Interlayer filler and laminated body
Patent Information
- Application Number
- PCT/JP2024/080183
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-10-27
- Filing Date
- 2024-10-28
- Publication Date
- 2025-06-26
AI Technical Summary
Existing interlayer films for window glass, such as plasticizer-free EVA films, suffer from increased haze at high temperatures, reduced transparency, and insufficient impact resistance at low temperatures. Additionally, there is a lack of effective plasticizers that prevent migration into functional devices like light-modulating films without compromising kneadability.
The use of a thermoplastic resin with a glass transition temperature of 60°C or higher, combined with a plasticizer having a specific oxygen-to-carbon atom ratio of 0.36 or more, is employed. This combination ensures that the interlayer filler maintains low haze values at both 23°C and 80°C, prevents plasticizer migration, and provides excellent impact resistance at low temperatures.
The proposed interlayer filler effectively suppresses plasticizer migration into functional devices, maintains transparency at high temperatures, and exhibits improved impact resistance at low temperatures, thereby enhancing productivity and performance.
Abstract
Description
DESCRIPTIONTitle of InventionINTERLAYER FILLER AND LAMINATED BODYTechnical Field
[0001] The present invention relates to an interlayer filler and a laminated body including the interlayer filler.Background Art
[0002] In recent years, there has been an increasing demand for providing window glass with various functions, and for example, introduction of a light-modulating film including a liquid crystal layer has been considered. In the case where a functional device (functional film) such as a light-modulating film is introduced into window glass, it has been studied to provide an interlayer film composed of a thermoplastic resin between two glass members and incorporate the functional device inside the interlayer film.
[0003] Conventionally, polyvinyl acetal resin blended with a plasticizer is generally used as an interlayer film for use in window glass. When a general interlayer film is used with a light-modulating film, the plasticizer may migrate to a liquid crystal layer or the like of the light-modulating film, deteriorating the performance of the light-modulating film due to contamination by the plasticizer. For this reason, PTL 1 and PTL 2, for example, indicate that a plasticizer-free interlayer material such as a plasticizer- free ethylene-vinyl acetate copolymer resin (EVA) film is used as an interlayer material that incorporates a functional device such as a liquid crystal film. Also, disclosed are an interlayer material with a low plasticizer content, and an aspect of using a plasticizer that does not migrate to a suspended particle device film or a plasticizer that does not diffuse into a liquid crystal film or the like.Citation ListPatent Literature
[0004] PTL 1 : JP 2009-534557 APTL 2: JP 2009-534283 ASummary of InventionTechnical Problem
[0005] However, the plasticizer- free EVA films disclosed in PTLs 1 and 2 have a problem that the haze of the resin increases at high temperatures, resulting in deteriorated transparency.
[0006] To reduce contamination by a plasticizer, use of a polyvinyl butyral (PVB) film containing a small amount of plasticizer has also been studied in recent years. Although a PVB film with a small amount of plasticizer requires that the glass transition temperature (Tg) of the PVB resin itself should be lowered to ensure the flexibility of the interlayer film, lowering the Tg of the PVB resin causes a problem that the PVB resin coalesces during storage, resulting in reduced productivity, however.
[0007] Furthermore, the interlayer films disclosed in PTLs 1 and 2 that contain no plasticizers or suppress the migration of a plasticizer to a functional device often have insufficient impact resistance at low temperatures (e.g., about -15°C to -25°C), while the contamination of the functional device is suppressed, leaving room for improvement.
[0008] In addition, the above patent literature neither discloses nor suggests what kind of plasticizer can be used to suppress migration of the plasticizer into a functional film such as a suspended particle device film. Moreover, if a plasticizer with a high viscosity is simply used to prevent migration to a functional film such as a suspended particle device film, kneading with a polyvinyl acetal resin may fail, and the plasticizer may not be uniformly dispersed in the interlayer material.
[0009] Accordingly, an object of the present invention in the first aspect is to provide an interlayer filler that suppresses migration of a plasticizer into a functional device such as a light-modulating film, ensures transparency at high temperatures, and is excellent in productivity.Furthermore, an object of the present invention in the second aspect is to provide an interlayer filler that suppresses migration of a plasticizer into a functional device such as a light-modulating film and has excellent impact resistance at low temperatures.In addition, an object of the present invention in the third aspect is to provide an interlayer filler containing a plasticizer with good kneadability as well as reduced migration toa functional film, a laminated body including the interlayer filler, a laminated glass including the laminated body, and an image display device including the interlayer filler.Solution to Problem
[0010] As a result of intensive studies, the present inventors have found that the object in the first aspect can be achieved by using a thermoplastic resin having a high glass transition temperature and a plasticizer with a specific structure in combination to satisfy specific requirements for haze values at 23°C and 80°C, thus completing the present invention described below. That is, the gist of the present invention in the first aspect is as described in [1] to
[0012] below.[1] An interlayer filler including a thermoplastic resin (A) having a glass transition temperature of 60°C or higher and a plasticizer (B) having a ratio of the number of oxygen atoms to the number of carbon atoms (the number of oxygen atoms / the number of carbon atoms) of 0.36 or more, the interlayer filler satisfying both formulas (1) and (2) below.Formula (1): (haze value at 23 °C) < 1.0%Formula (2): (haze value at 80°C) - (haze value at 23°C) < 0.5%[2] The interlayer filler according to [1] above, including a resin composition (X) including the thermoplastic resin (A) and the plasticizer (B), wherein a content of the plasticizer (A) in the resin composition (X) is 30 parts by mass or more based on 100 parts by mass of the thermoplastic resin (B).[3] The interlayer filler according to [1] or [2] above, wherein the plasticizer has a hydroxyl value of 20 mgKOH / g or more and 100 mgKOH / g or less.[4] The interlayer filler according to any one of [1] to [3] above, wherein the plasticizer is a polyoxyalkylene-based compound having a molecular weight of 600 or more.[5] The interlayer filler according to any one of [1] to [4] above, wherein the thermoplastic resin is a polyvinyl acetal resin.[6] A laminated body including: the interlayer filler according to any one of [1] to [5] above; and at least one selected from the group consisting of a transparent substrate and a functional device.[7] The laminated body according to [6] above, wherein the transparent substrate is at least one glass member selected from the group consisting of an inorganic glass and an organic glass.[8] The laminated body according to [6] or [7] above, wherein the interlayer filler and the functional device are positioned between a pair of transparent substrates.[9] The laminated body according to any one of [6] to [8] above, wherein the functional device is a variable transmittance device of any one of PDLC, SPD, and GHLC.
[0010] A laminated glass including the laminated body according to any one of [6] to [9] above.
[0011] A laminated glass including the laminated body according to any one of [6] to [9] above, wherein the laminated glass is used in a wheeled vehicle with window glass continuously integrated from a roof to a windshield.
[0012] An image display device including the interlayer filler according to any one of [1] to [5] above or the laminated body according to any one of [6] to [8] above.
[0011] In addition, as a result of intensive studies, the present inventors have found that the object in the second aspect can be achieved by using an interlayer filler including a thermoplastic resin (A) and a plasticizer (B) having a ratio of the number of oxygen atoms to the number of carbon atoms (the number of oxygen atoms / the number of carbon atoms) of 0.36 or more, wherein tensile yield stress is 40 MPa or less as measured at a tensile speed of 500 mm / min at -20°C, thus completing the present invention in the following second aspect.That is, the gist of the present invention in the second aspect is as described in
[0013] to
[0026] below.
[0013] An interlayer filler including a thermoplastic resin (A) and a plasticizer (B) having a ratio of the number of oxygen atoms to the number of carbon atoms (the number of oxygen atoms / the number of carbon atoms) of 0.36 or more, tensile yield stress of the interlayer filler being 40 MPa or less as measured at a tensile speed of 500 mm / min at -20°C.
[0014] The interlayer fdler according to
[0013] above, including a resin composition (X) including the thermoplastic resin (A) and the plasticizer (B), wherein a content of the plasticizer (B) in the resin composition (X) is 30 parts by mass or more based on 100 parts by mass of the thermoplastic resin (A).
[0015] The interlayer filler according to
[0013] or
[0014] above, wherein the plasticizer (B) has a zero shear viscosity of 5.0 mPa-s or more and 70.0 mPa-s or less at both 90°C and 120°C, and the plasticizer has a temperature dependence index obtained from formula (3) below of -5.5 or more:Temperature dependence index of plasticizer = (p 120 - p 30) / 90 (3) where T] 120 is a zero shear viscosity [mPa-s] of the plasticizer at 120°C; p30 is a zero shear viscosity [mPa-s] of the plasticizer at 30°C.
[0016] The interlayer filler according to any one of
[0013] to
[0015] above, wherein the thermoplastic resin (A) has a glass transition temperature of 60°C or higher.
[0017] The interlayer filler according to any one of
[0013] to
[0016] above, wherein the plasticizer (B) has a hydroxyl value of 20 mgKOH / g or more and 100 mgKOH / g or less.
[0018] The interlayer filler according to any one of
[0013] to
[0017] above, wherein the plasticizer (B) is a polyoxyalkylene-based compound having a molecular weight of 600 or more.
[0019] A laminated body including: the interlayer filler according to any one of
[0013] to
[0018] above; and at least one selected from the group consisting of a transparent substrate and a functional device.
[0020] The laminated body according to
[0019] above, wherein the transparent substrate is at least one glass member selected from the group consisting of an inorganic glass and an organic glass.
[0021] The laminated body according to
[0019] or
[0020] above, wherein the interlayer filler and the functional device are positioned between a pair of transparent substrates.
[0022] The laminated body according to any one of
[0019] to
[0021] above, wherein the functional device is a variable transmittance device of any one of PDLC, SPD, and GHLC.
[0023] A laminated glass including the laminated body according to any one of
[0019] to
[0022] above.
[0024] The laminated glass according to
[0023] above, which is a light-modulating laminated glass.
[0025] A laminated glass according to
[0023] or
[0024] above, wherein the laminated glass is used in a wheeled vehicle with a glass member continuously integrated from a roof to a windshield.
[0026] An image display device including the interlayer filler according to any one of
[0013] to
[0018] above.
[0012] As a result of intensive studies, the present inventors also found that the object in the third aspect can be achieved by using a plasticizer having a predetermined zero shear viscosity and a predetermined temperature dependency of viscosity, thus completing the present invention in the following third aspect. That is, the gist of the third aspect of the present invention is as described in
[0027] to
[0037] below.
[0027] An interlayer filler including a thermoplastic resin and a plasticizer, wherein a content of the plasticizer is 30 parts by mass or more based on 100 parts by mass of the thermoplastic resin; the plasticizer has a zero shear viscosity of 5.0 mPa-s or more and 70.0 mPa-s or less at both 90°C and 120°C; and the plasticizer has a temperature dependence index obtained from formula (3) below of-5.5 or more:Temperature dependence index of plasticizer = (p 120 - p30) / 90 (3) where r| 120 is a zero shear viscosity (mPa-s) of the plasticizer at 120°C; p30 is a zero shear viscosity (mPa-s) of the plasticizer at 30°C.
[0028] The interlayer filler according to
[0027] above, wherein the thermoplastic resin is a polyvinyl acetal resin having a glass transition temperature of 60°C or higher.
[0029] The interlayer filler according to
[0027] or
[0028] above, wherein the plasticizer has a poly oxy alkylene structure.
[0030] The interlayer filler according to any one of
[0027] to
[0029] above, wherein the plasticizer has a zero shear viscosity of 7.0 mPa-s or more and 40.0 mPa-s or less at both 90°C and 120°C.
[0031] The interlayer filler according to any one of
[0027] to
[0030] above, wherein a moisture content is 5% or more and 30% or less, as measured by a method of measuring a moisture content after a hydration test below:<Method of Measuring Moisture Content after Hydration Test>The interlayer filler is cut into a strip having a size of 1 cm x 4 cm to serve as a sample; the sample is placed in a 20-mL sample tube, to which ion exchanged water is added so that the sample becomes fully submerged in a liquid thereof, and then heated at 50°C for 2 hours using a block heater to obtain a sample after a hydration test; after being weighed, the sample after the hydration test is heated at 105°C, and heating is continued until a change in weight per minute reaches 0.1% or less to obtain a dried sample; a Kett moisture meter is used for drying; and the moisture content after the hydration test is calculated from the weight of the sample after the hydration test and the weight of the dried sample using an equation below:Moisture content after hydration test (%) = [(weight of sample after hydration test) - (weight of dried sample)] / (weight of dried sample) x 100
[0032] A laminated body including the interlayer filler according to any one of
[0027] to
[0031] above and a transparent substrate.
[0033] The laminated body according to
[0032] above, further including one or more functional films.
[0034] The laminated body according to
[0033] above, wherein the functional film includes at least one light-modulating member selected from the group consisting of PDLC, SPD, and GHLC.
[0035] A laminated glass including the laminated body according to any one of
[0032] to
[0034] above.
[0036] A laminated glass including the laminated body according to
[0034] above, wherein the laminated glass is used in a wheeled vehicle with window glass continuously integrated from a roof to a windshield.
[0037] An image display device including the interlayer filler according to any one of
[0027] to
[0031] above.Advantageous Effects of Invention
[0013] According to the first aspect of the present invention, it is possible to provide an interlayer filler that suppresses the migration of a plasticizer into a functional device such as a light-modulating film, ensures transparency at high temperatures, and is excellent in productivity.According to the second aspect, it is possible to provide an interlayer filler that suppresses the migration of a plasticizer into a functional device such as a light-modulating film and has excellent impact resistance at low temperatures.Furthermore, according to the third aspect, it is possible to provide an interlayer filler containing a plasticizer with good kneadability as well as reduced migration to a functional film, a laminated body including the interlayer filler, a laminated glass including the laminated body, and an image display device including the interlayer filler.Brief Description of Drawings
[0014] [Fig. 1] Fig. 1 is a schematic cross-sectional view illustrating an example of a laminated body.[Fig. 2] Fig. 2 is a schematic cross-sectional view illustrating an example of a laminated body.[Fig. 3] Fig. 3 is a schematic cross-sectional view illustrating an example of a laminated body.[Fig. 4] Fig. 4 is a schematic cross-sectional view illustrating an example of a laminated body.[Fig. 5] Fig. 5 is a schematic cross-sectional view illustrating an example of a laminated body.[Fig. 6] Fig. 6 is a schematic cross-sectional view illustrating an example of a laminated body.[Fig. 7] Fig. 7 is a schematic cross-sectional view illustrating an example of a laminated body.[Fig. 8] Fig. 8 is a schematic perspective view illustrating an example of a wheeled vehicle to which a laminated glass is applied.[Fig. 9] Fig. 9 is a schematic cross-sectional view illustrating an example of an image display device.Description of Embodiments
[0015] «First Embodiment»First, the first aspect of the present invention will be described as a first embodiment. <Interlayer Filler>The interlayer filler in the first embodiment of the present invention contains a thermoplastic resin (A) having a glass transition temperature of 60°C or higher and a plasticizer having a ratio of the number of oxygen atoms to the number of carbon atoms (number of oxygen atoms / number of carbon atoms) of 0.36 or more, the interlayer filler satisfying both formulas (1) and (2) below.Formula (1): (haze value at 23°C) < 1.0%Formula (2): (haze value at 80°C) - (haze value at 23°C) < 0.5%With the above-described configuration, the first embodiment of the present invention can provide an interlayer filler that suppresses the migration of a plasticizer into a functional device such as a light-modulating film, ensures transparency at high temperatures, and is excellent in productivity.
[0016] (Haze Value)The interlayer filler of the first embodiment of the present invention has a haze value of less than 1.0% at 23°C, as shown in formula (1). If the interlayer filler has a haze value of 1.0% or more, it becomes difficult to maintain transparency at room temperature, which in turn makes it difficult to maintain transparency at high temperatures. From the viewpoint of ensuring high transparency, the lower the haze value of the interlayer filler at 23 °C, the better, and the haze value is preferably 0.8% or less, and more preferably 0.6% or less. The haze value should be 0% or more but may be 0.1% or more for practical use.
[0017] The interlayer filler of the first embodiment of the present invention has a value obtained by subtracting the haze value at 23 °C from the haze value at 80°C (hereinafter, sometimes referred to as "haze difference") of less than 0.5%, as shown in formula (2). When the haze difference is 0.5% or more, the interlayer filler becomes clouded when heated at a high temperature, making it difficult to maintain transparency. From the viewpoint of ensuring transparency at high temperatures, the lower the haze difference, the better, preferably 0.4% or less, and more preferably 0.3% or less. In addition, the haze value at 80°C is generally the same as or larger than the haze value at 23 °C. Therefore, the haze difference is usually 0% or more and may be 0.1% or more.
[0018] In the first embodiment, the haze value of the interlayer filler at 80°C is not particularly limited but is, for example, less than 1.5%, preferably 1.2% or less, and more preferably 1.0% or less. The haze value at 80°C of the interlayer filler should be 0% or more, but for practical use, 0.1% or more or 0.2% or more.
[0019] The haze value at 23 °C, the haze value at 80°C, and the haze difference can be adjusted by the type of the thermoplastic resin (A). In addition, the haze value at 23 °C and the haze value at 80°C can be reduced by allowing the interlayer filler to be free of an additive reducing permeability of the interlayer filler or an additive having light scattering properties or to make the content a small amount thereof even if containing.
