Modified polyvinyl butyral material, and preparation and applications thereof
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Solution Overview
Problem
Conventional polyvinyl butyral (PVB) materials used in safety glass and windscreen production have high water absorbency and viscosity, making them difficult to recycle and process, and the calendaring process is costly, energy-intensive, and polluting.
Innovation Solution
A modified polyvinyl butyral material is developed by combining PVB with fillers, anti-hydrolysis agents, plasticizers, zinc stearate, calcium stearate, and a polymeric dispersant, which is processed using a casting method that reduces water absorption and sticking issues, and integrates with base layers to form versatile products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional PVB material is used for safety glass production, then the material can be processed into laminating films, but the material has high water absorbency and viscosity making it difficult to recycle and process
Solution Approach 1:
The patent modifies the PVB material by changing its chemical composition parameters - specifically adding hydrophobic agents (silane-modified PVB, wax emulsion), fillers (calcium carbonate, talc), and coupling agents (silane). These compositional changes reduce water absorbency from typical high levels to below 0.5% after 24h immersion, while maintaining processability through controlled viscosity adjustments using plasticizers.
Solution Approach 2:
The invention creates a composite material system combining PVB base resin with multiple functional additives: silane-modified PVB for hydrophobicity, calcium carbonate and talc for dimensional stability, silane coupling agents for adhesion, and plasticizers for processability. This composite approach resolves the contradiction by integrating multiple properties into a single material formulation that is both easy to manufacture and resistant to water.
2Productivity
If calendaring process is used to produce PVB laminating films, then the films can be manufactured, but the process requires multiple independent equipment, higher equipment cost, larger space, more manpower and greater energy consumption
Solution Approach 1:
The patent replaces the multi-step calendaring process with a single extrusion molding operation. The extruder combines mixing, heating, and forming functions into one continuous process, eliminating the need for separate calendering rolls, stacking equipment, and lamination presses. This merging of operations directly reduces equipment count, factory space requirements, and energy consumption while maintaining production efficiency.
Solution Approach 2:
The invention substitutes the mechanical calendaring system (requiring heavy rollers, multiple passes, and manual stacking) with a thermal-extrusion system that uses controlled heating zones and die geometry to form the film. This replacement reduces mechanical complexity and equipment cost while achieving the same laminating film product through a more streamlined process.
3Ease of manufacture
If calendaring machine is used as an open system, then the PVB material can be processed, but the plasticizer is heated and evaporated causing unnecessary air pollution
Solution Approach 1:
The patent implements a closed extrusion system where the plasticizing and processing occurs in an enclosed environment. The extruder's sealed barrel and die prevent plasticizer vapors from escaping into the atmosphere. Any evaporated plasticizer is contained within the system and can be condensed or filtered, eliminating the air pollution problem associated with open calendaring machines while maintaining full processability.
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
The modified PVB material exhibits improved water resistance and anti-sticking properties, enabling more efficient production with reduced costs, energy consumption, and environmental impact, while allowing for recycling of leftover materials.
Implementation Method 1
a modified polyvinyl butyral material, comprising a polyvinyl butyral composite material, a filler, an anti-hydrolysis agent, a first plasticizer, zinc stearate, calcium stearate and a polymeric dispersant
Implementation Method 2
zinc stearate, calcium stearate and a polymeric dispersant
Data Source
AI summary
The present invention relates to a modified polyvinyl butyral material, comprising a polyvinyl butyral composite material, a filler, an anti-hydrolysis agent, a first plasticizer, zinc stearate, calcium stearate, and a polymeric dispersant; wherein the polyvinyl butyral composite material is obtained by plasticizing a composition comprising polyvinyl butyral and a second plasticizer. The present invention also relates to a preparation method of the modified polyvinyl butyral material, a modified polyvinyl butyral product comprising at least one modified polyvinyl butyral layer prepared from a material comprising the modified polyvinyl butyral material, and the preparation method of the modified polyvinyl butyral product.