A sound-insulating PVB film and its preparation method

Abstract

This invention discloses a sound-insulating PVB film and its preparation method, belonging to the field of PVB film technology. It includes a first PVB film layer, a second PVB film layer, and a sound-insulating layer disposed between the first and second PVB film layers. The sound-insulating layer comprises TPU and TPEE. The PVB resins in the first and second PVB film layers have different hydroxyl values. The different hydroxyl values ​​of the PVB resins in the two film layers enhance adhesion, while also providing better flowability and easier film formation. The sound-insulating layer, made from a mixture of TPU and TPEE, improves weather resistance and impact resistance. The PVB film layer and the sound-insulating layer enhance sound insulation performance through complementary effects. The PVB film layer primarily insulates sound by absorbing sound wave energy and providing damping, while the sound-insulating layer absorbs sound wave energy primarily through its material properties. The combination of the two not only enhances the damping effect on sound waves but also reduces resonance, further enhancing sound insulation performance.

Description

Technical Field

[0001] This invention relates to the field of PVB film technology, and in particular to a PVB film with sound insulation function and its preparation method. Background Technology

[0002] PVB is a product of the condensation of polyvinyl alcohol and butyraldehyde under acid catalysis. Due to the long branched chains of PVB molecules, it has good flexibility, a low glass transition temperature, and high tensile strength and impact resistance. Films made from PVB have excellent light transmittance and impact resistance, and are widely used in automotive windshields, window glass, architectural glass, and other fields. They also provide sound and heat insulation.

[0003] Continuous technological advancements and innovations will drive the performance of sound-insulating PVB films to new heights, while emerging new materials, advanced processes, and new technologies will further support their development. With accelerating urbanization and improving living standards, the demand for sound-insulating materials is steadily increasing. As a high-quality sound-insulating material, PVB films have a broad market prospect and significant development potential.

[0004] While PVB films typically offer excellent sound insulation, their effectiveness diminishes at certain noise frequencies. For example, patent application CN201610975475.1 describes a sound-insulating PVB film prepared by composites of three layers of PVB films with different thicknesses and melt indices. This film effectively blocks noise in the 1000–4000 Hz frequency range. However, the resulting PVB film may exhibit reduced weather resistance, decreasing its mechanical properties in low or high temperature environments and consequently reducing its sound insulation performance. For instance, in low-temperature environments, the PVB film may harden, further degrading its sound insulation properties. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide a PVB film with sound insulation function and its preparation method, so as to at least improve the mechanical properties and sound insulation performance under high and low temperature environments.

[0006] The objective of this invention is achieved through the following technical solution:

[0007] A sound-insulating PVB film includes a first PVB film layer, a second PVB film layer, and a sound-insulating layer disposed between the first PVB film layer and the second PVB film layer.

[0008] The sound insulation layer comprises TPU resin and TPEE resin;

[0009] The hydroxyl values ​​of the PVB resin in the first and second PVB film layers are different.

[0010] In this invention, the sound-insulating PVB film is composed of three layers: a first PVB film layer, a second PVB film layer, and a sound-insulating layer, sequentially laminated together. The first and second PVB film layers have different hydroxyl values ​​in the PVB resin to enhance adhesion, resulting in better bonding to both the sound-insulating layer and glass, while also exhibiting better flowability and easier film formation. The sound-insulating layer is made from a mixture of TPU and TPEE resins, providing sound insulation while also improving weather resistance and impact resistance. The PVB film layer and the sound-insulating layer enhance sound insulation through complementary effects. The PVB film layer primarily insulates sound by absorbing sound wave energy and providing damping, while the sound-insulating layer absorbs sound wave energy primarily through its material properties. The combination of these two layers not only enhances the damping effect on sound waves but also reduces resonance, thereby further improving sound insulation performance.

[0011] Furthermore, the reason for using a mixture of TPU resin and TPEE resin in the sound insulation layer of this invention is as follows:

[0012] TPU, as an intermediate layer material, is difficult to mold and prone to bubble formation. At the same time, its performance may be affected in high-temperature environments, such as causing thermal aging and thermal diffusion problems. TPEE, on the other hand, has excellent processing performance and excellent high-temperature resistance. Mixing the two can enhance the overall processing performance and high-temperature resistance.

[0013] When TPEE is used alone as an intermediate layer material, higher processing temperatures and pressures are required, the process parameters are more complex, and TPEE's UV resistance is not as good as TPU's. Long-term exposure to ultraviolet light may cause aging, discoloration and other problems.

[0014] Blending TPEE with TPU can enhance the overall UV resistance of the film while reducing processing temperature and pressure. Simultaneously using TPU and TPEE blends can achieve a synergistic effect, enhancing mechanical properties while maintaining high elasticity, improving processing flowability, and enabling use in extreme environments.