[0020] In the present invention, the interlayer filler is sandwiched between two clear float glass plates and subjected to thermocompression bonding to prepare a laminated glass, and haze values at 23 °C and 80°C obtained by measuring the resulting laminated glass are referred to as the haze value at 23°C and the haze value at 80°C in formulas (1) and (2). Note that in the measurement of the haze values, the measurement should be taken using a laminated glass sample obtained by bonding two clear float glass plates to each other via an interlayer filler cut into a square of 5 cm long x 5 cm wide under the following production conditions. In this case, soda-lime glass with a thickness of 2.0 mm should be used as the clear float glass plate. (Production Conditions)The interlayer filler is sandwiched between two glass plates (clear float glass) and subjected to thermocompression bonding using a vacuum laminator for 5 minutes under conditions of a temperature of 90°C, a vacuum pressure of 0.1 kPa, and a compression pressure of 100 kPa to obtain a laminated structural body temporarily compression-bonded. Subsequently, the laminated structural body is further subjected to thermocompression bonding using an autoclave under conditions of a temperature of 140°C, a pressure of 1.3 MPa, and a holding time of 30 minutes to obtain a laminated glass.
[0021] [Thermoplastic Resin (A)]The thermoplastic resin (A) contained in the interlayer filler in the first embodiment of the present invention has a glass transition temperature of 60°C or higher. If the thermoplastic resin (A) has a glass transition temperature of lower than 60°C, thermoplastic resins (A) may coalesce with each other during storage, resulting in a decrease in productivity. The glass transition temperature of the thermoplastic resin (A) is preferably62°C or higher, more preferably 65°C or higher, from the viewpoint of further reducing coalescence during storage or the like. The glass transition temperature of the thermoplastic resin (A) may be, for example, 120°C or lower, but is preferably 95 °C or lower and more preferably 75°C or lower. The flexibility of the thermoplastic resin (A) can be easily ensured by adjusting the glass transition temperature to a certain temperature or lower.Note that the glass transition temperature can be measured using a dynamic viscoelasticity measuring device with the thermoplastic resin (A) in a film form. Details of the measurement conditions are as described in Examples.
[0022] The specific type of thermoplastic resin is not particularly limited as long as the Tg is 60°C or higher, and examples thereof include a (methjacrylic resin, a polyvinyl acetal resin, a polyvinyl alcohol-based resin (PVA), a polyolefin-based thermoplastic elastomer (POE), a polyurethane-based thermoplastic elastomer (TPU), a cyclic olefin-based resin (COP) such as a cyclic olefin-based copolymer (COC), an ionomer-based resin, a saponified ethylene-vinyl acetate copolymer (EVOH), an ethylene-methacrylic acid copolymer resin, a styrene-isoprene copolymer resin, and a styrene -butadiene copolymer resin.These thermoplastic resins may be used alone or in combination with two or more thereof. Among these thermoplastic resins, a polyvinyl acetal resin is preferred from the viewpoint of impact absorption and from the viewpoint of reducing the haze value at 23 °C and haze difference.The case where a polyvinyl acetal resin is used as the thermoplastic resin (A) will be described in more detail below.
[0023] (Polyvinyl Acetal Resin)Examples of the polyvinyl acetal resin include a polyvinyl acetal resin obtained by acetalizing polyvinyl alcohol (PVA) with an aldehyde.The aldehyde is not particularly limited, but in general, an aldehyde having 1 to 10 carbon atoms is suitably used. Examples of the aldehyde having 1 to 10 carbon atoms include, but not particularly limited to, n-butyraldehyde, isobutyraldehyde, n-valeraldehyde, 2-ethylbutyraldehyde, n-hexylaldehyde, n-octylaldehyde, n-nonylaldehyde, n-decylaldehyde, formaldehyde, acetaldehyde, and benzaldehyde. These aldehydes may be used alone or in combination with two or more thereof.Among the above, n-butyraldehyde, n-hexylaldehyde, and n-valeraldehyde are preferable, and n-butyraldehyde is more preferable. Therefore, the polyvinyl acetal resin is preferably a polyvinyl butyral resin.
[0024] Polyvinyl alcohol (PVA) used as a raw material of a polyvinyl acetal resin is obtained, for example, by saponification of polyvinyl ester such as polyvinyl acetate. The saponification degree of the polyvinyl alcohol is generally from 70 to 99.9 mol%. The polyvinyl acetal resins may be used alone or in combination with two or more thereof.The average degree of polymerization of PVA is preferably 200 or more, more preferably 500 or more, even more preferably 1000 or more, and still more preferably 1500 or more. The average degree of polymerization of PVA is preferably 5000 or less, more preferably 4000 or less, even more preferably 3500 or less, and still more preferably 2500 or less.Note that the average degree of polymerization of the polyvinyl alcohol can be determined by the method in conformity with JIS K 6726 "Testing methods for polyvinyl alcohol".
[0025] The amount of hydroxy groups in the polyvinyl acetal resin is preferably 15 mol% or more and 38 mol% or less. When the amount of hydroxy groups is 15 mol% or more, adhesiveness and impact resistance tend to be improved. When the amount of hydroxy groups is 38 mol% or less, the laminated glass is prevented from becoming too hard. The amount of hydroxy groups is more preferably 20 mol% or more, even more preferably 25 mol% or more, from the viewpoint of, for example, adhesiveness to a glass member or the like. The amount of hydroxy groups is more preferably 35 mol% or less, and even more preferably 33 mol% or less.When a polyvinyl butyral resin is used as the polyvinyl acetal resin, the amount of hydroxy groups is preferably 15 mol% or more and 38 mol% or less from the same viewpoint. The amount of hydroxy groups is more preferably 20 mol% or more, even more preferably 25 mol% or more, and more preferably 35 mol% or less, even more preferably 33 mol% or less.The amount of hydroxy group in the polyvinyl acetal resin is a value in percentage of the mole fraction determined by dividing the amount of ethylene groups to which hydroxy groups are bonded by the total amount of ethylene groups of the main chain. The amount of ethylene groups to which hydroxy groups are bonded can be measured in conformity with, for example, JIS K 6728 "Testing methods for polyvinyl butyral".
[0026] The amount of acetal groups in the polyvinyl acetal resin is preferably 47 mol% or more and 85 mol% or less. The amount of acetal groups is more preferably 55 mol% ormore, even more preferably 60 mol% or more, and more preferably 80 mol% or less, even more preferably 75 mol% or less.Note that the amount of acetal groups means the degree of butyralization or the amount of butyral groups when the acetal group is a butyral group, and the polyvinyl acetal resin (A) is a polyvinyl butyral resin.
[0027] The amount of acetal groups can be determined in the percentage of the mole fraction determined, for example, by subtracting the amount of ethylene groups to which hydroxy groups are bonded and the amount of ethylene groups to which acetyl groups are bonded from the total amount of ethylene groups in the main chain, and then dividing the resulting value by the total amount of ethylene groups in the main chain. The amount of acetal groups (e.g., the degree of butyralization or amount of butyral groups) may be calculated from the results measured by a method in conformity with, for example, JIS K 6728 "Testing methods for polyvinyl butyral".
[0028] The amount of acetyl groups in the polyvinyl acetal resin is preferably 30 mol% or less, more preferably 20 mol% or less, even more preferably 10 mol% or less, and still more preferably 2 mol% or less. When the amount of acetyl groups is equal to or less than the upper limit, the interlayer filler and the laminated body (such as a laminated glass) including the interlayer filler have high moisture resistance. The amount of acetyl groups is not particularly limited but is preferably 0.01 mol% or more, and more preferably 0.1 mol% or more.The amount of acetyl groups is a value in percentage of the mole fraction determined by dividing the amount of ethylene groups to which acetyl groups are bonded by the total amount of ethylene groups of the main chain. The amount of ethylene groups to which acetyl groups are bonded can be measured in conformity with, for example, JIS K 6728 "Testing methods for polyvinyl butyral".
[0029] The polyvinyl acetal-based resin usually has an acetal group, a hydroxy group, and an acetyl group in the side chain. From the viewpoint of increasing the glass transition temperature, the polyvinyl acetal-based resin is preferably an unmodified polyvinyl acetal- based resin, which has no other functional groups than these in the side chain.The polyvinyl acetal-based resin may be a modified polyvinyl acetal-based resin having a modification group other than an acetal group, a hydroxy group, and an acetyl group in the side chain. Examples of the modification group include a carboxamide group (-CONHR), an acyl group (-COR) other than an acetyl group, and a polyoxyalkylene group. In each of the carboxamide group and the acyl group, R is a hydrocarbon group having 2 to 30 carbon atoms, preferably an alkyl group having 3 to 24 carbon atoms, more preferably an alkyl group having 5 to 20 carbon atoms.Examples of the polyoxyalkylene group include a polyoxyethylene group, a polyoxypropylene group, a polyoxybutylene group, and a group constituted of a copolymer of two or more selected from the group consisting of oxyethylene, oxypropylene, and oxy butylene.
[0030] (Plasticizer (B))The plasticizer (B) used in the interlayer filler in the first embodiment of the present invention contains an oxygen atom and a carbon atom and has a ratio of the number of oxygen atoms to the number of carbon atoms (hereinafter, sometimes referred to as "the number of oxygen atoms / the number of carbon atoms") of 0.36 or more. If the number of oxygen atoms / the number of carbon atoms is less than 0.36, the plasticizer is likely to migrate into the functional device. Therefore, the functional device is easily contaminated by the migrated plasticizer. For example, a liquid crystal layer of the functional device is transparentized, which may deteriorate the function of the functional device.The number of oxygen atoms / the number of carbon atoms in the plasticizer (B) is preferably 0.37 or more, more preferably 0.38 or more, from the viewpoint of further preventing the functional device from being contaminated by the plasticizer (B). The number of oxygen atoms / the number of carbon atoms in the plasticizer (B) is, for example, 0.50 or less, preferably 0.47 or less, and more preferably 0.44 or less. When the number of oxygen atoms / the number of carbon atoms is equal to or less than a certain value, the thermoplastic resin (A) and the plasticizer (B) can be properly compatible with each other without causing the polarity of the plasticizer (B) to become excessively high.
[0031] Examples of the plasticizer (B) include a poly hydric alcohol compound such as glycol, an ester compound of glycol and a monobasic organic acid or a polybasic organic acid, and an ether compound of a monohydric or polyhydric alcohol and a polyoxyalkylene.The plasticizer (B) is preferably a poly oxyalkylene-based compound which has a polyoxyalkylene structure. Examples of polyoxyalkylene include polyoxyethylene, polyoxypropylene, polyoxybutylene, and a random copolymer or block copolymer thereof. The polyoxyalkylene-based compound may be a polyhydric alcohol compound, an ester compound, or an ether compound as described above, or may be any other compound.The plasticizer (B) may not have a hydroxy group but preferably has a hydroxy group. When the plasticizer (B) contains a hydroxy group, it is possible to suppress the elution of the plasticizer into the functional device, particularly the liquid crystal layer of the functional device, while enhancing the flexibility of the interlayer filler and to prevent the deterioration of the liquid crystal layer caused by the plasticizer.
[0032] Examples of the polyoxyalkylene-based compound include poly oxyalkylene or a derivative thereof. More specific examples thereof include a polyoxyalkylene glycol constituted of the poly oxyalkylene above and an ether compound of polyoxy alkylene with a polyhydric alcohol. Each of the compounds may have a hydroxy group at all terminals or may be a derivative in which a hydrogen atom is replaced with an alkyl group or an acyl group at some or all of the terminal hydroxy groups. The number of carbon atoms in the alkyl group and the acyl group is not particularly limited as long as the number of oxygen atoms / the number of carbon atoms is within a predetermined range, but may be about 1 to 8, preferably 1 to 4.
[0033] Examples of polyoxyalkylene glycol include polyoxyethylene glycol, poly oxypropylene glycol, polyoxybutylene glycol, and polyoxyethylene poly oxypropylene glycol.Examples of the ether compound of polyoxyalkylene with a polyhydric alcohol include an ether compound of a polyhydric alcohol such as glycerol, diglycerol, trimethylolpropane, erythritol, pentaerythritol, and bisphenol A with polyoxyalkylene; specifically polyoxyethylene glyceryl ether, polyoxypropylene glyceryl ether, polyoxyethylene diglyceryl ether, polyoxypropylene diglyceryl ether, and polyoxyalkylene pentaerythritol ether.
[0034] In addition, examples of the derivative in which hydrogen atoms at some or all of the terminal hydroxy groups are replaced with alkyl groups or acyl groups include a derivative in which hydrogen atoms at some or all of the terminal hydroxy groups of the polyoxyalkylene glycol or ether compound described above are replaced with alkyl groups or acyl groups. Specific examples thereof include polyoxyethylene glycol monomethyl ether, polyoxyethylene glycol dimethyl ether, polyoxypropylene glycol monomethyl ether, polyoxypropylene glycol dimethyl ether, polyoxyethylene polyoxypropylene glycol monomethyl ether, polyoxyethylene polyoxypropylene glycol dimethyl ether, polyoxyethylene glycolmonobutyl ether, polyoxypropylene glycolmonobutyl ether, and polyoxyethylene polyoxypropylene monobutyl ether.
[0035] Of the above, the polyoxy alkylene-based compound is preferably a compound having a polyoxyethylene, polyoxypropylene, or polyoxyethylene polyoxypropylene structure, among which a compound having a poly oxypropylene or polyoxyethylene polyoxypropylene structure is more preferable. Specifically, preferred is polyoxyethylene polyoxypropylene glycol, polyoxypropylene glyceryl ether, polyoxypropylene diglyceryl ether, or a derivative thereof in which hydrogen atoms at some of the terminal hydroxy groups are replaced with alkyl groups.
[0036] The plasticizer (B) may be used alone or in combination with two or more thereof. In the case of using two or more plasticizers in combination, it is preferable to use a mixture of a plurality of plasticizers in a resin composition (X) described later. In the case of mixing a plurality of plasticizers, a plasticizer in which the number of oxygen atoms / the number of carbon atoms is 0.36 or more may be mixed with a plasticizer in which the number of oxygen atoms / the number of carbon atoms is less than 0.36 so that the number of oxygen atoms / the number of carbon atoms in the plasticizer (B) as a whole falls within the above range.
[0037] The molecular weight of the polyoxyalkylene-based compound is preferably 600 or more. When the poly oxy alkylene-based compound has a molecular weight equal to or greater than a certain level, it is easier to improve flexibility or the like while maintaining good mechanical strength. The molecular weight of the polyoxyalkylene-based compound is more preferably 900 or more, and even more preferably 1200 or more. The molecular weight of the polyoxy alkylene-based compound is preferably 3000 or less, more preferably 2500 or less, and even more preferably 2100 or less.The molecular weight of the polyoxyalkylene-based compound is the molecular weight obtained from a structural formula and is the weight-average molecular weight when the molecular weight distribution has a wide range. When two or more plasticizers are used in combination, the molecular weight of the polyoxyalkylene-based compound is the weightaverage molecular weight of the entire plasticizer. The weight-average molecular weight can be measured as a polystyrene-equivalent molecular weight by gel permeation chromatography (GPC). Examples of a column to be used for GPC include SHODEX KF- 806L.
[0038] The plasticizer (B) has a hydroxyl value of, for example, 0 mgKOH / g or more and 400 mgKOH / g or less, preferably 5 mgKOH / g or more and 200 mgKOH / g or less, morepreferably 20 mgKOH / g or more and 100 mgKOH / g or less, and even more preferably 20 mgKOH / g or more and 70 mgKOH / g or less. The hydroxyl value of the plasticizer (B) can prevent an increase in moisture permeability of the interlayer filler caused by the hydroxy groups by keeping the hydroxyl value below a certain level, therefore making it easy to prevent moisture from penetrating into the functional device and interfering with the function of the functional device. In addition, the hydroxyl value can be kept above a certain level to suppress the elution of the plasticizer into the liquid crystal layer, thus preventing contamination of the functional device due to the plasticizer.Note that the hydroxyl value of the plasticizer (B) can be measured in conformity with JIS K 0070-1992.
[0039] The interlayer filler in the first embodiment of the present invention preferably includes a resin composition (X) containing the thermoplastic resin (A) and the plasticizer (B) described above, and the content (hereinafter, sometimes referred to as "content (X)") of the plasticizer (B) based on 100 parts by mass of the thermoplastic resin (A) in the resin composition (X) is preferably 20 parts by mass or more, more preferably 25 parts by mass or more, and even more preferably 30 parts by mass or more. The interlayer filler can be sufficiently flexible even when the thermoplastic resin (A) with a high glass transition temperature is used, by making the content (X) of plasticizer (B) equal to or greater than a certain amount. The content (X) of the plasticizer (B) is preferably 100 parts by mass or less, more preferably 70 parts by mass or less, and even more preferably 50 parts by mass or less. The content (X) of the plasticizer can be kept below a certain level to suppress migration of the plasticizer into the functional device, thus preventing the functional device from deteriorating functionally. In addition, even when interlayer fillers are stacked during storage, suppression of the interlayer fillers coalescing with each other is achieved, resulting in good handling properties.
[0040] The resin composition (X) may contain a component other than the thermoplastic resin (A) and the plasticizer (B). For example, the resin composition (X) may contain a resin component other than the thermoplastic resin (A) or an additive described later. However, the resin composition (X) may be mainly composed of the thermoplastic resin (A) and the plasticizer (B), and the total content of the thermoplastic resin and the plasticizer in the resin composition (X) is usually 70% by mass or more, preferably 80% by mass or more, and more preferably 90% by mass or more and 100% by mass or less based on the total amount of the resin composition (X).
[0041] (Structure of Interlayer Filler)The interlayer filler in the first embodiment of the present invention is preferably in the shape of a film. The interlayer filler in the first embodiment of the present invention may be a film with a single-layer structure or a film with a multilayer structure. The interlayer filler with a single-layer structure may be formed of a single resin layer formed of the resin composition (X) described above (hereinafter, the resin layer formed of the resin composition (X) is sometimes referred to as "resin layer (x)").
