Low Moisture PVB Sheets for Non-Autoclave Lamination

Solution Overview

Problem

Existing methods for manufacturing low moisture content polymer sheets for non-autoclave glass lamination processes are complex and difficult, increasing the manufacturing complexity and cost.

Innovation Solution

Producing poly(vinyl butyral) sheets with a well-defined low residual hydroxyl content, which equilibrates to a desirable moisture level without additional conditioning, facilitating efficient non-autoclave lamination processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional methods are used to produce low moisture content polymer sheets, then the required low moisture content is achieved, but the manufacturing process complexity increases

Engineering Contradiction:

Improvemoisture contentVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The polymer resin is pre-dried to remove moisture before lamination, and the lamination process itself serves as the conditioning step that achieves the desired moisture content. This eliminates separate conditioning steps while ensuring low moisture content is achieved through the combination of pre-drying and the lamination process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention specifies precise moisture content ranges (0.05-5.0% by weight) and hydroxyl content ranges (0.5-5.0 mmol/g) as key parameters to control during resin selection and processing. By controlling these parameters through resin formulation and pre-drying, the patent achieves low moisture content without complex manufacturing processes

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If conditioning steps are added to reduce moisture content, then low moisture content is achieved, but manufacturing time increases

Engineering Contradiction:

Improvemoisture contentVSAvoidconditioning time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The polymer resin is pre-dried to remove moisture before lamination, and the lamination process itself serves as the conditioning step that achieves the desired moisture content. This eliminates separate conditioning steps while ensuring low moisture content is achieved through the combination of pre-drying and the lamination process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The lamination process continuously performs multiple functions: it bonds the glass substrates while simultaneously conditioning the polymer to achieve the desired moisture content. This continuous process eliminates idle conditioning time and integrates moisture control into the productive lamination operation

Inventive Principle:

Principle #20Continuity of useful action

3Manufacturing precision

If additional conditioning steps are implemented, then moisture content is reduced, but manufacturing cost increases

Engineering Contradiction:

Improvemoisture contentVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The polymer resin is pre-dried to remove moisture before lamination, and the lamination process itself serves as the conditioning step that achieves the desired moisture content. This eliminates separate conditioning steps while ensuring low moisture content is achieved through the combination of pre-drying and the lamination process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The lamination process is designed to perform multiple functions simultaneously: bonding the glass substrates and conditioning the polymer to achieve the desired moisture content. This multi-functional approach eliminates the need for separate conditioning equipment and operations, reducing manufacturing cost

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach simplifies the manufacturing process by eliminating or reducing the need for conditioning steps, thereby reducing time and expense, while maintaining the required low moisture content for effective lamination.

Implementation Method 1

poly(vinyl butyral) sheets that have been produced by using plasticized poly(vinyl butyral) having a well defined, low residual hydroxyl content... equilibrate to a repeatable, relatively low, and desirable moisture content

Methodology Applied

Scientific EffectMoisture diffusion: Diffusion

Data Source

PatentEP1907204B1Low moisture polymer sheets for non autoclave process

Publication Date: 2014.03.12 SOLUTIA INC

AI summary

The present invention is in the field of polymer interlayers used in multiple layer glass panels, and specifically the present invention is in the field of polymer interlayers having relatively low moisture content, and being suitable in a non autoclave process.