[0015] Preferably, both the first PVB film layer and the second PVB film layer comprise the following components in parts by weight:

[0016] 70-80 parts PVB resin, 24-30 parts plasticizer, 0.15-3.5 parts antioxidant, and 0.1-0.2 parts ultraviolet absorber;

[0017] The hydroxyl value of the PVB resin is 17-20%.

[0018] Preferably, the difference in hydroxyl value of the PVB resin in the first PVB film layer and the second PVB film layer is 0.5%.

[0019] Preferably, the sound insulation layer B comprises the following components in parts by weight:

[0020] 10-20 parts TPU resin, 10-20 parts TPEE resin, 1-5 parts plasticizer, 0.05-0.15 parts antioxidant, 0.035-0.07 parts UV absorber, and 0.0175-0.035 parts surface modifier.

[0021] In this solution, weather resistance is further enhanced by adding antioxidants and UV absorbers; and because TPU and

[0022] TPEE has a different molecular structure and chemical properties, so when the two are mixed, the compatibility may not be ideal. Therefore, a surface modifier needs to be added to solve the problem of uneven dispersion.

[0023] Preferably, the antioxidant is one or more of 2,6-di-tert-butyl-4-methylphenol (BHT), pentaerythritol tetrakis[β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate] (antioxidant 1010), tris(2,4-di-tert-butylphenyl) phosphite, and dilauryl thiodipropionate.

[0024] Preferably, the ultraviolet absorber is one or more of UV-P, UVP-327, UV-5411, YASORBUV-2908, and UV-571.

[0025] Preferably, the surface modifier is one or more of methacrylate, acrylic acid, and silane coupling agent.

[0026] Preferably, the thickness of the first PVB film layer and the second PVB film layer is 0.33 mm, and the thickness of the sound insulation layer is 0.1 mm.

[0027] Furthermore, to achieve the above objectives, the present invention also provides a method for preparing a PVB film with sound insulation function, comprising the following steps:

[0028] S1. Antioxidant and UV absorber are dissolved in plasticizer, mixed evenly, and then extruded with two PVB resin powders with different hydroxyl values ​​through a twin-screw extruder to obtain two layers of PVB film, namely the first PVB film layer and the second PVB film layer; Antioxidant, UV absorber, and surface modifier are dissolved in plasticizer, mixed evenly, and then mixed evenly with TPU resin and TPEE resin, and extruded through a twin-screw extruder to obtain a TPU / TPEE blend film, namely the sound insulation layer;

[0029] S2. The three-layer film from step S1 is hot-pressed and laminated using a hot press to obtain a PVB film with sound insulation function.

[0030] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0031] 1. In this invention, the sound-insulating PVB film is composed of three layers: a first PVB film layer, a second PVB film layer, and a sound-insulating layer, sequentially laminated together. The first and second PVB film layers have different hydroxyl values ​​in the PVB resin to enhance adhesion, providing good bonding to both the sound-insulating layer and the glass, while also exhibiting better flowability and easier film formation. The sound-insulating layer is made from a mixture of TPU and TPEE resins, serving a sound-insulating function while improving weather resistance and impact resistance, and reducing processing difficulty. The PVB film layer and the sound-insulating layer enhance sound insulation performance through complementary effects. The PVB film layer primarily insulates sound by absorbing sound wave energy and providing damping, while the sound-insulating layer absorbs sound wave energy primarily through its material properties. The combination of the two not only enhances the damping effect on sound waves but also reduces resonance, thereby further enhancing sound insulation performance.

[0032] 2. The PVB film prepared by this invention has good mechanical properties, with a haze of less than 0.11% and a light transmittance of more than 88.1%. After irradiation in the UVA band for 100 hours, its appearance shows almost no discoloration or bubbles. After irradiation at 140℃ for 2 hours, its appearance shows almost no discoloration or bubbles. The sound insulation is 35-37dB, with significant sound insulation effect. It also has excellent resistance to thermal shock and minimal impact on sound insulation effect at high and low temperatures. Attached Figure Description

[0033] Figure 1 The structure of PVB film for sound insulation.

[0034] Among them, 1-first PVB film layer, 2-PVB film layer, 3-sound insulation layer. Detailed Implementation

[0035] Example 1

[0036] like Figure 1 As shown, the sound-insulating PVB film includes a first PVB film layer 1, a second PVB film layer 2, and a sound-insulating layer 3 disposed between the first PVB film layer 1 and the second PVB film layer 2.

[0037] The thickness of the first PVB film layer 1 and the second PVB film layer 2 is 0.33 mm, and the thickness of the sound insulation layer 3 is 0.1 mm.