[0042] When the interlayer filler is a film with a multilayer structure, each layer is preferably a resin layer (x) formed of the resin composition (X) described above. As long as at least one layer is a resin layer (x) formed of the resin composition (X) described above, however, a part of the layers in the multilayer structure may be formed of the resin composition (X) described above, and another part of the layers may be formed of a resin layer (also referred to as "resin layer (y)") other than the resin layer (x). That is, in the case of an interlayer filler with a multilayer structure, a part of the layers may be formed of the resin composition (X) described above, and the remaining layer(s) may be formed of a resin composition (hereinafter, also referred to as "resin composition (Y)") other than the resin composition (X).
[0043] When the interlayer filler is a multilayer structure of which at least two layers are each a resin layer (x) formed of the resin composition (X) described above, the thermoplastic resin (A) in the resin composition (X) forming each resin layer (x) may be of the same type as each other or different types, but is preferably of the same. Therefore, the thermoplastic resin (A) in each resin composition (X) forming each resin layer (x) is preferably a polyvinyl acetal resin, more preferably a polyvinyl butyral resin.Similarly, when the interlayer filler is a multilayer structure of which at least two layers are each a resin layer (x) formed of the resin composition (X) described above, the plasticizer (B) in each resin layer (x) may be of the same type as each other or different types, but is preferably of the same. Therefore, the plasticizer (B) in each resin composition (X) forming each resin layer (x) is preferably a polyoxyalkylene-based compound, more preferably a polyoxyalkylene-based compound having a molecular weight of 600 or more.In addition, when the interlayer filler is a multilayer structure of which at least two layers are each a resin layer (x) formed of the resin composition (X) described above, the resin composition (X) forming each resin layer (x) may have the same composition as each other or may have different compositions from each other.
[0044] When the interlayer filler in the first embodiment of the present invention is a multilayer structure, a layer disposed on at least one surface of the interlayer filler is preferably the resin layer (x), and each layer disposed on both surfaces is more preferably the resin layer (x). When the resin layer (x) is disposed on the surface, the resin layer (x) can be disposed at a position in contact with the functional device in a laminated body described later, therefore effectively suppressing the migration of the plasticizer into the functional device from the interlayer filler.
[0045] In the interlayer filler, the resin layer (y) (resin composition (Y)) preferably contains a thermoplastic resin, and the thermoplastic resin in the resin layer (y) may be appropriately selected from the thermoplastic resins described above as the thermoplastic resin (A), of which a polyvinyl acetal resin is preferable, and a polyvinyl butyral resin is more preferable.Therefore, when the interlayer filler is a multilayer structure including a resin layer (y) in addition to the resin layer (x), the thermoplastic resin used for both the resin layer (x) and the resin layer (y) is preferably a polyvinyl acetal resin, more preferably a polyvinyl butyral resin.The resin layer (y) (resin composition (Y)) may further contain a plasticizer. As the plasticizer used in the resin layer (y), the plasticizer (B) described above may be used as long as the resin layer (y) becomes a layer other than the resin layer (x) mentioned above, or other conventionally known plasticizers may also be used. In other words, the plasticizer used in the resin layer (y) may include a plasticizer in which the number of (oxygen atoms / the number of carbon atoms) is less than 0.36. The plasticizer in which the number of (oxygen atoms / the number of carbon atoms) is less than 0.36 may be a known plasticizer conventionally used in an interlayer film.In a multilayer body having the interlayer filler, the interlayer filler may be peeled off from other layers, and the peeled interlayer filler may satisfy the requirements of the above formulas (1) and (2).
[0046] The thickness of the interlayer filler in the first embodiment of the present invention is not particularly limited but is preferably 100 pm or more, more preferably 200 pm or more, even more preferably 300 pm or more, and may be, for example, 1500 pm or less, but is preferably 1000 pm or less, more preferably 800 pm or less, and even more preferably 500 pm or less. When the thickness of the interlayer filler is equal to or greater than the lower limit, it becomes easier to maintain the impact absorption of the interlayer filler, and thesafety is ensured in case of using it in a laminated glass, for example. In addition, adhesiveness to other members such as a transparent substrate and a functional device can be easily maintained. On the other hand, when the thickness is equal to or less than the upper limit, the transparency of the interlayer filler can be improved, making it easier to reduce the haze value at 23 °C and haze difference. In addition, the total thickness of the laminated body incorporating the interlayer filler can be prevented from becoming larger than necessary.
[0047] In the interlayer filler in the first embodiment of the present invention, the resin layer (x) may be disposed on at least one surface as described above. The thickness of the resin layer (x) disposed on the surface is, for example, 50 pm or more, preferably 100 pm or more, more preferably 150 pm or more, and even more preferably 200 pm or more, and is, for example, 1500 pm or less, preferably 1000 pm or less, more preferably 700 pm or less, and even more preferably 450 pm or less. When the thickness of the resin layer (x) disposed on the surface of the interlayer filler is equal to or greater than the lower limit, migration of the plasticizer into the functional device can be appropriately suppressed. In addition, the coalescence of interlayer fillers can be prevented, making it easier to improve handling properties, productivity, and the like.Regarding the resin layer (x) disposed on the surface of the interlayer filler herein, when the interlayer filler is a single resin layer (x), the thickness of the interlayer filler and the thickness of the resin layer (x) disposed on the surface are the same as each other. When the resin layer (x) disposed on the surface of the interlayer filler is continuously laminated on other resin layer(s) (x), it means that the total thickness of the continuously laminated resin layers (x) is the thickness of the resin layer (x) disposed on the surface.Therefore, when the interlayer filler is a multilayer structure and all the resin layers are the resin layer (x), the thickness of the interlayer filler and the thickness of the resin layer (x) disposed on the surface become the same as each other.
[0048] (Additive)The interlayer filler may contain an additive other than the thermoplastic resin (A) and plasticizer (B) as described above. Examples of the additive include a heat shielding substance. That is, the interlayer filler in the first embodiment of the present invention may contain a heat shielding substance as an additive. Examples of the heat shielding substance include component S which is at least one of a phthalocyanine compound, a naphthalocyanine compound, and an anthracyanine compound, and a heat shielding particle.As the heat shielding substance, the component S may be used alone, the heat shielding particle may be used alone, or both may be used.
[0049] A conventionally known phthalocyanine compound, naphthalocyanine compound, and anthracyanine compound can be used as the component S. Examples of the component S include phthalocyanine, a derivative of phthalocyanine, naphthalocyanine, a derivative of naphthalocyanine, anthracyanine, and a derivative of anthracyanine. The phthalocyanine compound and the derivative of phthalocyanine preferably each has a phthalocyanine skeleton. Each of the naphthalocyanine compound and the derivative of naphthalocyanine preferably has a naphthalocyanine skeleton. Each of the anthracyanine compound and the derivative of anthracyanine preferably has an anthracyanine skeleton.The component S may contain at least one of a vanadium atom or a copper atom. The component S is preferably at least one of phthalocyanine or a derivative of phthalocyanine containing at least one of a vanadium atom and a copper atom.
[0050] A metal oxide particle can be used as the heat shielding particle. Infrared rays (heat rays) can be effectively cut off by using the heat shielding particle as the heat shielding substance. Although the energy amount of an infrared ray with a wavelength of 780 nm or longer, which is longer than that of visible light, is smaller than that of an ultraviolet ray, the thermal action of the infrared ray is large, and therefore, when the infrared ray is absorbed into a substance, heat is released from the substance. Accordingly, an infrared ray is generally called a heat ray. The heat shielding particle may be a particle capable of absorbing infrared rays, i.e., heat rays.Specific examples of the heat shielding particle include a metal oxide particle such as an aluminum-doped tin oxide particle, an indium-doped tin oxide particle, an antimony-doped tin oxide particle (ATO particle), a gallium-doped zinc oxide particle (GZO particle), an indium-doped zinc oxide particle (IZO particle), an aluminum-doped zinc oxide particle (AZO particle), a niobium-doped titanium oxide particle, a sodium-doped tungsten oxide particle, a cesium-doped tungsten oxide particle, a thallium-doped tungsten oxide particle, a rubidium-doped tungsten oxide particle, a tin-doped indium oxide particle (ITO particle), a tin-doped zinc oxide particle, a silicon-doped zinc oxide particle, and a lanthanum hexaboride (LaB6) particle. Other heat shielding particles may also be used.The heat shielding particles may be used alone or in combination with two or more thereof.
[0051] When the interlayer filler has a single-layer structure, the heat shielding substance may be contained in the resin composition (X) forming the single-layer structure. When the interlayer filler has a multilayer structure, the heat shielding substance may be contained in any one of the resin layers forming the interlayer filler, and may be contained in at least one of resin layers (x) (resin compositions (X)), in at least one of resin layers (y) (resin compositions (Y)), or in both of them.
[0052] In the case of using component S as a heat shielding substance, the content of the component S is, based on the weight of the resin layer (resin composition (X) or resin composition (Y)) in which the component S is contained, preferably 0.001% by weight or more and 0.2% by weight or less, more preferably 0.005% by weight or more and 0.1% by weight or less, even more preferably 0.01% by weight or more and 0.05% by weight or less. When the content of the component S is within the above range, the interlayer filler can exhibit appropriate heat-shielding performance, while maintaining transparency.In addition, in the case of using the heat shielding particle as the heat shielding substance, the content of the heat shielding particle is, based on the weight of the resin layer (resin composition (X) or resin composition (Y)) in which the component S is contained, is preferably 0.01% by weight or more and 6% by weight or less, more preferably 0.1% by weight or more and 5.5% by weight or less, even more preferably 0.5% by weight or more and 4% by weight or less. When the content of the heat shielding particle is within the above range, the interlayer filler can exhibit appropriate heat-shielding performance, while maintaining transparency.
[0053] The interlayer filler may contain an additive other than the heat shielding substance, and specific examples thereof include an adhesive strength modifier, a moisture resistance improver, a light stabilizer, an antioxidant, a dispersant, an ultraviolet absorber, an infrared absorber, a pigment, a dye, a fluorescent brightener, a crystal nucleus agent, an antistatic agent, an anti-blocking agent, a refractive index modifier, and a light scattering agent which may be used alone or in combination with two or more thereof.When the interlayer filler has a single-layer structure, these additives should be contained in the resin composition (X) forming the single-layer structure. When the interlayer filler has a multilayer structure, the heat shielding substance may be contained in any one of the resin layers forming the interlayer filler, and may be contained in at least one of resin layers (x) (resin compositions (X)), in at least one of resin layers (y) (resin compositions (Y)), or in both of them.The content of the additive in each resin composition in the first embodiment may be appropriately adjusted so that the haze value at 23 °C is within the predetermined range described above.
[0054] (Sound Insulation Performance)When the interlayer filler has a multilayer structure with at least three resin layers, sound insulation performance may be imparted by a laminated structure in which the central resin layer is a core layer and the resin layer on each side thereof is a skin layer.The core layer herein may be the resin layer (x) or the resin layer (y). The skin layer may be either the resin layer (x) or the resin layer (y), but it is preferred that at least one skin layer is the resin layer (x), and it is more preferred that both are the resin layer (x). The resin layer (x) forming the skin layer may constitute one surface or both surfaces of the interlayer filler.The resin used for both the skin layer and the core layer is preferably a polyvinyl acetal resin, and more preferably a polyvinyl butyral resin.
[0055] Both the skin layer and the core layer preferably contain a plasticizer. In this case, the difference between a content (1) of the plasticizer in the core layer and a content (2) of the plasticizer in each skin layer is preferably 5 parts by mass or more and 60 parts by mass or less, more preferably 10 parts by mass or more and 55 parts by mass or less, and even more preferably 15 parts by mass or more and 50 parts by mass or less.Note that the content (1) is the content of the plasticizer in the core layer (resin composition forming the core layer) based on 100 parts by mass of the thermoplastic resin, and the content (2) is the content of the plasticizer in the skin layer (resin composition forming the skin layer) based on 100 parts by mass of the thermoplastic resin.The difference between the content (1) of the plasticizer in the core layer and the content (2) of the plasticizer in the skin layer can be kept above a certain level to exhibit sound insulation performance. From the viewpoint of improving the sound insulation performance, the content (2) of the plasticizer in at least one skin layer may be less than the content (1) of the plasticizer in the core layer. That is, the content (1) of the plasticizer in the core layer may be greater than the content (2) of the plasticizer in the skin layer.The contents (1) and (2) may be appropriately adjusted within the range described in the content (X) described above.
[0056] Further, the polyvinyl acetal resin in the skin layer and the polyvinyl acetal resin in the core layer may have different resin compositions. That is, the polyvinyl acetal resins having different amounts of acetyl groups and hydroxy groups in the skin layer and the core layer may be used.
[0057] As described above, in the interlayer filler having a skin layer and a core layer, the skin layer and the core layer may be either the resin layer (x) or the resin layer (y), but it is preferable that both skin layers are the resin layers (x). Therefore, the content (X) of the plasticizer in the resin layer (x) forming the skin layer is preferably adjusted as indicated in the content (2) of the plasticizer above. The resin layer (x) forming the skin layer is preferably a layer forming the surface of the interlayer filler.In the interlayer filler having a skin layer and a core layer, the core layer may also be the resin layer (x) in addition to the skin layer. Therefore, the content (X) of the plasticizer in the resin layer (x) forming the core layer is preferably adjusted as indicated in the content (1) of the plasticizer above.
[0058] The interlayer filler having the core layer and the skin layer as described above preferably has a loss factor of 0.4 or more at the second resonance frequency, a loss factor of 0.4 or more at the third resonance frequency, and a loss factor of 0.4 or more at the fourth resonance frequency, as measured with a laminated glass produced by sandwiching the interlayer filler between two glass plates, followed by thermocompression bonding. As described above, the sound insulation performance can be ensured when the loss factors at the second, third, and fourth resonance frequencies are equal to or greater than a certain value.From the viewpoint of sound insulation, the loss factor at the second resonance frequency is preferably 0.45 or more, more preferably 0.5 or more, and even more preferably 0.55 or more, and the loss factor at the third resonance frequency is preferably 0.45 or more, more preferably 0.5 or more, and even more preferably 0.55 or more. In addition, the loss factor at the fourth resonance frequency is preferably 0.45 or more, more preferably 0.5 or more, and even more preferably 0.55 or more.
[0059] In the measurement of the loss factor, clear float glass having a width of 25 mm, a length of 300 mm, and a thickness of 2 mm should be used as the glass plate, and the laminated glass may be produced under the conditions described in the measurement of the haze value above. The loss factors at the second, third, and fourth resonance frequencies aremeasured by a central excitation method at 20°C in mechanical impedance measurement in conformity with ISO 16940.Note that the loss factor measured by the central excitation method at 20°C should be calculated by the half- width method with the frequency response function. If it is impossible to calculate the loss factor by the half-width method at less than 3 dB, the ndB-width method should be used to calculate the loss factor.
[0060] (Optical Properties of Interlayer Filler)In the interlayer filler in the first embodiment of the present invention, the total light transmittance of a laminated glass produced by sandwiching the interlayer filler between two clear float glass plates, followed by thermocompression bonding, is preferably 80% or more, more preferably 85% or more, and even more preferably 88% or more. The transparency of the interlayer filler can be easily maintained when the total light transmittance is kept above a certain level, making it suitable for use in window glass.However, a specific color may be imparted to the interlayer filler by adding a coloring agent, such as a dye or a pigment, as long as the haze value at 23 °C and haze difference are within a predetermined range. Imparting color can improve the design quality of the laminated body, which will be described later.
[0061] The total light transmittance can be measured as follows: Using a spectrophotometer (e.g., "U-4150" manufactured by Hitachi High-Technologies Corporation), the laminated glass is installed on the light path between a light source and an integrating sphere, in parallel to the normal line of the optical axis and at a position in contact with the integrating sphere so that the transmitted light is received by the integrating sphere. The total light transmittance means a visible light transmittance calculated from the spectral transmittance measured in this state. The total light transmittance can be measured using a spectrophotometer.
[0062] Regarding the chromaticity of the interlayer filler in the first embodiment of the present invention, L* in a L*a*b* color space measured with the laminated glass produced by sandwiching the interlayer filler between two clear float glass plates, followed by thermocompression bonding, is preferably 85 or more, more preferably 90 or more, and even more preferably 95 or more. In addition, both a* and b* in the L*a*b* color space measured with the produced laminated glass are preferably within the range of -10 or more and 10 or less, more preferably within the range of -5 or more and 5 or less, and even more preferably within the range of -2 or more and 2 or less. When the L* is equal to or more than the lowerlimit, the transparency is easily improved. The absolute values of a* and b* can be reduced to make the interlayer filler close to achromatic color. In order to impart a specific color and improve the design quality, however, the interlayer filler may contain a coloring agent such as a pigment or a dye so that the chromaticity is out of the predetermined range described above.Note that the chromaticity was obtained by measuring the spectral transmittance of transmitted light using a spectrophotometer (e.g., "U-4100" manufactured by Hitachi High- Technologies Corporation). The measuring conditions were as follows: a scanning speed of 300 nm / min and a slit width of 8 nm. From the resulting spectral transmittance, a*, b*, and L* in a 10° field of view with a D65 light source were determined in conformity with JIS Z 8781(2009).
