CN101031419A - 减少声透射用玻璃层压体 - Google Patents

减少声透射用玻璃层压体 Download PDF

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CN101031419A
CN101031419A CNA2005800314563A CN200580031456A CN101031419A CN 101031419 A CN101031419 A CN 101031419A CN A2005800314563 A CNA2005800314563 A CN A2005800314563A CN 200580031456 A CN200580031456 A CN 200580031456A CN 101031419 A CN101031419 A CN 101031419A
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layered product
pvb
polymer
pet
layer
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J·C·安德森
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EIDP Inc
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EI Du Pont de Nemours and Co
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Abstract

本发明是一种有声衰减性能的玻璃层压体，这使其适合用来作为建筑学应用中和/或车辆中的声学玻璃装配。

Description

减少声透射用玻璃层压体
本申请要求2004年9月20日提交的美国临时申请No.60/611,596的权益。
                          发明背景
发明领域
本发明涉及玻璃装配应用中使用的层压体。本发明具体地涉及可用来作为隔音用声学玻璃装配的层压体。
相关技术描述
有隔音性能的玻璃层压体已经在建筑学应用中以及车辆中得到使用。这样的声学层压体是减少外声源向建筑物或汽车等的内部的声透射所希望的。
增塑的聚乙烯醇缩丁醛(PVB)片材已用于制造透明层压体构件，例如：运输器包括汽车、摩托车、船和飞机的风挡，建筑物例如办公(写字)楼、公寓楼、房屋、和/或商用建筑物的窗户等。
在现代运输器中-尤其在火车、飞机和汽车中，乘客舒适已经成为涉及各该运输器的商业交易中的一个重要卖点。现代运输器的一个重要特色是能最大限度降低源于该运输器客舱外部的噪音。汽车尤其注重改善旅客乘坐的声学品质。来自发动机舱、轮胎在道路或地面上滚动的声音、和汽车在空气中快速移动时产生的风噪音等的噪音，全都是对汽车按意向使用时所发生的噪音的贡献者。
为了改善乘客旅行的寂静性，已经对汽车进行了各种改进和修饰。然而，噪音的一个主要来源是透过运输器窗户的声音。汽车的窗户典型地是声波的良导体-尤其在临界声频即在人耳可感受的声频。进而，办公楼及其它建筑物中从该建筑物外部传来的噪音的声减少设定得使外部噪音能达到建筑物内部分散水平会是理想的。