[0038] The specific preparation method is as follows:

[0039] S1. Preparation of the first PVB film layer 1 and the second PVB film layer 2:

[0040] 0.5 parts by weight of antioxidant BHT and 0.15 parts by weight of ultraviolet absorber UV-P were dissolved in 25 parts by weight of 3G8 plasticizer and mixed evenly to prepare a 3G8 mixed solution. The 3G8 mixed solution was then mixed with 60 parts by weight of a plasticizer with a hydroxyl value of [missing value].

[0041] 17.5% PVB resin powder and 20 parts by weight of PVB resin powder with a hydroxyl value of 17% were extruded through a twin-screw extruder at 160°C to obtain two layers of PVB film, namely the first PVB film layer 1 and the second PVB film layer 2.

[0042] Preparation of sound insulation layer 3:

[0043] 0.1 parts by weight of antioxidant BHT, 0.05 parts by weight of ultraviolet absorber UV-P, and 0.02 parts by weight of surface modifier methacrylate were dissolved in 3 parts by weight of 3G8 plasticizer and mixed evenly to prepare a 3G8 mixed solution. The 3G8 mixed solution was then mixed with 20 parts by weight of TPU resin and 10 parts by weight of TPEE resin and stirred evenly. The mixture was then extruded through a twin-screw extruder at 190°C and a screw speed of 80 r / min to obtain a TPU / TPEE blend film, i.e., sound insulation layer 3.

[0044] S2. Preheat the three-layer film (A, B, and C) to 120℃. Set the lamination temperature for the first stage to 130℃ and the pressure to -0.1MPa, the lamination temperature for the second stage to 140℃ and the pressure to -0.2KPa, and the lamination temperature for the third stage to 170℃ and the pressure to 97KPa. Perform hot-pressing composite using a hot press to obtain a sound-insulating PVB film.

[0045] Example 2

[0046] Compared to Example 1, the PVB resin powder was adjusted to 60 parts by weight of PVB resin powder with a hydroxyl value of 18% and 20 parts by weight of PVB resin powder with a hydroxyl value of 17.5%, while the remaining parameters and steps were the same as in Example 1.

[0047] Example 3

[0048] Compared to Example 1, the PVB resin powder was adjusted to 60 parts by weight of PVB resin powder with a hydroxyl value of 18.5% and 20 parts by weight of PVB resin powder with a hydroxyl value of 18%, while the remaining parameters and steps were the same as in Example 1.

[0049] Example 4

[0050] Compared to Example 1, the PVB resin powder was adjusted to 60 parts by weight of PVB resin powder with a hydroxyl value of 19% and 20 parts by weight of PVB resin powder with a hydroxyl value of 18.5%, while the remaining parameters and steps were the same as in Example 1.

[0051] Example 5

[0052] Compared to Example 1, the PVB resin powder was adjusted to 60 parts by weight of PVB resin powder with a hydroxyl value of 19.5% and 20 parts by weight of PVB resin powder with a hydroxyl value of 19%, while the remaining parameters and steps were the same as in Example 1.

[0053] Example 6

[0054] Compared to Example 1, the PVB resin powder was adjusted to 60 parts by weight of PVB resin powder with a hydroxyl value of 20% and 20 parts by weight of PVB resin powder with a hydroxyl value of 19.5%, while the remaining parameters and steps were the same as in Example 1.

[0055] Example 7

[0056] Compared to Example 1, the weight proportions of TPU and TPEE were adjusted, and the adjusted weight proportions are as follows:

[0057] The TPU is 15 parts by weight and the TPEE is 15 parts by weight.

[0058] The remaining parameters and steps are the same as in Example 1.

[0059] Example 8

[0060] Compared to Example 1, the weight proportions of TPU and TPEE were adjusted, and the adjusted weight proportions are as follows:

[0061] The TPU is 10 parts by weight and the TPEE is 20 parts by weight.

[0062] The remaining parameters and steps are the same as in Example 1.

[0063] Comparative Example 1

[0064] Compared to Example 1, no surface modifier methacrylate was added.

[0065] The remaining parameters and steps are the same as in Example 1.

[0066] Comparative Example 2

[0067] Compared to Example 1, the PVB resin was replaced with 60 parts by weight of PVB resin powder with a hydroxyl value of 17.5% and 20 parts by weight of PVB resin powder with a hydroxyl value of 16.5%.

[0068] The remaining parameters and steps are the same as in Example 1.

[0069] Comparative Example 3

[0070] Compared to Example 1, the PVB resin was replaced with 60 parts by weight of PVB resin powder with a hydroxyl value of 18% and 20 parts by weight of PVB resin powder with a hydroxyl value of 16%.

[0071] The remaining parameters and steps are the same as in Example 1.

[0072] Performance testing.

[0073] The PVB films prepared in Examples 1-8 and Comparative Examples 1-3 were subjected to relevant performance tests, and the test results are shown in Table 1.