[0063] The interlayer filler in the first embodiment of the present invention may be formed such that heat shielding properties are imparted to the laminated glass in which the interlayer filler is used. In this case, the solar transmittance measured with the laminated glass produced by sandwiching the interlayer filler between two clear float glass plates, followed by thermocompression bonding, is preferably 50% or less. When the solar transmittance is equal to or less than the above upper limit, excellent heat shielding properties can be obtained. In addition, the interlayer filler preferably has a solar reflectance of 15% or less, as measured with the laminated glass obtained by sandwiching the interlayer filler between two clear float glass plates, followed by thermocompression bonding. When the solar reflectance is equal to or greater than the above lower limit, the interlayer filler of the present invention can exhibit excellent heat shielding properties. More preferably, the interlayer filler has both a solar transmittance of 50% or less and a solar reflectance of 15% or more, as measured with the laminated glass.The solar transmittance is more preferably 45% or less and even more preferably 41% or less. The lower the solar transmittance, the better, preferably 0% or more. The solar reflectance is preferably 20% or more, more preferably 28% or more, and even more preferably 38% or more. The higher the solar reflectance, the better, preferably 100% or less.
[0064] The solar transmittance and solar reflectance can be determined by measuring the solar transmittance and solar reflectance of the produced laminated glass at wavelengths of 300 nm to 2500 nm in conformity with JIS R 3106: 1998 using a spectrophotometer (e.g., "U-4100" manufactured by Hitachi High-Technologies Corporation).Note that the loss factor, the total light transmittance, the chromaticity, the solar transmittance, and the solar reflectance described above can be determined by measurement on a laminated glass produced under the same production conditions as in the measurement of the haze value.It is also preferable that the laminated glass having the interlayer filler of the present invention, which will be described later, has one or both of the solar transmittance and solar reflectance.The solar transmittance and the solar reflectance described above can be easily adjusted to be within the above desired range by adding a heat shielding substance to the interlayer filler. In addition, the solar transmittance and solar reflectance of the laminated glass can be easily adjusted to be within the above desired range by providing a layer containing a heat shielding substance in the laminated glass and also be adjusted by coating a transparent substrate such as glass with a heat shielding substance.
[0065] In addition, the refractive index of the interlayer filler is preferably 1 .47 or more and 1.50 or less. When the interlayer filler has a single-layer structure, the refractive index of the interlayer filler with a single-layer structure may be within the above range. In the case of the multilayer structure, the refractive index of each resin layer should be within the above range, but the refractive index of at least resin layer (x) is preferably within the above range.
[0066] (Method of Producing Interlayer Filler)In the case of a single-layer structure, the interlayer filler in the first embodiment of the present invention may be obtained, for example, by mixing the thermoplastic resin (A), the plasticizer (B), and other components to be blended, if necessary, and then forming the resulting resin composition (X) through extrusion, press molding, or the like.In the case of a multilayer structure, the interlayer filler may be obtained, for example, by mixing each component as described above to prepare the resin composition (X) or both the resin composition (X) and resin composition (Y) for forming each layer, and then forming and laminating each layer through extrusion, press molding, or the like. In this case, when extrusion is employed, co-extrusion is preferred.
[0067] <Laminated Body>The laminated body of the present invention includes the interlayer filler of the present invention and at least one of a transparent substrate and a functional device.
[0068] (Transparent Substrate)Examples of the transparent substrate include an organic substrate and an inorganic substrate. Examples of the organic substrate include an organic resin plate and a resin film.The organic resin plate is also referred to as organic glass. Examples of the organic glass include, but not particularly limited to, various organic glass plates such as a polycarbonate plate, a (meth)acrylic plate such as a polymethyl methacrylate plate, an acrylonitrile styrene copolymer plate, an acrylonitrile butadiene styrene copolymer plate, a polyester plate such as a polyethylene terephthalate plate, a fluorine -based resin plate, a polyvinyl chloride plate, a chlorinated polyvinyl chloride plate, a polypropylene plate, a polystyrene plate, a polysulfone plate, an epoxy resin plate, a phenol resin plate, an unsaturated polyester resin plate, and a polyimide resin plate. The organic glass plate may be appropriately subjected to a surface treatment or the like.Of the above, a polycarbonate plate is preferable from the viewpoint of excellent transparency, impact resistance, and combustion resistance, and a methacrylate plate such as a polymethyl methacrylate plate is preferable from the viewpoint of high transparency and excellent weather resistance and mechanical strength, among which the polycarbonate plate is preferable.The thickness of the organic glass is not particularly limited but is preferably 0.1 mm or more, more preferably 0.3 mm or more, and preferably 5.0 mm or less, more preferably 3.0 mm or less.
[0069] Examples of the resin film include, but not particularly limited to, a (meth)acrylic resin film, a polycarbonate film, a polyester resin film such as a polyethylene terephthalate (PET) film and a polyethylene naphthalate (PEN) film, a polyolefin resin film such as a polyethylene film and a polypropylene film, a cyclic polyolefin (COP) film, a triacetylcellulose (TAC) film, a polyethersulfone (PES) resin film, and a polyimide resin film. On the surface of the resin film, a surface layer may be provided, such as a hard coat layer formed of (meth)acrylic resin or the like or a coating layer containing a heat shielding substance.The thickness of the resin film is not particularly limited but is preferably 30 pm or more, more preferably 50 pm or more, and preferably 500 pm or less, more preferably 450 pm or less.Usually, a material that has a relatively large thickness and low flexibility, which generally cannot be bent, is referred to as an organic resin plate, while a material that has a relatively small thickness and is generally bendable is referred to as a resin film; however, these are not clearly distinguished from each other.
[0070] Examples of the inorganic substrate include inorganic glass. Examples of the inorganic glass include, but not particularly limited to, various glass plates such as float plate glass, tempered glass, colored glass, polished plate glass, figured glass, meshed plate glass, wired plate glass, ultraviolet-absorbing plate glass, infrared-reflecting plate glass, infraredabsorbing plate glass, and green glass. The inorganic glass may be subjected to surface treatment or the like, and a surface layer formed of a coating layer containing a heat shielding substance or the like may be provided.The thickness of the inorganic glass is not particularly limited but is preferably 0.1 mm or more, more preferably 1.0 mm or more, and preferably 5.0 mm or less, more preferably 3.2 mm or less.
[0071] The organic substrate or the inorganic substrate may be appropriately provided, for example, with an electrode and a sensor. The electrode is composed of a conductive layer laminated on each of the above substrates.Examples of the sensor include a touch sensor. The touch sensor is a sensor that detects touch input, in which a finger, stylus, or another object approaches or contacts a substrate, the sensor being composed of a conductive layer that is laminated to the substrate. The touch sensor detects touch input with an electrical change in the conductive layer, such as capacitance, current, or voltage caused by a finger, stylus, or another object approaching to or in contact with a substrate.The conductive layer is not particularly limited, and any conventionally known electrode material having transparency can be used without particular limitation. Examples thereof include an indium tin oxide (ITO) conductive film, a tin oxide conductive film, a zinc oxide conductive film, and a polymer conductive film.
[0072] Among the above, either inorganic glass or organic glass is preferable as the transparent based material used in the laminated body. Note that the inorganic glass and the organic glass may be collectively referred to herein as a glass member.
[0073] (Functional Device (Functional Film))The functional device may be a sheet-like member having a sheet shape. Note that the functional device may also be referred to herein as a functional film. The functional device may be electrically controllable. In this case, the device includes an electrical circuit,the operation of which can be switched by the flow of current or by a change in the amount of current flowing.Specific examples of the electrically controllable functional device include an electrically controllable film and boards such as an electrically controllable flexible printed circuit board. More specific examples thereof include a film or a flexible printed circuit board having a device such as a light-modulating member, a coil, an antenna, a piezoelectric element, an LED element, a battery, sensors such as a touch sensor, switches, a memory, a processor, an integrated circuit such as a communication IC, or a display element such as an organic EL display element or a liquid crystal display element. Furthermore, the functional device may be, for example, a glass panel in which one of the above devices is mounted on a glass member, or an image display panel in which a display element is incorporated. One of these devices may be singly incorporated into a sheet or two or more in a combination may be incorporated into a sheet- like member (functional device).
[0074] The functional device is preferably a variable transmittance device, more preferably a transmittance- variable device of any one type of a polymer dispersed liquid crystal (PDLC), an electrochromic (EC), a suspended particle device (SPD), an electrophoretic device, and a guest host liquid crystal (GHLC), and still more preferably any one of PDLC, SPD, and GHLC. Although these variable transmittance devices, particularly PDLC, SPD, and GHLC, may be transparentized or otherwise deteriorate in performance due to migration of or contact with a plasticizer contained in a general interlayer film. By using a specific plasticizer (B) as the plasticizer, however, the interlayer filler of the present invention prevents migration of the plasticizer (B) and makes the performance less likely to deteriorate even upon contact with the plasticizer. The variable transmittance devices are generally used as a light-modulating member.By using the variable transmittance device, for example, when a laminated body is applied to window glass, the inflow of heat rays from the outside can be prevented in a light shielding mode with a low transmittance, whereas a sense of openness can be obtained in a light transmission mode with a higher transmittance than in the light shielding mode.In addition, the functional device is also preferably a device having a liquid crystal layer, and the device having a liquid crystal layer may be a light-modulating member as described above or a device other than the light-modulating member.
[0075] The flexible printed circuit board is generally a board on which a wiring is printed and a device is mounted on a substrate. As the board, a resin board is used. Examples of theresin board to be used include, but are not particularly limited to, a polyester resin board such as polyethylene terephthalate and polyethylene naphthalate, and a polyimide resin board.Note that the resin board in the flexible printed circuit board has flexibility, which may not be clearly distinguished from the resin film. The wiring may be formed of a metal material, such as metal paste, or a metal oxide, or a conductive material other than a metal oxide and a metal.The flexible printed circuit board may be one which is referred to as flexible hybrid electronics (FHE), which may be a combination of an electronic component such as a sensor, a battery, and an antenna with an integrated circuit such as a memory, a processor, and a communication IC. A flexible printed circuit board with near-field communication (NFC) including an antenna and an integrated circuit may also be used.
[0076] The electrically controllable film includes at least a substrate film and a device mounted on the substrate film. The device may be disposed between two substrate films. Examples of the substrate film include various resin films such as a polyester resin film including a polyethylene terephthalate and polyethylene naphthalate; an acrylic resin film; a cellulose derivative film including triacetylcellulose (TAG); a polyether sulfone (PES) resin film; and a polyimide resin film.
[0077] In the electrically controllable film, an electrode layer may also be provided on the surface of the substrate film on the device side. Any conventionally known electrode material can be used as the electrode layer without particular limitations, but a transparent electrode layer is preferred. Specific examples of the electrode material include an indium tin oxide (ITO) conductive film, a tin oxide conductive film, a zinc oxide conductive film, and a polymer conductive film.
[0078] The electrically controllable film is more preferably a light-modulating film (variable transmittance device) in which the device is a light-modulating member. The lightmodulating film includes two substrate films and a light-modulating member (lightmodulating layer) disposed between the two substrate films. Examples of the lightmodulating film include a PDLC film, an electrochromic film, an SPD film, an electrophoretic film device, and a GHLC film, in which the light-modulating member is PDLC, electrochromic, SPD, electrophoretic device, and GHLC, respectively. Among these, a PDLC film, an SPD film, and a GHLC film are preferable.
[0079] In the polymer-dispersed liquid crystal (PDLC) film, the light-modulating layer is formed of a polymer-dispersed liquid crystal. Examples of the polymer-dispersed liquid crystal include a so-called network-type liquid crystal in which a network structure is formed by a polymer in a liquid crystal layer (light-modulating layer).In the SPD film, the light-modulating layer is composed of a layer containing a resin matrix and a light-modulating suspension dispersed in the resin matrix. In the case of an electrochromic film, the light-modulating layer may contain an electrochromic material. The electrochromic material is not limited as long as it is a compound with electrochromic properties. The compound may be an inorganic compound, an organic compound, or a mixed valence complex.An electrophoretic film device has, for example, an electrophoretic part between two substrates each having an electrode layer. The electrophoretic part includes, for example, electrophoretic particles and a dispersant for dispersing the electrophoretic particles.In the guest host liquid crystal (GHLC) film, the light-modulating layer is formed of guest-host (G-H) materials doped with a dye.
[0080] The functional device may not be electrically controlled. Specific examples thereof include any one of a heat shielding film (heat absorption and reflection), a color film, a polarizing plate, and an optical compensation plate, or a composite thereof.
[0081] The thickness of each functional device in the laminated body is not particularly limited but is preferably 100 pm or more, more preferably 200 pm or more, and even more preferably 300 pm or more, and is also preferably 1500 pm or less, more preferably 1000 pm or less, even more preferably 800 pm or less, and still more preferably 500 pm or less. Note that the thickness of the functional device sometimes varies depending on the position, and is, when the thickness varies, the maximum thickness.
[0082] The laminated body is not particularly limited but preferably has at least the interlayer filler of the present invention described above and a functional device. In the laminated body, the interlayer filler of the present invention is preferably disposed between the functional device and another member to bond the functional device with another member. Here, another member may be a transparent substrate such as a glass member, a functional device, or a member other than the transparent substrate and the functional device.The interlayer filler of the present invention may be disposed at a position in contact with the functional device. Even when the interlayer filler of the present invention isdisposed at a position in contact with the functional device, the migration of the plasticizer contained in the interlayer filler into the functional device is suppressed, thus preventing contamination of the functional device and deterioration of the function of the functional device.
[0083] In the laminated body, two or more interlayer fillers are preferably provided. The two or more interlayer fillers are preferably disposed, for example, to sandwich the functional device from both surfaces. With such a configuration, the functional device is covered with the interlayer filler on at least both surfaces. Therefore, the functional device can be incorporated into the laminated body in a state of being properly held between the interlayer fillers. In addition, the functional device becomes easier to properly bond to other member with each interlayer fillers provided on both sides thereof.
[0084] The laminated body is also preferably a laminated glass including a pair of transparent substrates and an interlayer filler, wherein at least the interlayer filler is disposed between the pair of transparent substrates, both of which are glass members, and more preferably further contains a functional film between the pair of transparent substrates. For example, as one mode of a laminated glass, using a light-modulating film (variable transmittance device) as a functional device, it may be a light-modulating laminated glass in which the interlayer filler and the light-modulating film are disposed between a pair of glass members.
[0085] Next, preferred modes of the laminated body will be described in more detail with reference to the drawings.The laminated body 10 is not particularly limited but preferably has a pair of transparent substrates 21 and 22, an interlayer filler 11, and a functional device (functional film) 12 that are disposed between the transparent substrates 21 and 22, as illustrated in Figs.1 to 7. Each of the transparent substrates 21 and 22 is preferably a glass member. With the transparent substrates 21 and 22 being glass members, the laminated body 10 is a laminated glass in which two glass members are adhered by an interlayer filler 11. That is, the laminated body illustrated in Figs. 1 to 7 is preferably a laminated glass.
[0086] In the laminated body 10 such as a laminated glass, one functional device (functional film) 12 may be provided as illustrated in Figs. 1, 2, 6, and 7, or two or more functional devices (functional films) 12 may be provided as illustrated in Figs. 3 to 5. When a plurality of functional devices 12 are provided, the number thereof is not particularly limited but, forexample, 10 or less, preferably 5 or less, and more preferably 3 or less from the viewpoint of workability and from the viewpoint of properly holding the functional devices 12 by the interlayer filler 11.
[0087] When two or more functional devices 12 are provided, as illustrated in Fig. 3, the plurality of functional devices 12 may be provided along the thickness direction. When the plurality of functional devices 12 are provided along the thickness direction, the number of functional devices 12 arranged in the thickness direction is not particularly limited but is 3 or less from the viewpoint of preventing the thickness of the laminated body 10 from becoming too large. In addition, the two or more functional devices 12 may be provided along the plane direction as illustrated in Fig. 4. Although the plurality of functional devices 12 illustrated in Figs. 3 and 4 are in contact with each other, each functional device does not need to be in contact with each other.
[0088] Although the interlayer filler 11 may be disposed between the functional device 12 and each of the transparent substrates 21 and 22, the number of interlayer fillers provided between the functional device 12 and each of the transparent substrates 21 and 22 is not limited but may be, for example, one. That is, as illustrated in Figs. 1, 3, 4, and 5, an interlayer filler HA may be provided between the functional device 12 and the transparent substrate 21 , and an interlayer filler 1 IB may be provided between the functional device 12 and the transparent substrate 22.The number of interlayer fillers provided between the functional device 12 and each of the transparent substrates 21 and 22 may be two or more; that is, as illustrated in Fig. 2, interlayer fillers 11 Al and 11 A2 may be provided between the functional device 12 and the transparent substrate 21, and interlayer fillers 11B1 and 11B2 may be provided between the functional device 12 and the transparent substrate 22.
[0089] When a plurality of functional devices 12 are provided, the plurality of functional devices 12 may be disposed at positions between the same interlayer fillers 11 A and 1 IB as illustrated in Figs. 3 and 4. The plurality of functional devices 12 may also be disposed at positions between different interlayer fillers (i.e., positions between the interlayer fillers 11 A and 11C and positions between the interlayer fillers 11C and 1 IB) as illustrated in Fig. 5. Accordingly, the pair of functional devices 12 and 12 may be provided with the interlayer filler 11C therebetween and adhered to each other by the interlayer filler 11C.
[0090] The functional device 12 may be smaller than the interlayer filler 11 and transparent substrates 21 and 22. In this case, the functional device 12 is preferably covered with the interlayer filler 11 not only on both surfaces thereof but also on the end surface (peripheral edges) and may be embedded in the interlayer filler 11.Specifically, as illustrated in Fig. 1, the functional device 12 is smaller than the interlayer fillers 11 A and 1 IB and the transparent substrates 21 and 22, which are disposed on both surfaces of the functional device, and a peripheral edge 12S of the functional device 12 is preferably disposed further inside than a peripheral edge 1 IS of the interlayer fillers 11 A and 1 IB when the laminated body 10 is viewed in the thickness direction. Similarly, the functional device 12 is preferably disposed further inside than peripheral edges 21 S and 22S of the transparent substrates 21 and 22. Here, the peripheral edge 12S of the functional device 12 may be disposed further inside than the peripheral edge 1 IS of the interlayer fillers 11 A and 1 IB over the entire circumference. Similarly, the peripheral edge 12S of the functional device 12 may be disposed further inside than the peripheral edges 21 S and 22S of the transparent substrates 21 and 22 over the entire circumference.