各种专利描述了解决运输器中和/或建筑物中噪音减少的发明性尝试。美国专利No.5,368,917和美国专利No.5,478,615描述了包含惯常聚乙烯醇缩丁醛(PVB)的运输器用声学层压玻璃装配。美国专利No.6,132,882描述了一种隔音层压体，包含一个减振层例如聚丙烯酸酯、至少一个可挠曲塑料层例如PVB、和一枚刚性玻璃或塑料片材。美国专利No.5,773,102描述了一种隔音层压玻璃板，其中一种高性能声学薄膜与至少一种有普通声学性能的薄膜例如PVB组合。美国专利No.5,190,826描述了隔音层压玻璃中使用的夹层。美国专利No.6,074,732描述了一种由其间有依次为PVB/PET/丙烯酸酯/PET/PVB的聚合物层的两枚玻璃片材制成的隔音层压窗。该PVB层是惯常的(即非声学的)PVB。美国专利No.6,432,522描述了包含一种有至少2层的夹层薄膜的、有消音性能的透明层压体。WO 01/19747A1描述了玻璃层压体，其中PVB用20～50wt％一种双组分增塑剂混合物软化(增塑)的，该混合物包含30～70wt％一种聚亚烷基二醇作为组分之一。然而，使用软化PVB的层压体的抗冲击性能会受到有害影响。
乙烯酸共聚物或其盐的使用产生了尤其可用来作为汽车和建筑物中抗威胁玻璃装配单元的刚性夹层。由于这些材料的刚性和对有已知声学性能的其它夹层材料例如PVB的粘合力相对缺乏，赋予这样的夹层以隔音性能会是困难的。
可能理想的是有一种具有保留了其抗冲击性能和耐穿透性能的隔音性能的层压体。在抗威胁玻璃装配单元中有这样的性能会是特别理想的。
发明概要
一方面，本发明是一种隔音层压体物品，包含：至少3层复合夹层，其中该复合夹层中的一层是一种配置于2个不类似聚合物层之间的聚酯(PET)聚合物，且其中该不类似聚合物是选自下列一组的聚合物：聚乙烯醇缩丁醛(PVB)、ionoplast树脂(离聚物)、聚氨酯(PU)、聚氯乙烯、聚碳酸酯、聚缩醛、乙烯酸共聚物包括乙烯酸三元共聚物(酸共聚物)、和聚烯烃包括聚乙烯和聚丙烯。
发明详细描述
在一种实施方案中，本发明是一种有隔音性能的层压体。本发明的层压体在约10℃～约30℃范围内的温度下在约10Hz～约10,000Hz的频率范围内有隔音性能。本发明的层压体包含一种包含至少三个聚合物层的多层复合夹层。较好，该复合夹层赋予该层压体以在约10℃～约30℃范围内的温度下在约1000Hz～约5000Hz范围内的隔音性能。更好，该夹层在约15℃～约25℃范围内的温度下提供了上述隔音性能。
隔音-如该术语在本专利申请中所使用的-系指声音从一种层压体的入射表面(暴露于声波的表面)透射到该层压体的内表面(该入射表面的反面)时发生的声音损失。个体层压体玻璃装配构造有可以为每一种构造测定的而且可以与该玻璃装配的声音透射损失相关联的损失因子和等效弯曲刚性模量。本发明的层压体玻璃装配构造包含三层夹层层压体构造，其用本文中所述方法在50～10000Hz的全量程内在20℃测定的损失因子大于约0.05。较好，本发明的层压体在50～10000Hz的全量程内有至少约0.08的损失因子，更好在50～10000Hz的全量程内的损失因子是至少约0.15。
在本发明的实施例中，可以测定等效弯曲刚性模量来提供本发明的层压体玻璃装配的声音透射损失。
本发明的隔音层压体包含或基本组成为一个聚酯(PET)层配置于至少两个化学上区别于该PET层的其它聚合物夹层之间，使得该层压体构件可以描述为包含如下结构：聚合物1/PET/聚合物2。聚合物1和聚合物2既可以是相同的材料，也可以是不同的材料。虽然该复合夹层的层压体构造没有严格的顺序，但会较好的是，将该PET层直接配置于至少2个其它层之间，使得聚合物1和聚合物2各自接触到该介入PET层的相反表面。可以设想其它层压体构件，使之利用多个其中任何一层或以能提供理想声学效果的任何组合并用本文中所述的化学上各异的夹层。特别好的是该层压体有适合于使该层压体付诸典型玻璃装配应用的粘合力。适合的粘合力可以是这些聚合物层之间固有的，也可以是工艺处理的结果，还可以是这些层的至少一个表面上的涂层。
