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 PVB 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, anti-sticking issues, and equipment costs while allowing for the reuse of leftover materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional PVB material is used in safety glass production, then the material provides necessary adhesive and protective properties, but the material exhibits high water absorbency and high viscosity making it difficult to recycle and process
Solution Approach 1:
The patent modifies the PVB material by changing its chemical composition parameters - specifically reducing the vinyl alcohol content from conventional levels to 5-15 mol% and adding specific additives (wax emulsion, silicone oil, titanium dioxide). These parameter changes result in modified PVB that maintains adhesive properties while significantly reducing water absorbency and viscosity, enabling easier processing and recycling.
Solution Approach 2:
The patent creates a composite material system by combining modified PVB with multiple functional additives including wax emulsion (for water resistance), silicone oil (for viscosity control), titanium dioxide (for UV protection and opacity), and various plasticizers. This composite approach allows the material to simultaneously achieve low water absorbency, reduced viscosity, and maintained adhesive properties.
2Ease of manufacture
If PVB leftover materials are discarded directly, then the production process is simple, but the environment is impacted and PVB materials are wasted
Solution Approach 1:
The patent implements a recovery system for PVB leftover materials by modifying their composition to enable recycling. The modified PVB with reduced water absorbency and viscosity can be reprocessed into new products such as plastic pellets, flooring materials, or composite boards, transforming waste into valuable resources and reducing environmental impact while maintaining production efficiency.
3Ease of manufacture
If calendaring process is used to prepare PVB layers, then the PVB material can be processed into films, but multiple independent equipment are needed resulting in higher equipment cost, larger space, more manpower and greater energy consumption
Solution Approach 1:
The patent merges multiple separate calendaring operations into a single extrusion-based film formation process. The modified PVB composition allows the material to be extruded directly into films with controlled thickness and properties, eliminating the need for multiple independent calendaring machines and reducing equipment complexity, factory space, and energy consumption while maintaining film production quality.
4Ease 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 transitions from open-system calendaring to a closed extrusion system where the modified PVB is processed. The closed system prevents plasticizer evaporation into the atmosphere, and the modified composition with optimized plasticizer content and added stabilizers further reduces emissions, eliminating air pollution while maintaining effective material processing.
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 and environmental impact, and allows for the recycling of previously wasted materials.
Implementation Method 1
a modified polyvinyl butyral material, comprising a polyvinyl butyral composite material, a filler, an anti-hydrolysis agent
Implementation Method 2
the polyvinyl butyral composite material is obtained by plasticizing a composition comprising polyvinyl butyral and a second plasticizer
Implementation Method 3
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.