[0091] The distance L between the peripheral edge 12S of the functional device 12 and the peripheral edge 1 IS of the interlayer filler may be 5 mm or more. The distance T is preferably 10 mm or more, preferably 500 mm or less, more preferably 200 mm or less, and even more preferably 100 mm or less. When the distance L is in the above range, the functional device 12 can be properly embedded in the interlayer filler. Note that the distance L means the shortest distance between the peripheral edge 12S of the functional device 12 and the peripheral edge 11 S of the interlayer fillers 11 A and 1 IB (interlayer fillers 11 Al and 11B1 in Fig. 2) on both surfaces of the functional device 12.
[0092] As illustrated in Figs. 3 and 4, when two or more functional devices 12 are provided between the same interlayer fillers 11 A and 1 IB, each functional device 12 may be provided further inside than the peripheral edge 11 S of the interlayer fillers 11 A and 1 IB on both sides, and the distance F of each functional device 12 may be as described above.Similarly, as illustrated in Fig. 5, when two or more functional devices 12 are provided between different interlayer fillers, each functional device 12 may be provided further inside than the peripheral edge 1 IS of the interlayer fillers 11 A and 11C (or the peripheral edge 1 IS of the interlayer fillers 11C and 1 IB) on both sides, and the distance F of each functional device 12 may be as described above.However, the functional device 12 does not necessarily need to be smaller than the interlayer filler 11 and the transparent substrates 21 and 22, for example, when the end surface is subjected to a sealing treatment, and may have the same size as these when viewed from the thickness direction.
[0093] An electrode wiring (not shown) may be connected to the functional device 12. The electrode wiring is a lead electrode that electrically connects the outside of the laminated body to the functional device 12. The electrode wiring may be disposed between the interlayer fillers, as in the functional device 12. The functional device 12 may be supplied with power from the outside via an electrode wiring 15 or may be supplied with power by means other than the electrode wiring without the electrode wiring. For example, if the functional device is provided with an antenna, power may be supplied via the antenna.
[0094] As illustrated in Fig. 6, when the peripheral edge 12S of the functional device 12 is disposed on the inner peripheral side than the peripheral edges 21 S and 22S of the transparent substrates 21 and 22, the laminated body 10 may include a sealant 25 disposed on the outer peripheral side of the functional device 12. When the peripheral edge 12S of the functional device 12 is disposed on the inner peripheral side, a gap is likely to be generated on the outer peripheral side of the functional device 12 due to the arrangement on the inner peripheral side, but the gap can be easily filled by disposing the sealant 25. Therefore, the contamination from the end portion of the functional device 12 can be further reduced.
[0095] The sealant 25 disposed on the outer peripheral side of the functional device 12 is preferably disposed on the outer peripheral side over the entire circumference of the functional device 12. Accordingly, the sealant 25 is preferably formed in a frame shape when viewed in a plane in the thickness direction.Although the sealant 25 is disposed between the two interlayer fillers 11 A and 1 IB together with the functional device 12 in the configuration of Fig. 6, the present invention is not limited to such a configuration, and the sealant 25 may be disposed further on the outer peripheral side of the laminated body constituted of the interlayer fillers 11 A and 12B and the functional device 12 as shown in Fig. 7. Of course, a sealant 25 may also be provided even when a plurality of functional devices 12 are provided, and in this case, the plurality of sealants 25 may be provided corresponding to the number of functional devices 12.
[0096] In addition, when a sealant is provided, a shielding layer may be provided to hide the sealant. A so-called black ceramic may be used as the shielding layer. The black ceramic is a black shielding portion, preferably made of, for example, ceramic colored in black. The shielding portion may be provided, for example, on either one surface of the transparent substrates 21 and 22, such as a glass member, in a frame shape along the peripheral edge.
[0097] Although the description has been made on the premise that all of the interlayer fillers 11 in the laminated body described above are the interlayer fillers of the present invention, at least one interlayer filler 11 may be the interlayer filler of the present invention described above. For example, the interlayer filler 11 that is disposed at a position in contact with the functional device 12 may be the interlayer filler of the present invention. In addition, the interlayer filler 11 that is disposed at a position in contact with the functional device 12 used may be an interlayer filler in which the resin layer (x) described above is disposed on the surface in contact with the functional device 12.
[0098] The sealant 25 may be formed of any known material, preferably the resin composition (X) described above. Therefore, the sealant 25 may also be the interlayer filler of the present invention described above. The sealant 25 is formed of the resin composition (X), thereby being capable of preventing contamination of the functional device 12 by the sealant 25.
[0099] In each of the laminated bodies 10, at least one of the functional devices 12 is preferably a variable transmittance device such as a light-modulating film. In case of the plurality of functional devices 12, it is preferable that at least one is a variable transmittance device and the rest is a functional device other than the variable transmittance device. The other functional device may be one which control the variable transmittance devices, such as sensors and switches.In general, the variable transmittance device may be larger than the other functional device in the case of being used in combination with the other functional device, and the variable transmittance device may have a larger occupied area in the laminated body 10 than the other functional device when viewed from the thickness direction.Of course, each of the plurality of functional devices 12 may be variable transmittance device. For example, as illustrated in Fig. 5, when the functional device 12 is disposed at a position between different interlayer fillers (i.e., a position between the interlayer fillers 11 A and 11C and a position between the interlayer fillers 11C and 1 IB), each functional device 12 is preferably a variable transmittance device.
[0100] In the laminated body 10, the thickness of the laminated structure except for the transparent substrates 21 and 22 may be thinner in the end portion than in the central portion. By making the end portion thinner than the central portion, the moisture permeability of the laminated body 10 to the functional device 12 can be reduced. In this case, the thickness of the laminated structure except for the transparent substrates 21 and 22 is preferably thinner in the end portion than in the central portion by 100 pm or more, and more preferably thinner by 200 pm or more and 300 pm or less.
[0101] (Method of Producing Laminated Body)The laminated body of the present invention can be produced, for example, by preparing an interlayer filler and compression-bonding each member via the prepared interlayer filler. For example, the laminated body can be produced by stacking a transparent substrate, an interlayer filler, a functional device, an interlayer filler, and a transparent substrate in this order, followed by compression bonding.In addition, when the laminated body includes a pair of transparent substrates, and an interlayer filler and a functional device that are disposed between the pair of transparent substrates, the laminated body may be produced by first integrating members other than the transparent substrates in advance to obtain a laminated intermediate, and then subjecting the two transparent substrates to compression bonding via the laminated intermediate. In this case, the laminated intermediate can be produced by subjecting the members forming the laminated body excluding the transparent substrates to compression bonding, for example, by stacking the interlayer filler, the functional device, and the interlayer filler in this order, followed by compression bonding.
[0102] <Applications>The interlayer filler and laminated body such as a laminated glass of the present invention can be used in various fields, and specifically, can be used for window glass of various vehicles such as a wheeled vehicle including an automobile and a train, a ship and an airplane, various buildings such as a multi-floor building, a condominium, a detached house, a hall, and a gymnasium, a machine tool for cutting, polishing, and the like, and a construction machine such as an excavator and a crane. The interlayer filler and laminated body can also be used for interior partitions of buildings.
[0103] The laminated glass of the present invention can be used in a wheeled vehicle with window glass (glass member) continuously integrated from a roof to a windshield. In this case, as illustrated in Fig. 8, the laminated glass (laminated body) of one embodiment of the present invention can be used for window glass 30 continuously integrated from a roof 31 to a windshield 32 of a wheeled vehicle 100. In this case, it is preferable that the roof 31 of the window glass 30 is made to have variable transmittance, and the windshield 32 is made to be transparent. For example, by providing a light-modulating film on the roof 31 of the glass member 30 and no light-modulating films on the windshield 32 of the glass member 30, the roof 31 of the glass member 30 can be made to have variable transmittance and the windshield 32 can be made to be transparent. With the variable transmittance of the roof 31 , the inflow of heat rays from the outside can be prevented in a light shielding mode with a low transmittance, and a sense of openness can be obtained in a light transmission mode with higher transmittance than in the light shielding mode.The windshield 32 may also have a wedge-shaped cross section by varying the total thickness of the interlayer filler between the two transparent substrates. For example, when the windshield 32 is used for a head-up display (HUD) application, an HUD image is displayed in a portion with a wedge-shaped cross section, thereby making it easy to reduce a reflected double image generated when the HUD image is displayed.
[0104] The interlayer filler of the present invention can also be used in an image display device. The image display device of the present invention has the interlayer filler of the present invention. The image display device may further have a transparent substrate and an image display panel in addition to the interlayer filler of the present invention.
[0105] Next, an example of an image display device of the present invention will be described with reference to Fig. 9. An image display device 40 illustrated in Fig. 9 is applied to an image display device with a touch panel. The image display device with a touch panel is preferably an in-vehicle image display device. The image display device 40 includes an image display panel 41, a transparent substrate 21, and a touch panel 42 disposed between the image display panel 41 and the transparent substrate 21, and the interlayer fillers 11 A and 1 IB are disposed between the touch panel 42 and the image display panel 41 and between the transparent substrate 21 and the touch panel 42, respectively.
[0106] The transparent substrate 21 is preferably either an organic glass (organic glass plate) or an inorganic glass (inorganic glass plate), more preferably an inorganic glass.Examples of the image display panel 41 include an organic EL display element and a liquid crystal display element, among which the liquid crystal display element is preferable. The image display panel 41 is preferably provided with a polarizing plate (polarizing film) on the outermost surface on the surface side. Note that the outermost surface on the surface side is referred to as the outermost surface on the surface protective panel side, and the opposite side is also referred to as the back surface side.The polarizing plate (polarizing film) generally has a configuration in which a protective film is provided on both surfaces of a polarizer such as a polyvinyl alcohol resin film. The protective film is composed of a resin film described above and is preferably either a PET film, a COP film, or a TAC film. Therefore, an organic substrate is generally disposed on the outermost surface on the surface side of the image display panel 41.In addition, even when a polarizing plate (polarizing film) is not provided on the surface of the surface side of the image display panel 41, a protective film may be provided on the outermost surface on the surface side, and therefore, even in such a case, the outermost surface on the surface side of the image display panel 41 will be made of an organic substrate.
[0107] The touch panel 42 may be constituted of any of inorganic glass, an organic resin plate, or a resin film to which a touch sensor is attached, preferably inorganic glass or a resin film to which a touch sensor is attached.In the touch panel 42, regarding the inorganic glass, the organic resin plate, or the resin film, two or more selected from these may be laminated to form a multilayer structure. In this case, the touch sensor may be attached to any of inorganic glass, an organic resin plate, or a resin film in the touch panel 42.In addition, a protective film made of a resin film may be disposed on either the outermost surface on the surface side or the outermost surface on the back surface side of the touch panel 42. Therefore, the surface of the touch panel 42 that is bonded to the interlayer fillers 11A and 1 IB is any one of inorganic glass, organic glass, and resin film.
[0108] The interlayer fillers 11A and 1 IB are adhered to the image display panel 41 and the touch panel 42 and to the touch panel 42 and the transparent substrate 21, respectively, to join them. Either one of the interlayer fillers 11 A and 1 IB may be the interlayer filler of the present invention described above, but both are preferably the interlayer fillers of the present invention. In addition, the interlayer filler 11 A is the interlayer filler of the present invention, and the interlayer filler 1 IB may be an optical transparent resin (OCR) or an optical transparent adhesive (OCA). Also in the image display device 40, the interlayer filler11 A or 1 IB which is the interlayer filler of the present invention, can prevent migration from the interlayer filler 11 to the touch panel 42 or the image display panel 41.
[0109] The image display device is preferably an in-vehicle display device, and in particular, the in-vehicle display device is preferably provided in the front section in front of the driver's seat. In particular, the in-vehicle display device is preferably disposed on the lower side of the windshield of the vehicle, in front of either the driver's seat or the passenger’s seat. In other words, the image display device is preferably disposed at a position where a conventional instrument panel would be disposed.
[0110] «Second Embodiment»Next, the second aspect of the present invention will be described using the second embodiment.<Interlayer Filler>The interlayer filler in the second embodiment of the present invention includes a thermoplastic resin (A) and a plasticizer (B) having a ratio of the number of oxygen atoms to the number of carbon atoms (the number of oxygen atoms / the number of carbon atoms) of 0.36 or more, wherein tensile yield stress is 40 MPa or less as measured at a tensile speed of 500 mm / min at -20°C.[01 H][Tensile Yield Stress]The interlayer filler in the second embodiment of the present invention has a tensile yield stress of 40 MPa or less, measured at a tensile speed of 500 mm / min at -20°C. If the tensile yield stress exceeds 40 MPa, the impact resistance of the interlayer filler at low temperatures deteriorates.From the viewpoint of improving the impact resistance at low temperatures, the tensile yield stress of the interlayer filler is preferably 35 MPa or less, more preferably 32 MPa or less, and even more preferably 25 MPa or less. From the viewpoint of ensuring mechanical strength at low temperatures, the tensile yield stress of the interlayer filler is preferably 1 MPa or more, more preferably 10 MPa or more, and even more preferably 15 MPa or more.The tensile yield stress of the interlayer filler can be adjusted to a desired range by controlling the type and amount of the plasticizer contained in the interlayer filler.[0H2]The reason why the impact resistance at low temperatures is improved by adjusting the tensile yield stress of the interlayer filler within an above range is presumed to be as follows.The yield stress is related to the brittle-to-ductile transition of the fracture mode. If the yield stress is smaller than the brittle fracture stress, ductile fracture occurs by yielding and stretching when an impact load is applied to the interlayer filler. On the other hand, if the yield stress is larger than the brittle fracture stress, brittle fracture occurs before yielding when an impact load is applied to the interlayer filler. From the viewpoint of improving the impact resistance, the fracture mode of the interlayer filler is considered to be a ductile fracture in which the impact energy is absorbed by yielding and stretching. The design of the interlayer filler with a low yield stress at low temperatures is expected to provide an interlayer filler that is less prone to brittle fracture and has excellent impact resistance. [0H3]The tensile yield stress of the interlayer filler in the second embodiment of the present invention is determined by the tensile stress-strain curve obtained in a tensile test performed under the condition of a tensile speed of 500 mm / min at -20°C. The tensile yield stress is the tensile stress at the first point on the tensile stress-strain curve at which an increase in elongation is observed without an increase in load, and is the tensile stress at the point at which plastic deformation begins (yield point). If the tensile stress-strain curve has a maximum point at the point at which plastic deformation begins, this maximum point (upper yield point) is taken as the yield point. The shape of the test piece used for the tensile test is a dumbbell No. 4 shape described in JIS K 6251 :2004 and thickness thereof may be 0.01 to 1 mm.
[0114] [Thermoplastic Resin (A)]The interlayer filler in the second embodiment of the present invention contains a thermoplastic resin (A), as in the first embodiment. From the same viewpoint as in the first embodiment, the thermoplastic resin (A) preferably has a glass transition temperature of 60°C or higher, and the glass transition temperature of thermoplastic resin (A) is preferably 62°C or higher and more preferably 65°C or higher. From the same viewpoint as in the first embodiment, the glass transition temperature of the thermoplastic resin (A) may be, for example, 120°C or lower, but is preferably 95 °C or lower and more preferably 75 °C or lower. [0H5]Examples of the thermoplastic resin (A) in the second embodiment include a (meth)acrylic resin, a polyvinyl acetal resin, a polyvinyl alcohol-based resin (PVA), an ethylene vinyl acetate copolymer (EVA), a polyolefin-based thermoplastic elastomer (POE), a polyurethane-based thermoplastic elastomer (TPU), a polyolefin-based resin such as a polyethylene resin and a polypropylene resin, a cyclic olefin-based resin (COP) such as acyclic olefin-based copolymer (COC), an ionomer-based resin, a saponified ethylene-vinyl acetate copolymer (EVOH), an ethylene-methacrylic acid copolymer resin, an isobutylene resin, a styrene-isoprene copolymer resin, and a styrene-butadiene copolymer resin. These thermoplastic resins may be used alone or in combination with two or more thereof. Among these thermoplastic resins, polyvinyl acetal resin is preferred from the viewpoint of impact resistance and transparency.Examples of the resin having a Tg of 60°C or higher in the second embodiment include the thermoplastic resins illustrated in the first embodiment. In the case of using a polyvinyl acetal resin as the thermoplastic resin (A), the details of the polyvinyl acetal resin are as described in the first embodiment.
[0116] [Plasticizer (B)]The plasticizer (B) used in the interlayer filler in the second embodiment of the present invention contains an oxygen atom and a carbon atom and has a ratio of the number of oxygen atoms to the number of carbon atoms (hereinafter, sometimes referred to as "the number of oxygen atoms / the number of carbon atoms") of 0.36 or more, as in the first embodiment.The detailed description of the plasticizer (B) used in the interlayer filler in the second embodiment of the present invention is as described for the plasticizer (B) used in the interlayer filler in the first embodiment and is omitted, except for the content thereof, zero shear viscosity, and temperature dependence index described below.
