer of claim 1, wherein said forming of said polymer layer comprises using a mirror surface die roll.

11. The interlayer of claim 1, wherein said forming includes extruding molten poly(vinyl butyral) through an extrusion die having a die lip temperature in the range of from 170 to 230°

C. and said first surface has an R_z value of less than 10 micrometers prior to said embossing.