在一种实施方案中，该PET层可以是火焰处理的，以提高对不相似聚合物层的粘合力。在一种特别好的实施方案中，该PET层有一种施用到其至少一个表面、较好施用到该PET的两个表面上的聚烯丙胺系底漆涂层。涂有本文中所述底漆的PET可以为本来无法以惯常方式层压的2种不相似聚合物夹层的层压提供一种手段。该底漆及其对PET聚合物层的施用描述于美国专利No.5,411,845、No.5,770,312、No.5,690,994、和No.5,698,329中。一般地说，该PET薄膜是用惯常方法挤塑和流延成为薄膜的，而且该聚烯丙胺涂料是要么(i)在拉伸之前要么(ii)在机器方向拉伸作业与横向拉伸作业之间、和/或在2种拉伸作业以及在展幅机炉中热定形之后施用到该PET薄膜上的。较好的是，该涂料可以在横向拉伸作业之前施用，使得有涂层的PET纤维网能在展幅机炉中在约220℃的温度约束下加热，以期使该聚烯丙基胺能固化到该PET表面上。除这种固化涂层外，还可以在该拉伸和展幅机炉热定形之后在它上面施用另一层聚烯丙基胺涂层，以期得到更厚的总体涂层。以这种一般方式处理的有涂层PET是本文中用来提高层压体构造中不类似聚合物层之间的粘合力的底漆(PRIMER)。有涂层的PET层会是，例如，生产一种层压体构造所需要的，其中本文中以上提到的聚合物1和聚合物2选自离聚物共聚物和聚乙烯醇缩丁醛。PVB和ionoplast夹层通常没有诸如中间粘合剂层的火焰处理不会令人满意地互相粘附。
本发明层压体中的粘合强度是用90°剥离试验测定的。本发明中不类似聚合物层之间的粘合强度，在没有任何提高粘合力的处理时可以是约零(0)～约小于10磅/英寸，而有火焰处理时粘合强度可以提高到约10磅/英寸。使用本文中所述的PRIMER可以使剥离强度提高到至少约10磅/英寸、且较好达到至少15磅/英寸。剥离强度可以给出该多层层压体的完整性的指示，而高剥离强度会是充分构建的层压体中良好耐脱层性能的指示剂。
可用于本发明层压体中的适用聚合物包括例如：PET；PVB(标准非声学PVB和/或“声学”PVB，其中声学PVB是高度增塑的PVB，如本文中所述)；ionoplast树脂，即乙烯酸共聚物离聚物(即至少部分中和的酸共聚物)；乙烯-乙酸乙烯酯(EVA)；聚氨酯；聚氯乙烯；聚碳酸酯；聚缩醛；乙烯酸共聚物(包括乙烯酸三元共聚物)；聚烯烃，包括聚乙烯和聚丙烯。对于本文中的使用较好的是本身透明或可以使之变得透明的聚合物，因此它们适合于在玻璃装配终端应用中使用。对于本文中的使用特别好的是PET、PVB、和ionoplast树脂。
非声学PVB是一种可在Butacite商品名下购自杜邦公司(E.I.DuPont de Nemours and Company(DuPont))的市售产品。适合于本文中使用的Ionoplast树脂是乙烯和不饱和羧酸的共聚物(包括三元共聚物)，其中至少该共聚物中酸基的一部分已经中和成该酸的盐形式。适合于本发明中使用的Ionoplast树脂的挤塑片材可以在SentryGlasPlus(SGP)的商品名下购自杜邦公司。
聚酯薄膜(PET)是也可以市购的众所周知聚合物薄膜。适合于本文中使用的PET还可以包含一个硬涂层例如一种耐磨蚀聚硅氧烷材料或一种如美国专利申请序列号No.10/925,842中所述的低聚物涂层在其表面之一上。有聚硅氧烷涂层的PET可购自杜邦公司。在PET和其它聚合物例如PVB和SGP的层压体中，惯常上可以通过某一处理步骤例如火焰处理来提高PET对其它聚合物的粘合力。在本发明的实施中，在使用惯常层压方法将这些层层压之前要么对该PET火焰处理要么将PRIMER施用到该不类似聚合物的任意表面上，可以改善PET对其余任何一种聚合物的粘合力。使用PRIMER来改善PET对PVB的粘合可以消除为得到这些聚合物之间的适当粘合而对火焰处理的需要。
在一种实施方案中，可以使用该PET来使有低增塑剂含量(＜15pph份)-因而有较高模量-的僵硬PVB粘附到“正常”PVB和/或粘附到本文中定义的其它聚合物夹层材料上。