[0117] The zero shear viscosity at both 90°C and 120°C of the plasticizer (B) used in the interlayer filler in the second embodiment is preferably 5.0 mPa-s or more and 70.0 mPa-s or less. When the zero shear viscosity at 90°C and 120°C of the plasticizer (B) is 5.0 mPa-s or more, the plasticizer is less likely to migrate to the functional device. On the other hand, when the zero shear viscosity at 90°C and 120°C of the plasticizer (B) is 70.0 mPa-s or less, the processability of the interlayer filler is improved. From these viewpoints, the zero shear viscosity at both 90 °C and 120°C of the plasticizer (B) used in the interlayer filler according to the second embodiment is preferably 6.0 mPa-s or more and 40.0 mPa-s or less. From the above viewpoints, the zero shear viscosity at 90°C of the plasticizer (B) used in the interlayer filler according to the second embodiment of the present invention is more preferably 10.0 mPa-s or more and 38.0 mPa-s or less, and even more preferably 15.0 mPa-s or more and 35.0 mPa-s or less. From the above viewpoints, on the other hand, the zero shear viscosity at 120°C of the plasticizer (B) used in the interlayer filler according to the second embodimentis more preferably 7.0 mPa-s or more and 30.0 mPa-s or less, and even more preferably 8.0 mPa-s or more and 20.0 mPa-s or less. The zero shear viscosity of the plasticizer (B) at 90°C and 120°C can be measured by a method described in Examples below.
[0118] In the second embodiment, the temperature dependence index of the plasticizer (B) obtained from formula (3) below is preferably -5.5 or more. If the temperature dependence index of the plasticizer (B) is -5.5 or more, the kneadability with the thermoplastic resin becomes good. From such a viewpoint, the temperature dependence index of the plasticizer (B) obtained from formula (3) below is preferably -4.5 or more, more preferably -3.5 or more, and even more preferably -3.0 or more. The upper limit of the range of the temperature dependence index of plasticizer (B) is not particularly limited but it is usually 0 or less.Temperature dependence index of plasticizer = (p 120 - p30) / 90 (3) where iq 120 is a zero shear viscosity [mPa-s] of the plasticizer at 120°C; p30 is a zero shear viscosity [mPa-s] of the plasticizer at 30°C.[0H9]The interlayer filler according to the second embodiment preferably includes a resin composition (X) containing the thermoplastic resin (A) and the plasticizer (B) described above, as in the first embodiment, and the content (content (X)) of the plasticizer (B) based on 100 parts by mass of the thermoplastic resin (A) in the resin composition (X) is preferably 30 parts by mass or more, more preferably 40 parts by mass or more, even more preferably 45 parts by mass or more, still more preferably 50 parts by mass or more, and further preferably 60 parts by mass or more.As described above, the interlayer filler has improved impact resistance at low temperatures by using a relatively large amount of the plasticizer even when a plasticizer having a ratio of the number of oxygen atoms to the number of carbon atoms (the number of oxygen atoms / number of carbon atoms) of 0.36 or more is used.That is, by blending a relatively large amount of the plasticizer (B) having a ratio of the number of oxygen atoms to the number of carbon atoms (the number of oxygen atoms / the number of carbon atoms) of 0.36 or more, it becomes easier to adjust the tensile yield stress at -20°C to the desired range, and to obtain an interlayer filler suppressing migration of the plasticizer into the functional device, and having excellent impact resistance at low temperatures.In addition, even when the thermoplastic resin (A) with a high glass transition temperature is used, the interlayer filler can be made to be sufficiently flexible by making the content (X) of plasticizer (B) equal to or greater than a certain amount. In the secondembodiment, the content (X) of the plasticizer (B) is preferably 150 parts by mass or less, more preferably 100 parts by mass or less, and even more preferably 90 parts by mass or less. The content (X) of the plasticizer can be kept below a certain level to suppress migration of the plasticizer into the functional device, thus preventing deterioration of the function of the functional device. In addition, even if interlayer fillers are stacked during storage, suppression of the interlayer fillers coalescing with each other is achieved, resulting in good handling properties.
[0120] The resin composition (X) in the second embodiment may contain a component other than the thermoplastic resin (A) and the plasticizer (B), as with the first embodiment. For example, the resin composition (X) may contain a resin component other than the thermoplastic resin (A) or an additive. However, the resin composition (X) may be mainly composed of the thermoplastic resin (A) and the plasticizer (B), the total content of which is as described in the first embodiment.
[0121] (Structure of Interlayer Filler)The interlayer filler in the second embodiment of the present invention is preferably in the shape of a film. The interlayer filler in the second embodiment of the present invention may be a film with a single-layer structure or a multilayer structure. The interlayer filler with a single-layer structure should be formed of a single resin layer (resin layer (x)) formed of the resin composition (X) described above.
[0122] When the interlayer filler is a film having a multilayer structure, each layer is preferably a resin layer (x) formed of the resin composition (X) described above, as with the first embodiment. As long as at least one layer is the resin layer (x) formed of the resin composition (X) described above, however, a part of the layers in the multilayer structure may be formed of the resin composition (X) described above while another part of the layers may be formed of a resin layer ("resin layer (y)") other than the resin layer (x).The configuration of each layer when the interlayer filler has a multilayer structure, the thickness of the interlayer filler of the present invention and the thickness of the resin layer (x) disposed on the surface are also as described in the first embodiment, and the description thereof will be omitted.
[0123] (Additive)The interlayer filler may contain an additive other than the thermoplastic resin (A) and plasticizer (B) as described above. Examples of the additive include a heat shielding substance. That is, the interlayer filler of the present invention may contain a heat shielding substance as an additive. Examples of the heat shielding substance include at least one of the component S and a heat shielding particle described above.As the heat shielding substance, the component S may be used alone, the heat shielding particle may be used alone, or both of them may be used.The details of the heat shielding substance such as the component S and the heat shielding particles, and the configuration of the interlayer filler when the heat shielding substance is used including the content of the heat shielding substance and the others are as described in the first embodiment, and the description thereof will be omitted.
[0124] The interlayer filler in the second embodiment may contain an additive other than the heat shielding substance, and specific examples thereof and the configuration of the interlayer filler when an additive other than the heat shielding substance is used are as described in the first embodiment. The additives other than the heat shielding substance may be used alone or in combination with two or more.
[0125] (Sound Insulation Performance)When the interlayer filler in the second embodiment has a multilayer structure with at least three resin layers, sound insulation performance may be imparted by a laminated structure in which the central resin layer is a core layer and the resin layer on each side thereof is a skin layer. In this case, the configuration of the interlayer filler such as the configuration of each resin layer, the loss factor, and the others are as described in the first embodiment.
[0126] (Optical Properties of Interlayer Filler)Optical properties of the interlayer filler according to the second embodiment are the same as those of the interlayer filler according to the first embodiment. Specifically, the total light transmittance and chromaticity of the laminated glass produced by sandwiching the interlayer filler according to the second embodiment between two clear float glass plates, followed by thermocompression bonding and the refractive index of the interlayer filler are the same as the total light transmittance and chromaticity of the interlayer filler and the refractive index of the interlayer filler in the first embodiment, and the description thereof will be omitted.Furthermore, the interlayer filler in the second embodiment may be provided with heat shielding properties if necessary, and the solar transmittance and solar reflectance measured with a laminated glass produced by sandwiching the interlayer filler in this case between two clear float glass plates, followed by thermocompression bonding, are also the same as those in the first embodiment, and the description thereof will be omitted.
[0127] The method of producing an interlayer filler in the second embodiment of the present invention is the same as that in the first embodiment, and the description thereof will be omitted.
[0128] <Laminated Body>The laminated body according to the second embodiment has the interlayer filler of the present invention and at least one of the transparent substrate and the functional device, and the detailed description thereof is the same as described in the first embodiment including the description made using Figs. 1 to 7, and the description thereof will be omitted. The method of producing the laminated body is also the same as that described in the first embodiment.
[0129] <Applications>The interlayer filler, the laminated body, and the laminated glass according to the second embodiment can be used in various fields as in the first embodiment, and the details of modes in each application in which the interlayer filler, the laminated body, and the laminated glass are used, including the usage modes described using Figs. 8 and 9, are as described in the first embodiment, and the description thereof will be omitted. As described above, also in the second embodiment, the laminated glass can be used in a wheeled vehicle having window glass (glass member) continuously integrated from the roof to the windshield, and the interlayer filler can be used for an image display device, among which the interlayer filler is preferably used for an in-vehicle display device.
[0130] «Third Embodiment»Next, the third aspect of the present invention will be described using the third embodiment. clnterlayer Filler>The interlayer filler in the third embodiment of the present invention includes a thermoplastic resin and a plasticizer, wherein a content of the plasticizer is 30 parts by mass or more based on 100 parts by mass of the thermoplastic resin, the plasticizer has a zero shearviscosity of 5.0 mPa-s or more and 70.0 mPa-s or less in the range of 0°C or higher and 120°C or lower, and a temperature dependence index of the plasticizer obtained from formula (3) below is -5.5 or more:Temperature dependence index of plasticizer = (p 120 - p30) / 90 (3) where pl20 is a zero shear viscosity (mPa-s) of the plasticizer at 120°C; p30 is a zero shear viscosity (mPa-s) of the plasticizer at 30°C.With the above-described configuration, the third embodiment of the present invention can suppress migration of the plasticizer into a functional film such as a light-modulating film and improve the kneadability of the interlayer filler.
[0131] [Thermoplastic Resin (A)]The thermoplastic resin (A) contained in the interlayer filler in the third embodiment of the present invention also preferably has a glass transition temperature of 60°C or higher, more preferably 62°C or higher, and even more preferably 65°C or higher. The glass transition temperature of the thermoplastic resin (A) may be, for example, 120°C or lower, but is preferably 95°C or lower and more preferably 75°C or lower, as in each of the above embodiments.The specific type of thermoplastic resins is not particularly limited but as illustrated in the second embodiment. As the thermoplastic resins, the thermoplastic resins illustrated in the second embodiment may be used alone or in combination with two or more thereof. Among these thermoplastic resins, a thermoplastic resin having a Tg of 60°C or higher is preferred from the viewpoint of impact absorption, transparency, and the like.The resin having a Tg of 60°C or higher is not particularly limited but is as illustrated in the first embodiment, among which a polyvinyl acetal resin is preferable.When a polyvinyl acetal resin is used as the thermoplastic resin (A), the polyvinyl acetal resin is as described in the first embodiment.
[0132] (Plasticizer (B))The zero shear viscosity at both 90°C and 120°C of the plasticizer (B) used in the interlayer filler in the third embodiment of the present invention is 5.0 mPa-s or more and 70.0 mPa-s or less. When the zero shear viscosity at 90°C and 120°C of the plasticizer (B) is less than 5.0 mPa-s, the plasticizer may be more likely to migrate to the functional device. On the other hand, when the zero shear viscosity at 90°C and 120°C of the plasticizer (B) is more than 70.0 mPa-s, the kneadability of the interlayer filler may deteriorate. From such a viewpoint, the zero shear viscosity at both 90°C and 120°C of the plasticizer (B) used in theinterlayer filler in the third embodiment of the present invention is preferably 7.0 mPa-s or more and 40.0 mPa-s or less. From the above viewpoint, the zero shear viscosity at 90°C of the plasticizer (B) used in the interlayer filler in the third embodiment of the present invention is more preferably 10.0 mPa-s or more and 38.0 mPa-s or less, even more preferably 20.0 mPa-s or more and 36.0 mPa-s or less, and still more preferably 30.0 mPa-s or more and 35.0 mPa-s or less. From the above viewpoint, on the other hand, the zero shear viscosity at 120°C of the plasticizer (B) used in the interlayer filler in the third embodiment of the present invention is more preferably 10.0 mPa-s or more and 30.0 mPa-s or less, even more preferably 14.0 mPa-s or more and 25.0 mPa-s or less, and still more preferably 16.0 mPa-s or more and 20.0 mPa-s or less. The zero shear viscosity of the plasticizer (B) at 90°C and 120°C can be measured by a method described in Examples below.
[0133] In the third embodiment of the present invention, the temperature dependence index of the plasticizer (B) obtained from formula (3) below is -5.5 or more. If the temperature dependence index of the plasticizer (B) is less than -5.5, kneading with the thermoplastic resin may become difficult. From such a viewpoint, the temperature dependence index of the plasticizer (B) obtained from formula (3) below is preferably -4.5 or more, more preferably - 3.5 or more, and even more preferably -3.0 or more. The upper limit of the range of the temperature dependence index of plasticizer (B) is not particularly limited but it is usually 0 or less.Temperature dependence index of plasticizer = (p 120 - p30) / 90 (3) where p 120 is a zero shear viscosity (mPa-s) of the plasticizer at 120°C; p30 is a zero shear viscosity (mPa-s) of the plasticizer at 30°C.
[0134] Examples of the plasticizer (B) in the third embodiment include a polyhydric alcohol compound such as glycol, an ester compound of glycol and a monobasic organic acid or a polybasic organic acid, and an ether compound of a monohydric or polyhydric alcohol and a poly oxy alkylene.The plasticizer (B) is preferably a compound which has a polyoxyalkylene structure, more preferably a polyoxyalkylene-based compound which has a polyoxyalkylene structure. The use of a polyoxyalkylene-based compound makes it easier to adjust the zero shear viscosity and the above temperature dependence index within a predetermined range.Examples of the polyoxyalkylene include polyoxyethylene, polyoxypropylene, polyoxybutylene, and a random copolymer or block copolymer thereof. Thepolyoxyalkylene-based compound may be a polyhydric alcohol compound, an ester compound, or an ether compound as described above, or may be any other compound.The plasticizer (B) may not have a hydroxy group but preferably has a hydroxy group. When the plasticizer (B) contains a hydroxy group, it is possible to suppress the elution of the plasticizer into the functional film, particularly the liquid crystal layer of the functional film, while enhancing the flexibility of the interlayer filler, and to prevent the deterioration of the liquid crystal layer caused by the plasticizer.Specific examples, preferred compounds, molecular weights, and the others of the polyoxyalkylene-based compound are as described in the first embodiment, and details thereof are omitted. Further, when the molecular weight of the polyoxyalkylene-based compound is 600 or more as described above, the zero shear viscosity is easily adjusted to a desired range.
[0135] In the third embodiment, the plasticizer (B) may be used alone or in combination with two or more thereof. When two or more plasticizers are used in combination in the interlayer filler, the two or more plasticizers mixed together should satisfy the requirements of the zero shear viscosity and the temperature dependence index described above.
[0136] In the interlayer filler according to the third embodiment of the present invention, the content (hereinafter, sometimes referred to as "content (X1)") of the plasticizer (B) based on 100 parts by mass of the thermoplastic resin (A) is 30 parts by mass or more. If the content of the plasticizer (B) is less than 30 parts by mass, the flexibility of the interlayer filler may not be ensured when the thermoplastic resin (A) with a high glass transition temperature is used. From such a viewpoint, the content (X') of the plasticizer (B) is preferably 35 parts by mass or less, and more preferably 37 parts by mass or more. The content (X') of the plasticizer (B) is preferably 100 parts by mass or less, more preferably 70 parts by mass or less, and even more preferably 50 parts by mass or less. The content (X') of the plasticizer can be kept below a certain level to further suppress migration of the plasticizer into the functional film, thus further preventing the functional film from deteriorating functionally. In addition, even if interlayer fillers are stacked during storage, suppression of the interlayer fillers coalescing with each other is achieved, resulting in good handling properties.
[0137] The interlayer filler may contain a component other than the thermoplastic resin (A) and the plasticizer (B). For example, the interlayer filler may contain a resin component other than the thermoplastic resin (A) or an additive.However, the interlayer filler may be mainly composed of the thermoplastic resin (A) and the plasticizer (B), and the total content of the thermoplastic resin and the plasticizer in the interlayer filler is usually 70% by mass or more, preferably 80% by mass or more, and more preferably 90% by mass or more and 100% by mass or less based on the total amount of the interlayer filler.
[0138] In the third embodiment, the moisture content of the interlayer filler after a hydration test described below is preferably 5% or more and 30% or less. When the moisture content of the interlayer filler is 5% or more, an increase in the water absorption rate during storage of the interlayer filler can be suppressed, thereby making it easy to control the adhesive force between the transparent substrate and the interlayer filler. When the moisture content is 30% or less, the generation of air bubbles inside the interlayer filler or at the interface between the interlayer filler and the transparent substrate can be suppressed. From such a viewpoint, the moisture content of the interlayer filler after a hydration test described below is more preferably 6% or more and 26% or less, and even more preferably 7% or more and 24% or less.The moisture content of the interlayer filler can be measured by a method described in Examples below. The moisture content of the interlayer filler can be controlled by the type and content of plasticizer.<Method of Measuring Moisture Content after Hydration Test>The interlayer filler is cut into a strip having a size of 1 cm x 4 cm to serve as a sample; the thickness is of the interlayer filler; the sample is placed in a 20-mL sample tube, to which ion exchanged water is added so that the sample becomes fully submerged in a liquid thereof, and then heated at 50°C for 2 hours using a block heater to obtain a sample after a hydration test; after being weighed, the sample after the hydration test is heated at 105°C, and heating is continued until a change in weight per minute reaches 0.1% or less to obtain a dried sample; a Kett moisture meter is used for drying; and the moisture content after the hydration test is calculated from the weight of the sample after the hydration test and the weight of the dried sample using the equation below:Moisture content after hydration test (%) = [(weight of sample after hydration test) - (weight of dried sample)] / (weight of dried sample) x 100
[0139] (Additive)The interlayer filler in the third embodiment may contain additives other than the thermoplastic resin (A) and plasticizer (B). Examples of the additive include a heatshielding substance. That is, the interlayer filler of the present invention may contain a heat shielding substance as an additive. Examples of the heat shielding substance include at least one of the component S and a heat shielding particle described above. As the heat shielding substance, the component S may be used alone, the heat shielding particle may be used alone, or both of them may be used. The details of the heat shielding substance such as the component S and the heat shielding particles, and the details of the interlayer filler when the heat shielding substance is used are the same as those in the first embodiment except for the points described below, and the description thereof will be omitted.
