Low distortion interlayer

• US 9,452,598 B2
• Filed: 06/29/2015
• Issued: 09/27/2016
• 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 James
• Primary Examiner(s): Khan, Tahseen N
• Application Number:
  US14/753,110
• Publication Number:
  US 20150298447A1
• Time in Patent Office: 456 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 method of producing a multiple layer interlayer, comprising the steps of:

forming a first polymer sheet comprising poly(vinyl butyral) and a plasticizer, wherein said first polymer sheet has a first surface and a second surface and wherein said first 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 between 10 and 95;

disposing a layer of polymer film in contact with said first surface of said first polymer sheet to form a stack; and

,

laminating said stack.

2. The method of claim 1, wherein said waviness index is less than 15,000 square micrometers.

3. The method of claim 1, wherein said waviness index is less than 12,000 square micrometers.

4. The method of claim 1, wherein said polymer film comprises poly(ethylene terephthalate).

5. The method of claim 1, wherein said R_z value is at least 30.

6. The method of claim 1, wherein said R_z value is at least 35.

7. The method of claim 1, wherein said second surface has a surface with 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.

8. The method of claim 1, further comprising the step of, prior to said laminating, adding to said stack a second polymer sheet comprising poly(vinyl butyral) and a plasticizer in contact with said polymer film opposite said first polymer sheet, wherein a surface of said second polymer sheet disposed in contact with said polymer film has a waviness index of less than 20,000 square micrometers, an R_z value of at least 20, and a permanence of between 10 and 95.

9. The method of claim 8, further comprising the steps of, prior to said laminating, adding to said stack a first layer of glass in contact with said first polymer sheet opposite said layer of polymer film, and, adding to said stack a second layer of glass in contact with said second polymer sheet opposite said layer of polymer film.

10. The method of claim 1, wherein said forming a first polymer sheet comprises the steps of:

forming a smooth polymer layer comprising poly(vinyl butyral) and plasticizer, wherein said smooth polymer layer has a first surface with a waviness index of less than 15,000 square micrometers and an R_z value of less than 15 micrometers, and

embossing said first surface with a roughness pattern to produce said first polymer sheet.

11. The method of claim 10, wherein said forming said smooth polymer sheet comprises using a die with a die lip temperature of from 170°

C. to 230°

C.

12. The method of claim 11, wherein said forming said smooth polymer sheet comprises using a mirror surface die roll.

13. A method of producing a polymer sheet, comprising:

forming a layer comprising poly(vinyl butyral) and a plasticizer, wherein said layer has a first surface and a second surface and a waviness index of less than 20,000 square micrometers and an R_z value of less than 20 micrometers on said first surface, and

embossing said layer on said first surface with a roughness pattern to produce said polymer sheet, wherein said polymer sheet has 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 on the side corresponding to said first surface of said layer.

14. The method of claim 13, wherein said waviness index of said polymer sheet is less than 15,000 square micrometers.

15. The method of claim 13, wherein said R_z value of said polymer sheet is at least 35.

16. The method of claim 13, wherein said permanence of said polymer sheet is at least 50.

17. The method of claim 13, wherein said R_z value of said layer is less than 5 micrometers.

18. The method of claim 13, further comprising embossing said layer on said second surface with a roughness pattern, wherein said polymer sheet has a waviness index of less than 20,000 square micrometers, and an R_z value of at least 20 micrometers on the side corresponding to said second surface of said layer.

19. The method of claim 13, wherein said waviness index of said polymer sheet is less than 12,000 square micrometers.

20. The method of claim 19, wherein said R_z value of said polymer sheet is at least 30.

21. A method of producing a multiple layer panel, comprising the steps of:

forming a first polymer sheet comprising poly(vinyl butyral) and a plasticizer, wherein said first polymer sheet has a first surface and a second surface and wherein said first 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 between 10 and 95;

disposing a layer of polymer film in contact with said first surface of said first polymer sheet to form a stack;

disposing a layer of glass in contact with said polymer sheet opposite said polymer film; and

,

laminating said stack.