Multi-Stage Acrylic Polymer for Plasticizer-Free Glass Laminates
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Solution Overview
Problem
Existing glass interlayer laminates require plasticizers, leading to moisture absorption issues during autoclave lamination and potential delamination over time, while lacking flexibility and clarity without specialized storage and handling.
Innovation Solution
A multi-stage polymer composition comprising a cross-linked core, intermediate layers, and a shell, made from specific alkyl(meth)acrylate monomers and cross-linking agents, which provides satisfactory optical, mechanical, and adhesive properties without the need for plasticizers or specialized storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If plasticizer is added to PVB to achieve adequate optical, mechanical, and adhesion properties, then flexibility and clarity are improved, but moisture absorption increases leading to bubbling and delamination
Solution Approach 1:
The invention extracts and eliminates the plasticizer component from the polymer composition entirely. The multi-stage acrylic polymer achieves flexibility and clarity through its inherent multi-stage structure with different glass transition temperatures in each layer, rather than relying on plasticizer additives that cause moisture absorption and delamination issues.
Solution Approach 2:
The invention uses a composite multi-stage polymer structure with distinct layers having different compositions and properties. The core layer provides flexibility while the shell layer provides adhesion and moisture resistance, creating a composite material that achieves multiple functions without plasticizers.
2Reliability
If PVB sheets are packaged and stored in low temperature environment to limit moisture adsorption, then delamination is prevented, but storage complexity and handling requirements increase
Solution Approach 1:
The multi-stage acrylic polymer is self-sufficient and does not require external storage conditions to prevent moisture absorption. The polymer composition itself provides inherent moisture resistance through its plasticizer-free formulation and multi-layer structure, eliminating the need for specialized low-temperature storage and handling procedures.
3Manufacturing precision
If multi-stage polymer structure is implemented with cross-linked core and intermediate layers, then optical and mechanical properties are improved, but manufacturing complexity increases
Solution Approach 1:
The invention segments the polymer into distinct functional layers (core, intermediate, shell) with specific monomer compositions and glass transition temperatures. This segmentation allows each layer to contribute specific properties (flexibility, adhesion, moisture resistance) while maintaining overall manufacturing feasibility through sequential polymerization.
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 multi-stage polymer composition achieves flexibility, clarity, and strong adhesion to glass without plasticizers, preventing delamination and eliminating the need for specialized storage and handling, ensuring reliable performance in glass laminates.
Implementation Method 1
comprising polymerized units derived from (i) 95 to 99.9 weight % of butyl acrylate, and (ii) 0.1 to 5 weight % of 1,3-butandeiol diacrylate and allyl methacrylate
Data Source
AI summary
Provided are multi-stage polymer compositions comprising (a) cross-linked core comprising polymerized units derived from (i) alkyl(meth)acrylate monomers, and (ii) one or more cross-linking monomers, graft-linking monomers, and combinations thereof, (b) a first intermediate layer comprising polymerized units derived from (i) one or more alkyl(meth)acrylate monomers, and (ii) cross-linking monomers, graft-linking monomers, and combinations thereof, (c) a second intermediate layer comprising polymerized units derived from (i) one or more alkyl(meth)acrylate monomers, styrenic monomers, and combinations thereof, and (ii) one or more chain transfer agents, and (d) a shell comprising polymerized units derived from (i) alkyl(meth)acrylate monomers, styrenic monomers, and combinations thereof, (ii) one or more monomers selected from the group consisting of acid functionalized monomers, hydroxyl-functionalized monomers, and combinations thereof, and (iii) optionally, of one or more chain transfer agents.