[0140] In the case of using the component S as the heat shielding substance in the third embodiment, the content of component S is preferably 0.001% by weight or more and 0.2% by weight or less, more preferably 0.005% by weight or more and 0.1% by weight or less, and even more preferably 0.01% by weight or more and 0.05% by weight or less based on the total amount of the interlayer filler. When the content of the component S is within the above range, the interlayer filler can exhibit appropriate heat shielding performance while maintaining the transparency.In addition, in the case of using the heat shielding particle as the heat shielding substance, the content of the heat shielding particle is preferably 0.01% by weight or more and 6% by weight or less, more preferably 0.1% by weight or more and 5.5% by weight or less, and even more preferably 0.5% by weight or more and 4% by weight or less based on the total amount of the interlayer filler. When the content of the heat shielding particles is within the above range, the interlayer filler can exhibit appropriate heat shielding performance while maintaining the transparency.
[0141] The interlayer filler may contain an additive other than the heat shielding substance, and specific examples thereof is as described in the first embodiment. The additives other than the heat shielding substance may be used alone or in combination with two or more thereof.
[0142] (Structure of Interlayer Filler)The interlayer filler in the third embodiment of the present invention is preferably in the shape of a film. The interlayer filler in the third embodiment of the present invention may be a film with a single-layer structure or a multilayer structure. The interlayer filler with a single-layer structure may be formed of a resin composition (resin composition (X)) containing the above thermoplastic resin (A), plasticizer (B), and other additives such as heatinsulating substances which are blended if necessary. The content of each component in the resin composition (X) is as described above, provided that the content stated on the basis of the total amount of the interlayer filler is read as that on the basis of the total amount of resin composition (X). The same applies when the term "resin composition (X)" is used in the following description of the third embodiment.On the other hand, when the interlayer filler is a film having a multilayer structure, the interlayer filler may have an overall composition as described above, but each layer may be formed of a resin composition (X) containing the thermoplastic resin (A), the plasticizer (B), and other additives which are blended if necessary, and the content of each component in the resin composition (X) forming each layer may be as described above.
[0143] However, the interlayer filler with a single-layer structure or a multilayer structure may be laminated with a resin layer (hereinafter, referred to as resin layer (y')) other than the interlayer filler to become a structure (hereinafter, sometimes referred to as a laminated filler), and in such a case, the interlayer filler may be disposed on one surface or both surfaces in the laminated filler.Note that the other resin layer (y') is preferably formed of a resin composition (Y') containing a thermoplastic resin. The resin composition (Y') preferably contains a thermoplastic resin, and the thermoplastic resin in the resin composition (Y') may be appropriately selected from the thermoplastic resins described above as the thermoplastic resin (A), of which a polyvinyl acetal resin is preferable, and a polyvinyl butyral resin is more preferable. The resin composition (Y') may further contain a plasticizer. The plasticizer used in the resin composition (Y1) may be the plasticizer (B) above, and other conventionally known plasticizers may also be used. In other words, the plasticizer used in the resin layer (y') may include a plasticizer in which the number of oxygen atoms / the number of carbon atoms is less than 0.36.
[0144] The thickness of the interlayer filler in the third embodiment of the present invention is, for example, 50 pm or more, preferably 100 pm or more, more preferably 150 pm or more, and even more preferably 200 pm or more, and is, for example, 1500 pm or less, preferably 1000 p m or less, more preferably 800 pm or less, and even more preferably 450 pm or less. When the thickness of the interlayer filler is equal to or greater than the lower limit, migration of the plasticizer into the functional film can be appropriately suppressed. It also becomes easier to maintain the impact absorption of the interlayer filler, and the safety is ensured in case of using it in a laminated glass for example. Furthermore, adhesiveness to othermembers such as a transparent substrate and a functional film can be easily maintained. On the other hand, when the thickness is equal to or less than the upper limit, the transparency of the interlayer filler can be improved, and the total thickness of the laminated glass incorporating the interlayer filler can be prevented from becoming larger than necessary.
[0145] (Sound Insulation Performance)When the interlayer filler has a multilayer structure with at least three resin layers, sound insulation performance may be imparted by a laminated structure in which the central resin layer is a core layer and the resin layer on each side thereof is a skin layer. In this case, each skin layer is not particularly limited but is preferably a layer forming the surface of the interlayer filler.The resin used for both the skin layer and the core layer is preferably a polyvinyl acetal resin, and more preferably a polyvinyl butyral resin.Both the skin layer and the core layer preferably contain a plasticizer. In this case, the contents (1) and (2) of the plasticizer in the skin layer and the core layer are as described in the first embodiment. The contents (1) and (2) may be appropriately adjusted within the range described in the content (X1) described above.Further, the polyvinyl acetal resin in the skin layer and the polyvinyl acetal resin in the core layer may have different resin compositions as described in the first embodiment.Although the mode in which each layer in the interlayer filler forms the skin layer and the core layer has been described above, each layer in the laminated filler may form the skin layer and the core layer. In this case, for example, the layer formed by the interlayer filler may form the skin layer, and the resin layer (y') may form the core layer, but other structures may also be used.
[0146] The interlayer filler or laminated filler having the core layer and the skin layer as described above preferably has a loss factor of 0.4 or more at the second resonance frequency, a loss factor of 0.4 or more at the third resonance frequency, and a loss factor of 0.4 or more at the fourth resonance frequency, which are obtained by measuring the loss factor of the laminated glass obtained by sandwiching the interlayer filler or laminated filler between two glass plates, followed by thermocompression bonding. A more preferable range of the loss factor and a measurement method are as described in the first embodiment.
[0147] (Optical Properties of Interlayer Filler)The haze value at 23 °C of the interlayer filler in the third embodiment of the present invention is preferably 1.0% or less. When the interlayer filler has a haze value of 1.0% or less, it becomes easy to maintain transparency at room temperature. From the viewpoint of maintaining high transparency, the lower the haze value of the interlayer filler at 23 °C, the better, and the haze value is preferably 0.8% or less, more preferably 0.6% or less. The haze value should be 0% or more but may be 0.1 % or more for practical use. The method of adjusting and measuring the haze value is as described in the first embodiment. In the third embodiment, the interlayer filler preferably satisfies the requirements of formulas (1) and (2) with respect to the haze value.
[0148] In addition to the haze value, optical properties of the interlayer filler according to the third embodiment are the same as those of the interlayer filler according to the first embodiment. Specifically, the total light transmittance and chromaticity of the laminated glass produced by sandwiching the interlayer filler in the third embodiment between two clear float glass plates, followed by thermocompression bonding and the refractive index of the interlayer filler are the same as the total light transmittance and chromaticity of the interlayer filler and the refractive index of the interlayer filler in the first embodiment, and the description thereof will be omitted.Furthermore, the interlayer filler in the third embodiment of the present invention may be provided with heat shielding properties if necessary, as in the first embodiment. In such case, the solar transmittance and solar reflectance measured with a laminated glass produced by sandwiching the interlayer filler between two clear float glass plates, followed by thermocompression bonding, are also the same as those in the first embodiment, and the description thereof will be omitted.
[0149] (Method of Producing Interlayer Filler)The method of producing an interlayer filler in the third embodiment of the present invention is the same as that in the first embodiment, and the description thereof will be omitted.
[0150] <Laminated Body>The laminated body in the third embodiment of the present invention includes the interlayer filler of the present invention and a transparent substrate. The laminated body of the present invention may further include one or more functional films.The laminated body in the third embodiment of the present invention is not particularly limited, but preferably has at least the interlayer filler of the present invention described above and a functional film.The detailed description of the transparent substrate and the functional film is the same as that of the transparent substrate and the functional device described in the first embodiment, and the description thereof will be omitted.The detailed description of the laminated body in the third embodiment of the present invention is the same as described in the first embodiment including the description made using Figs. 1 to 7, and the description thereof will be omitted. The method of producing the laminated body is also the same as that described in the second embodiment. Thus, the laminated body is preferably a laminated glass.Furthermore, in the laminated body in the third embodiment, a laminated filler having an interlayer filler may be used instead of the interlayer filler in the configuration of each laminated body described in the first embodiment, and in such case, the laminated filler may be disposed so that the interlayer filler is disposed at a position in contact with the functional device.
[0151] <Applications>The interlayer filler, the laminated body, and the laminated glass according to the third embodiment can be used in various fields as in the first embodiment. The details of modes in each application in which the interlayer filler, the laminated body, and the laminated glass are used, including the usage modes described using Figs. 8 and 9, are as described in the first embodiment, and the description thereof will be omitted. As described above, also in the third embodiment, the laminated glass can be used in a wheeled vehicle having window glass (glass member) continuously integrated from the roof to the windshield, and the interlayer filler can be used for an image display device, among which the interlayer filler is preferably used for an in-vehicle display device. Furthermore, a laminated filler may be used instead of the interlayer filler in each mode of each application in the third embodiment.
[0152] Although the present invention has been described above with reference to the first to third embodiments, the configurations described in the first to third embodiments may be appropriately combined as long as the effects of the present invention are achieved. Examples
[0153] The present invention will be described in more detail with reference to Examples, but the present invention is not limited to these Examples at all.<First Aspect>First, Examples and Comparative Examples in the first aspect of the present invention will be described. Note that the measurement method and evaluation method of each physical property value in the first aspect of the present invention are as described below.
[0154] (Measurement of Hydroxyl Value)The measurement was made by a method based on JIS K 0070-1992.
[0155] (Measurement of Glass Transition Temperature)Only the resin used in each of Examples and Comparative Examples was subjected to press molding under conditions of 180°C and 10 MPa using a heat molding machine to form a film having a thickness of 400 pm. The resulting resin film was cut into pieces having a length of 10 mm and a width of 5 mm to measure dynamic viscoelasticity using a dynamic viscoelasticity measuring device (device name: "DVA-200", manufactured by IT Keisoku Seigyo K.K.) under the following measuring conditions. The temperature at which the loss tangent tanS indicated the first peak counted from the low temperature side was defined as the glass transition temperature (Tg).(Measurement Conditions)Deformation mode: shear mode, measurement temperature: -50°C to 200°C, heating rate: 5°C / min, measurement frequency: 1 Hz, strain: 1%
[0156] (Measurement of Haze)The interlayer filler cut into a square of 5 cm long x 5 cm wide was sandwiched between two glass plates (clear float glass) and subjected to thermocompression bonding using a vacuum laminator for 5 minutes under conditions of a temperature of 90°C, a vacuum pressure of 0.1 kPa, and a compression pressure of 100 kPa, followed by a treatment using an autoclave under conditions of a temperature of 140°C, a pressure of 1.3 MPa, and a holding time of 30 minutes to obtain a laminated glass. The haze of the laminated glass at 23°C and 80°C was measured using a variable-temperature haze meter ("THM-150-FL" manufactured by Murakami Color Research Laboratory Co., Ltd.). Here, soda-lime glass having a visible light transmittance of 90.8% and a thickness of 2.0 mm was used as the glass plate.
[0157] (Evaluation of Liquid Crystal Device Contamination)The PDLC laminated glass obtained in each of Examples and Comparative Examples was placed in a constant temperature chamber at 110°C for 500 hours, and then the transparentized distance from the edge of the PDLC fdm was measured and evaluated as follows:AA: transparentized distance of less than 6 mmA: transparentized distance of 6 mm or more and less than 10 mmB: transparentized distance of 10 mm or more
[0158] (Evaluation of High Temperature Appearance)The PDLC laminated glass obtained in each of Examples and Comparative Examples was placed on a hot plate at 80°C for 5 minutes, and then the PDLC laminated glass was visually observed so that the angle formed by the main surface and the line of sight was 30°. The appearance state of the position where the PDLC film was not sealed was evaluated as follows:A: 1 or less out of 5 persons who can recognize cloudinessB: 2 or more out of 5 persons who can recognize cloudiness
[0159] (Evaluation of Productivity)The resin obtained in each of Examples and Comparative Examples was stored in an environment at room temperature (23 °C) and humidity of 50% RH for 2 weeks, and then observed and evaluated as follows:A: no coalescence between resins and no blocking occurredB: coalescence between resins caused blocking
[0160] [Example 1A] (Synthesis of Polyvinyl Butyral Resin)Polyvinyl alcohol resin having a degree of polymerization of 1700 was reacted with butylaldehyde in a conventional manner using a hydrochloric acid catalyst to obtain powdery polyvinyl butyral resin PVB (butyral group content: 69.5 mol%, acetyl group content: 1.3 mol%, and hydroxy group content: 29.3 mol%).
[0161] (Preparation of Interlayer Filler)A resin composition was obtained by sufficiently mixing 100 parts by mass of polyvinyl butyral resin (PVB) and 40 parts by mass of plasticizers shown in Tables 1 and 2 together, and the obtained resin composition was subjected to press molding under theconditions of 180°C and 10 MPa using a heat molding machine to obtain a film having a thickness of 400 pm as an interlayer filler.
[0162] (Preparation of PDLC Laminated Glass)A PDLC film ("GAU-LC-WH-C", manufactured by Gauzy Ltd.) was cut into a square of 4 cm long x 4 cm wide. In addition, the interlayer filler obtained in each of Examples and Comparative Examples was cut into two squares of 5 cm long x 5 cm wide and a rectangular frame-shaped piece with an outer dimension of 5 cm long x 5 cm wide and an inner dimension of 4 cm long x 4 cm wide.A laminated intermediate obtained by arranging a rectangular frame-shaped interlayer filler on the outer peripheral side of the PDLC film and arranging two square interlayer fillers on both surfaces of the film was sandwiched between two glass plates (clear float glass) and subjected to thermocompression bonding using a vacuum laminator for 5 minutes under conditions of a temperature of 90°C, a vacuum pressure of 0.1 kPa, and a compression pressure of 100 kPa, followed by a treatment using an autoclave under conditions of a temperature of 140°C, a pressure of 1.3 MPa, and a holding time of 30 minutes to obtain a laminated glass in which the PDLC film was sealed (hereinafter, also referred to as a "PDLC laminated glass").
[0163] [Examples 2 A to 9 A and Comparative Example 1 A]The procedure was the same as in Example 1 except that the type of plasticizers used and the blending amounts were changed as shown in Tables 1 and 2.
[0164] [Comparative Example 2A]An EVA film (product name: "Melthene-G 7055", thickness: 400 pm, manufactured by Tosoh Corporation) was used as the interlayer filler.
[0165] [Comparative Example 3 A]The procedure was the same as in Example 1 except that AO-PVB was used instead of PVB, and the type and the blending amount of the plasticizer used were changed as shown in Tables 1 and 2. AO-PVB was synthesized by the following method.(Synthesis of AO-PVB)In a flask equipped with a stirrer, a thermometer, a dropping funnel, and a reflux condenser, 1000 parts by mass of vinyl acetate, 110 parts by mass of poly oxypropylene monoallyl ether having an average repeating unit of m = 30, and 300 parts by mass ofmethanol were added, the inside of the system was purged with nitrogen, and then the temperature was raised to 60°C. To the system, 1.1 parts by mass of 2,2- azobisisobutyronitrile was added to initiate polymerization. The polymerization was stopped at 5 hours after the start of the polymerization. The solid concentration in the system when the polymerization was stopped was 53% by mass, and the polymerization yield based on the total monomers was 65% by mass. After removal of unreacted monomers under reduced pressure, a 30% by mass methanol solution of a copolymer was obtained.
[0166] While stirring 100 parts by mass of the resulting methanol solution of the copolymer at 40°C, 6.0 parts by mass of a 3% by mass NaOH methanol solution were added thereto, mixed well, and then left to stand. After 2 hours, the solidified polymer was pulverized with a pulverizer, washed with methanol, and dried to obtain a polymer powder (alkylene oxidemodified polyvinyl alcohol). The degree of polymerization of the alkylene oxide-modified polyvinyl alcohol was 1100.
[0167] To 753 parts by mass of pure water, 100 parts by mass of the resulting polymer powder (alkylene oxide-modified polyvinyl alcohol) was added, and the mixture was stirred and dissolved at a temperature of 90°C for approximately 2 hours. The solution was cooled to 40°C, 56 parts by mass of hydrochloric acid with a concentration of 35% by mass and 54 parts by mass of n-butylaldehyde were added, the liquid temperature was lowered to 20°C, and the temperature was maintained to conduct an acetalization reaction, thereby precipitating a reaction product. Then, the liquid temperature was maintained at 40°C for 3 hours to complete the reaction, followed by neutralization, washing with water, and drying according to a conventional method to obtain a white powder of a poly oxyalkylene group-modified polyvinyl butyral resin (AO-PVB).
[0168] Details of plasticizers used in Examples and Comparative Examples in the first aspect are shown in Table 1 below. Note that a plasticizer obtained by mixing a plasticizer 2 A and a plasticizer 3 A at a mass ratio of 1 : 1 was designated as a plasticizer 7A.[Table 1]*In the rows of formulas (1) and (2) in Table 2, those satisfying the requirements of each formula were labeled as OK, and those not satisfying were labeled as NG.*The 500 h transparentized distance in Table 2 is the transparentized distance in the evaluation of the liquid crystal device contamination.
[0170] In Examples 1 A to 9A, a thermoplastic resin with a glass transition temperature of 60°C or higher and a plasticizer having a ratio of the number of oxygen atoms / the number of carbon atoms of 0.36 or more were used, and the haze value at 23°C and the haze difference expressed by formula (2) were adjusted to fall within predetermined ranges, whereby migration of the plasticizer into the functional device was suppressed, thus suppressing contamination of the functional device. In addition, transparency at high temperatures could be maintained and productivity was excellent.In contrast, since the number of oxygen atoms / the number of carbon atoms of the plasticizer was less than 0.36 in Comparative Example 1 A, migration of the plasticizer into the functional devices could not be sufficiently suppressed, thus resulting in failure to suppress contamination of the functional device. In Comparative Example 2A, since the plasticizer-free EVA was used as the interlayer filler, the haze value at 80°C was high, the haze difference could not be adjusted to satisfy formula (2), and transparency at high temperatures could not be sufficiently ensured. In Comparative Example 3 A, since a thermoplastic resin having a low glass transition temperature was used, the resins coalesced with each other, resulting in failure to achieve excellent productivity.