[0074] Table 1 shows the impact resistance test methods as follows:

[0075] The PVB films and glass prepared in Examples 1-8 and Comparative Examples 1-3 were respectively used to make laminated glass according to the standard. After being placed in a freezer at -20±1℃ for 4 hours, the laminated glass was placed in the center of the sample frame of the falling ball impact tester and fixed. A quenched steel ball was placed 8500mm above the center of the glass and released for testing. The glass was considered qualified if the quenched steel ball did not penetrate the glass.

[0076] The PVB films and glass prepared in Examples 1-8 and Comparative Examples 1-3 were respectively used to make laminated glass according to the standard. After being placed in a freezer at 40±1℃ for 4 hours, the laminated glass was placed in the center of the sample frame of the falling ball impact tester and fixed. A quenched steel ball was placed 9000mm above the center of the glass and released for testing. The glass was considered qualified if the quenched steel ball did not penetrate the glass.

[0077] The number of samples tested was 6.

[0078] Table 1:

[0079]

[0080]

[0081]

[0082] Table 1 shows that the PVB films prepared in Examples 1-8 have good mechanical properties, with a haze of less than 0.11% and a light transmittance of more than 88.1%. After 100 hours of UVA irradiation, their appearance showed almost no discoloration or bubbles. After 2 hours at 140℃, their appearance showed almost no discoloration or bubbles. The sound insulation was 35-37 dB, demonstrating significant sound insulation effects. They also exhibited excellent resistance to thermal shock and minimal impact from high and low temperatures on sound insulation performance. The slight yellowing and bubbling observed in Comparative Example 1 after UVA irradiation and the 140℃ heat resistance test was due to the absence of a surface modifier, leading to uneven mixing of TPU and TPEE, resulting in unstable material performance and localized performance differences. Comparative Examples 2-3 showed performance degradation because the PVB resins with significantly different hydroxyl values ​​require higher temperatures and pressures for processing. Under the existing processing temperatures and pressures, the mixing of PVB resins was poor, leading to uneven processing and affecting overall performance.

Claims

1. A PVB film with sound insulation function, characterized in that, It includes a first PVB film layer (1), a second PVB film layer (2), and a sound insulation layer (3) disposed between the first PVB film layer (1) and the second PVB film layer (2); The first PVB film layer (1) and the second PVB film layer (2) each comprise the following components by weight: The composition includes 70-80 parts of PVB resin, 24-30 parts of plasticizer, 0.15-3.5 parts of antioxidant, and 0.1-0.2 parts of ultraviolet absorber; the hydroxyl value of the PVB resin is 17-20%. The hydroxyl values ​​of the PVB resin in the first PVB film layer (1) and the second PVB film layer (2) are different; and the difference in the hydroxyl values ​​of the PVB resin in the first PVB film layer (1) and the second PVB film layer (2) is 0.5%. The sound insulation layer (3) comprises the following components in parts by weight: 10-20 parts TPU resin, 10-20 parts TPEE resin, 1-5 parts plasticizer, 0.05-0.15 parts antioxidant, 0.035-0.07 parts UV absorber, and 0.0175-0.035 parts surface modifier.

2. The PVB film with sound insulation function according to claim 1, characterized in that, The antioxidant is one or more of the following: 2,6-di-tert-butyl-4-methylphenol, pentaerythritol tetrakis[β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], tris(2,4-di-tert-butylphenyl) phosphite, and dilauryl thiodipropionate.

3. The PVB film with sound insulation function according to claim 1, characterized in that, The ultraviolet absorber is one or more of UV-P, UVP-327, UV-5411, YASORBUV-2908, and UV-571.

4. A PVB film with sound insulation function according to claim 1, characterized in that, The surface modifier is one or more of methacrylate, acrylic acid, and silane coupling agent.

5. A PVB film with sound insulation function according to claim 1, characterized in that, The thickness of the first PVB film layer (1) and the second PVB film layer (2) is 0.33 mm, and the thickness of the sound insulation layer (3) is 0.1 mm.

6. The method for preparing a sound-insulating PVB film according to claim 1, characterized in that, Includes the following steps: S1. Take antioxidants and ultraviolet absorbers, dissolve them in plasticizer, mix them evenly, and then extrude them with two PVB resin powders with different hydroxyl values ​​through a twin-screw extruder to obtain two layers of PVB film, namely the first PVB film layer (1) and the second PVB film layer (2); take antioxidants, ultraviolet absorbers, and surface modifiers, dissolve them in plasticizer, mix them evenly, and then mix them evenly with TPU resin and TPEE resin, and extrude them through a twin-screw extruder to obtain a TPU / TPEE blend film, namely the sound insulation layer (3); S2. The three-layer film from step S1 is hot-pressed and laminated using a hot press to obtain a PVB adhesive with sound insulation function.

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