Modified Polyvinyl Butyral Material for Safety Glass
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Solution Overview
Problem
Conventional polyvinyl butyral (PVB) materials used in safety glass and windscreen production result in leftover materials that are difficult to recycle due to high water absorbency and viscosity, leading to environmental issues and inefficient processing, with the calendaring process being costly, energy-intensive, and polluting.
Innovation Solution
A modified polyvinyl butyral material is developed by combining a polyvinyl butyral composite with a filler, anti-hydrolysis agent, plasticizers, zinc stearate, calcium stearate, and a polymeric dispersant, which is processed using a casting method to reduce water absorption, improve anti-sticking properties, and optimize production line efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional PVB material is used in safety glass production, then the glass can be combined with thermoplastic PVB material for laminating films, but the leftover materials have high water absorbency and viscosity making them difficult to recycle
Solution Approach 1:
The patent applies parameter changes by modifying the PVB material through chemical composition adjustment - adding hydrophobic agents and adjusting molecular structure to reduce water absorbency. This transformation changes the material parameters from high water absorbency state to low water absorbency state, enabling both maintained laminating performance and improved recyclability of leftover materials
Solution Approach 2:
The patent creates composite materials by combining PVB base material with hydrophobic agents, lubricants, and other additives. This composite approach maintains the essential laminating properties of PVB while introducing new properties (water resistance, reduced viscosity) that enable easier recycling and processing of leftover materials
2Ease of manufacture
If calendaring process is used to prepare PVB layers, then the PVB material can be processed into laminating films, but the process requires multiple independent equipment, higher equipment cost, larger space, more manpower and greater energy consumption
Solution Approach 1:
The patent merges multiple separate calendaring operations into a single integrated extrusion process. The extruder combines mixing, heating, and forming functions that were previously distributed across multiple independent calendaring machines, thereby reducing equipment count, factory space requirements, and operational complexity while maintaining PVB layer processing capability
Solution Approach 2:
The extrusion equipment described in the patent performs multiple functions simultaneously - it mixes the modified PVB compound, heats it to appropriate temperature, extrudes it into film form, and can incorporate various additives. This multi-functional equipment replaces several specialized machines, reducing overall device complexity and improving manufacturing efficiency
3Ease of manufacture
If calendaring machine is used as an open system for PVB processing, then the plasticizer can be heated and evaporated during manufacturing, but unnecessary air pollution is caused
Solution Approach 1:
The patent implements a closed-system extrusion process that creates a controlled environment for plasticizer heating and evaporation. By replacing the open calendaring system with a closed extruder, the evaporated plasticizers are contained within the system rather than released into the atmosphere, thereby eliminating air pollution while maintaining the necessary heating and evaporation functions for proper 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 polyvinyl butyral material exhibits improved water resistance and anti-sticking properties, enabling more efficient processing with reduced costs and environmental impact, and allows for the recycling of leftover materials, addressing the environmental and economic challenges of the conventional calendaring process.
Implementation Method 1
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
Implementation Method 2
since the calendaring machine is an open system and the plasticizer is heated and evaporated during the manufacturing process, unnecessary air pollution is caused
Data Source
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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 (B) prepared from a material comprising the modified polyvinyl butyral material, and the preparation method of the modified polyvinyl butyral product.