[0171] <Second Aspect>Next, Examples and Comparative Examples in the second aspect of the present invention will be described. The measurement method and evaluation method of each physical property value in the second aspect of the present invention are as described below.
[0172] (Measurement of Elydroxyl Value and Glass Transition Temperature)The hydroxyl value and glass transition temperature were the same as those measured in the first aspect.
[0173] (Zero Shear Viscosity of Plasticizer)The loss modulus of the plasticizer at 30°C, 90°C, and 120°C was measured using a rheometer (MCR702e, manufactured by Anton Pearl Japan) according to the followingconditions, and r was calculated by dividing the obtained loss modulus by the frequency, and the average value of r at the frequency of 100 to 0.1 rad / s was taken as zero shear viscosity. <Measurement Conditions>Measuring jig: 50 mm cone plate, cone angle: 1 radTemperature control jig: Peltier plateShear strain: 10%Frequency: 100 to 0.1 rad / s
[0174] (Tensile Yield Stress)A tensile test sample (dumbbell No. 4 shape described in JIS K 6251 :2004, thickness: 400 pm) was prepared from the interlayer filler obtained in each of Examples and Comparative Examples, and a tensile test was performed at a speed of 500 mm / min at -20°C by a tensile tester ("RTI-1310" manufactured by A&D Co., Ltd.) to measure the tensile yield stress.
[0175] (Evaluation of Liquid Crystal Device Contamination)The evaluation was conducted in the same manner as in the first aspect.
[0176] (Evaluation of Low Temperature Impact Resistance)The interlayer filler cut into a square of 30 cm long x 15 cm wide was sandwiched between two glass plates (clear float glass) having a thickness of 3 mm and subjected to thermocompression bonding using a vacuum laminator for 5 minutes under conditions of a temperature of 90°C, a vacuum pressure of 0.1 kPa, and a compression pressure of 100 kPa, followed by a treatment using an autoclave under conditions of a temperature of 140°C, a pressure of 1.3 MPa, and a holding time of 30 minutes to obtain a laminated glass.The laminated glass of 30 cm long x 15 cm wide prepared by the method was cooled to -18°C. An area of 15 cm from the short side of the sample was hammered with a hammer having a head diameter of 30 mm, a total length of 50 mm, and a tip radius of 50 mm at intervals of 12.5 mm with a spring pressure of 6.0 kg / cm2. After removal of exfoliated glass fragments, if any, the condition of the interlayer filler was evaluated as follows:AAA: No cracks occurred in the interlayer filler. Alternatively, one crack occurred.AA: 2 or more and 10 or less cracks occurred in the interlayer filler.A: 11 or more cracks occurred in the interlayer filler, or the interlayer filler was broken and a part with an area ratio of less than 50% was dropped off.B: The interlayer filler was broken, and a part with an area ratio of 50% or more was dropped off.
[0177] [Example IB](Synthesis of Polyvinyl Butyral Resin (PVB))In the same manner as in Example 1 A, polyvinyl butyral resin (PVB) (glass transition temperature: 67°C) was synthesized.(Preparation of Interlayer Filler)A resin composition was obtained by sufficiently mixing 100 parts by mass of polyvinyl butyral resin (PVB) and 45 parts by mass of plasticizers shown in Tables 3 and 4 together, and the obtained resin composition was subjected to press molding under the conditions of 180°C and 10 MPa using a heat molding machine to obtain a film having a thickness of 400 pm as an interlayer filler.(Preparation of PDEC Eaminated Glass)A PDLC laminated glass was prepared in each of Examples and Comparative Examples in the same manner as in the Examples and Comparative Examples in the first aspect.
[0178] [Examples 2B to 13B and Comparative Examples IB to 6B]The procedure was the same as in Example 1 except that the type of plasticizers used and the blending amounts were changed as shown in Tables 3 to 5. Further, a plasticizer obtained by mixing a plasticizer 2B and a plasticizer 3B at a mass ratio of 1 :1 was designated as a plasticizer 7B.
[0179] [Table3]
[0182] The interlayer filler of each of Examples IB to 13B contained a thermoplastic resin and a plasticizer having a ratio of the number of oxygen atoms to the number of carbon atoms (the number of oxygen atoms / the number of carbon atoms) of 0.36 or more, had a tensile yield stress at -20°C of 40 MPa or less, suppressed migration of the plasticizer into the functional device, and had excellent impact resistance at low temperatures.In contrast, since the interlayer filler of Comparative Example IB did not use a plasticizer having a ratio of the number of oxygen atoms to the number of carbon atoms (the number of oxygen atoms / the number of carbon atoms) of 0.36 or more, the plasticizer easily migrated into and thus contaminated the functional device.The interlayer fillers of Comparative Examples 2B to 6B each had a tensile yield stress at -20°C of more than 40 MPa, indicating poor impact resistance at low temperatures.
[0183] <Third Aspect>Next, Examples and Comparative Examples in the third aspect of the present invention will be described. Note that the measurement method and evaluation method of each physical property value in the third aspect of the present invention are as described below.
[0184] (Zero Shear Viscosity of Plasticizer)The measurement was made in the same maimer as in the second aspect.
[0185] (Contamination of Functional Film by Plasticizer)A PDLC laminated glass was obtained as in the first aspect and evaluated in the same manner as the liquid crystal device contamination in the first aspect.
[0186] (Evaluation of Moisture Resistance Test)The interlayer filler was cut into 10 cm square pieces, each of which were sandwiched between two glass plates (clear float glass) and subjected to thermocompression bonding using a vacuum laminator for 5 minutes under conditions of a temperature of 90°C, a vacuum pressure of 0.1 kPa, and a compression pressure of 100 kPa, followed by a treatment using an autoclave under conditions of a temperature of 140°C, a pressure of 1.3 MPa and a holding time of 30 minutes to obtain a laminated glass. The whitening distance from the center of each side was measured 500 hours after placing the laminated glass in a constant temperature and humidity chamber set at a temperature of 85°C and a humidity of 85% RH.A: Less than 15 mmB: 15 mm or more
[0187] (Moisture Content after Hydration Test)The moisture content of the interlayer filler after the hydration test was measured as follows:The interlayer filler was cut into a strip having a size of 1 cm x 4 cm to serve as a sample; the thickness was of the interlayer filler; the sample was placed in a 20-mL sample tube, to which 7.0 g of ion exchanged water was added so that the sample became fully submerged in a liquid thereof, and then heated at 50°C for 2 hours using a block heater to obtain a sample after a hydration test; after having been weighed, the sample after the hydration test was heated at 105°C, and heating was continued until a change in weight per minute reached 0.1% or less to obtain a dried sample; a Kett moisture meter was used for drying; and the moisture content after the hydration test was calculated from the weight of the sample after the hydration test and the weight of the dried sample using the equation below: Moisture content after hydration test (%) = [(weight of sample after hydration test) -( weight of dried sample)] / (weight of dried sample) x 100
[0188] (Kneadability)A mixture of a polyvinyl butyral resin and a plasticizer was kneaded to evaluate the kneadability of the plasticizer based on the following criteria:A: easily kneadedB : increased viscosity of the mixture, making it difficult to knead
[0189] Plasticizers used in Examples and Comparative Examples in the third aspect are as listed below:• Plasticizer 1C: polyalkylene glycol derivative, manufactured by NOF Corporation, product name: "UNILUBE 50DE-25", molecular weight = 1750• Plasticizer 2C: polypropylene glycol, manufactured by NOF Corporation, product name: "UNIOL D-1000", molecular weight = 1000• Plasticizer 3C: polyoxypropylene glyceryl ether, manufactured by FUJIFILM Wako Pure Chemical Corporation, product name: "UNIOL TG-330", molecular weight = 330• Plasticizer 4C: polyoxypropylene glyceryl ether, manufactured by NOF Corporation, product name: "UNIOL TG-1000R", molecular weight = 1000■ Plasticizer 5C: polyoxypropylene diglyceryl ether, manufactured by NOF Corporation, product name: "UNILUBE DGP-700", molecular weight = 700■ Plasticizer 6C: poly oxypropylene diglyceryl ether, manufactured by Sakamoto Yakuhin Kogyo Co., Ltd., product name: "SC-P1600", molecular weight = 1600• Plasticizer 7C: polyoxyalkylene derivative, manufactured by NOF Corporation, product name: "UNILUBE 50MB-26", molecular weight = 2000• Plasticizer 8C: poly oxyalkylene derivative, manufactured by NOF Corporation, product name: "UNILUBE 50MB-11", molecular weight = 1000• Plasticizer 9C: polyoxyalkylene derivative, manufactured by NOF Corporation, product name: "UNILUBE 50MB-5", molecular weight = 500• Plasticizer 10C: tributyl citrate, manufactured by Tokyo Chemical Industry Co., Ltd., product name: none, molecular weight = 360.45• Plasticizer 11C: tri ethylene glycol-bis-(2-ethylhexanoate), manufactured by SEKISUI CHEMICAL CO., LTD., molecular weight = 402■ Plasticizer 12C: dioctyl adipate, manufactured by FUJIFILM Wako Pure Chemical Corporation, molecular weight = 166.17• Plasticizer 13C: polycaprolactone triol, manufactured by DIG Corporation, product name: "POLYLITE ODX-2586", molecular weight = 850• Plasticizer 14C: mixture of plasticizer 4C and plasticizer 7C at a mass ratio of 1 : 1
[0190] [Tabled]
[0191] [Example 1C](Synthesis of Polyvinyl Butyral Resin)Powdery polyvinyl butyral (PVB) resin was obtained in the same mamier as in Example 1A.(Preparation of Interlayer Filler)A resin composition was obtained by sufficiently mixing 100 parts by mass of polyvinyl butyral resin and 40 parts by mass of a plasticizer shown in Table 6 together, and the obtained resin composition was subjected to press molding under the conditions of 180°C and 10 MPa using a heat molding machine to obtain a film having a thickness of 400 pm as an interlayer filler.(Preparation of PDLC Laminated Glass)A PDLC laminated glass was prepared in each of Examples and Comparative Examples in the same manner as in the Examples and Comparative Examples in the first aspect.
[0192] [Examples 2C to 11C and Comparative Examples 1C to 5C]The procedure was the same as in Example 1 except that the type of plasticizers used and the blending amounts were changed as shown in Tables 8 and 9.
[0193] [Table8]
[0194] In the interlayer fillers of Examples 1C to 11C, the content of the plasticizer was 30 parts by mass or more based on 100 parts by mass of the thermoplastic resin, the plasticizer had a zero shear viscosity of 5.0 mPa-s or more and 70.0 mPa-s or less at both 90°C and 120°C, and a temperature dependence index of the plasticizer obtained from formula (3) above was -5.5 or more. Therefore, the contamination of the functional film by the plasticizer in the interlayer fillers of Examples 1C to 10C could be suppressed, while the resin composition had good kneadability.On the other hand, the interlayer filler of Comparative Example 1 C had a plasticizer zero shear viscosity at 120°C of less than 5.0 mPa-s, resulting in a greater degree of contamination of the functional film by the plasticizer. The interlayer fillers of Comparative Example 2C to 4C each had a plasticizer zero shear viscosity at 90°C and 120°C of less than 5.0 mPa-s, resulting in a greater degree of contamination of the functional film by the plasticizer. Furthermore, the interlayer filler of Comparative Example 5C had a plasticizer temperature dependence index of less than -5.5, which was obtained from formula (3) above, and thus the resin composition had poor kneadability.Reference Signs List
[0195] 10 laminated body (laminated glass)11, HA, 1 IB, 11C interlayer filler12 functional device (functional film)21, 22 transparent substrate25 sealant30 window glass (glass member)31 roof32 windshield40 image display device41 image display panel42 touch panel
Claims
CLAIMS
1. An interlayer filler comprising a thermoplastic resin (A) having a glass transition temperature of 60°C or higher and a plasticizer (B) having a ratio of the number of oxygen atoms to the number of carbon atoms of 0.36 or more, the interlayer filler satisfying both formulas (1) and (2) below.Formula (1): (haze value at 23°C) < 1.0%Formula (2): (haze value at 80°C) - (haze value at 23°C) < 0.5%
2. An interlayer filler comprising a thermoplastic resin (A) and a plasticizer (B) having a ratio of the number of oxygen atoms to the number of carbon atoms of 0.36 or more, tensile yield stress of the interlayer filler being 40 MPa or less as measured at a tensile speed of 500 mm / min at -20°C.
3. The interlayer filler according to claim 2, wherein the plasticizer (B) has a zero shear viscosity of 5.0 mPa-s or more and 70.0 mPa-s or less at both 90°C and 120°C, and a temperature dependence index of the plasticizer obtained from formula (3) below is -5.5 or more:Temperature dependence index of plasticizer = (p 120 - p30) / 90 (3) where rj 120 is a zero shear viscosity [mPa-s] of the plasticizer at 120°C; p30 is a zero shear viscosity [mPa-s] of the plasticizer at 30°C.
4. The interlayer filler according to claim 2, wherein the thermoplastic resin (A) has a glass transition temperature of 60°C or higher.
5. The interlayer filler according to any one of claims 1 to 4, comprising a resin composition (X) comprising the thermoplastic resin (A) and the plasticizer (B), wherein a content of the plasticizer (A) in the resin composition (X) is 30 parts by mass or more based on 100 parts by mass of the thermoplastic resin (B).
6. The interlayer filler according to any one of claims 1 to 4, wherein the plasticizer has a hydroxyl value of 20 mgKOH / g or more and 100 mgKOH / g or less.
7. The interlayer filler according to any one of claims 1 to 4, wherein the plasticizer is a polyoxyalkylene-based compound having a molecular weight of 600 or more.
8. The interlayer filler according to any one of claims 1 to 4, wherein the thermoplastic resin is a polyvinyl acetal resin.
9. A laminated body comprising: the interlayer filler according to any one of claims 1 to 4; and at least one selected from the group consisting of a transparent substrate and a functional device.
10. The laminated body according to claim 9, wherein the transparent substrate is at least one glass member selected from the group consisting of an inorganic glass and an organic glass.
11. The laminated body according to claim 9, wherein the interlayer filler and the functional device are positioned between a pair of transparent substrates.
12. The laminated body according to claim 9, wherein the functional device is a variable transmittance device of any one of PDLC, SPD, and GHLC.
13. A laminated glass comprising the laminated body according to claim 9.
14. The laminated glass according to claim 13, which is a light-modulating laminated glass.
15. A laminated glass comprising the laminated body according to claim 9, wherein the laminated glass is used in a wheeled vehicle with window glass continuously integrated from a roof to a windshield.
16. An image display device comprising the interlayer filler according to any one of claims 1 to 4.
17. An interlayer filler comprising a thermoplastic resin and a plasticizer, a content of the plasticizer being 30 parts by mass or more based on 100 parts by mass of the thermoplastic resin, the plasticizer having a zero shear viscosity of 5.0 mPa-s or more and 70.0 mPa-s or less at both 90°C and 120°C, anda temperature dependence index of the plasticizer obtained from formula (3) below being -5.5 or more:Temperature dependence index of plasticizer = (p 120 - p30) / 90 (3) where T| 120 is a zero shear viscosity (mPa-s) of the plasticizer at 120°C; p30 is a zero shear viscosity (mPa-s) of the plasticizer at 30°C.
18. The interlayer filler according to claim 17, wherein the thermoplastic resin is a polyvinyl acetal resin having a glass transition temperature of 60°C or higher.
19. The interlayer filler according to claim 17, wherein the plasticizer has a polyoxyalkylene structure.
20. The interlayer filler according to claim 17, wherein the plasticizer has a zero shear viscosity of 7.0 mPa-s or more and 40.0 mPa-s or less at both 90°C and 120°C.
21. The interlayer filler according to claim 17, wherein a moisture content is 5% or more and 30% or less, as measured by a method of measuring a moisture content after a hydration test below:<Method of Measuring Moisture Content after Hydration Test>The interlayer filler is cut into a strip having a size of 1 cm x 4 cm to serve as a sample; the sample is placed in a 20-mT sample tube, to which ion exchanged water is added so that the sample becomes fully submerged in a liquid thereof, and then heated at 50°C for 2 hours using a block heater to obtain a sample after a hydration test; after being weighed, the sample after the hydration test is heated at 105°C, and heating is continued until a change in weight per minute reaches 0.1% or less to obtain a dried sample; a Kett moisture meter is used for drying; and the moisture content after the hydration test is calculated from the weight of the sample after the hydration test and the weight of the dried sample using an equation below:Moisture content after hydration test (%) = [(weight of sample after hydration test) - (weight of dried sample)] / (weight of dried sample) x 100
22. A laminated body comprising the interlayer filler according to claim 17 and a transparent substrate.
23. The laminated body according to claim 22, further comprising one or more functional films.
24. The laminated body according to claim 23, wherein the functional film comprises at least one light-modulating member selected from the group consisting of PDLC, SPD, and GHLC.
25. A laminated glass comprising the laminated body according to any one of claims 22 to 24.
26. A laminated glass comprising the laminated body according to claim 24, wherein the laminated glass is used in a wheeled vehicle with window glass continuously integrated from a roof to a windshield.
27. An image display device comprising the interlayer filler according to claim 17 or 18.
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