在一种特别好的实施方案中，本发明的隔音层压体包含至少一层高度增塑了至少一种增塑剂或增塑剂混合物的隔音(声学)PVB。在这种实施方案中，该增塑剂是以约40pph～约50pph份PVB的数量包括在内的。较好，该夹层的增塑量是约41pph～约49pph、更好是约42pph～约49pph、最好是约44pph～约47pph。在一种好得多的实施方案中，该隔音PVB是用一种增塑剂高度增塑的。可用于本发明实施的PVB描述于美国专利申请序号10/519,661，该专利申请全文列为本文参考文献。
用于本发明实施的隔音(声学)PVB可以当与该层压体的其它成分组合时能提供所希望的声学效果的任何厚度使用。然而，较好，所使用的PVB有约15密耳～约90密耳范围内的厚度。更好，该隔音PVB的厚度在约1密耳～约60密耳范围内、甚至更好在约10密耳～约40密耳范围内。最好，该隔音PVB的厚度在约15密耳～约40密耳范围内。不同厚度的多枚PVB片材可以叠在一起，以得到一种有所希望的厚度的隔音PVB叠。
适合用于本发明实施的增塑剂是惯常地与PVB一起使用的任何一种增塑剂。例如，可用于制备有增塑PVB的惯常增塑剂包括如下增塑剂：聚乙二醇的二酯例如二(2-乙基己酸)三甘醇酯(3GO)、二庚酸四甘醇酯(4G7)、二(2-乙基丁酸)三甘醇酯、和己二酸二己酯。对于在高度增塑PVB中的使用来说，最好的是4G7。
较好，该增塑剂是就声学PVB而言可以本文中以上所述数量与羟基值(OH值)约17～约23的PVB兼容(即，与该夹层形成一个单一相)者。较好，本发明的PVB的OH值为约18～约21、更好该OH值是约18～约19.5、最好约18～约19。对于在本发明的实施例中的使用来说，特别好的是可与有任何羟基值较好范围的PVB兼容者。
一般来说，本发明的层压体可以用于建筑学应用以及运输器应用。例如，本发明的层压体可以用来作为：建筑物的窗；门；挡板；防风窗；防弹玻璃装配；汽车中的侧窗、夜间顶开窗、白天顶开窗和风挡；飞机和火车的窗户；及其它应用，其中隔音层压玻璃装配会是所希望的。
本发明的声学层压体可以与装饰性夹层组合，以产生除掺入设计、图表、颜色、或其它装饰性影像外还能减声透射的玻璃装配。
                        实施例
这些实施例和比较例是只为说明目的而提供的，且无意以任何一种与本说明书所提供的教诲不一致的方式限制本发明的范围。
有以下给出的结构的层压体是使用惯常真空胎法以135℃、200psi和30分钟的高压釜循环制造的。
测试方法
损失因子(η)测定
损失因子是从一种玻璃梁样品的输入阻抗测量确定的。将一枚玻璃层体样本(25mm×300mm)在其中心放置到一个冲击钮(15mm直径)上，并以一种氰基丙烯酸胶固定到它上面。该冲击钮支撑于一个阻抗头上，后者用来将所测量的力经由该冲击钮注入该样本中。使用一种0～5000Hz的白噪音型力注入该样本。然后使用下式计算该损失因子：
η＝Δfi/fresi，
式中Δfi是其阻抗比最大阻抗小3dB的共振曲线上频率(fresi)之间的频率差。该样本在测定之前和期间固定在一个有所希望设定温度的环境室中。该阻抗头连接一个阻尼延迟器，后者连接一个功率放大器，该放大器连接一个噪音发生器。该阻抗是由一台FFT分析仪/计算机装置测量的。该方法和装置的详细描述见ISO/PDPAS 16940(published 7/16/02)：″Glass in Building-Glazing and Airborne SoundInsulation-Measurement of the Mechanical Impedance ofLaminated Glass″，该文列为本文参考文献。
实施例1
玻璃/离聚物/PET/PVB/玻璃层压体是使用两面都涂有聚烯丙基胺底漆涂层的PET制备的。层压到该PET相反表面上的是各为30密耳厚PVB夹层(BE-1028 Butacite，可购自杜邦公司)和60密耳厚SentryGlasPlus ionoplast夹层(可购自杜邦公司)的一枚片材。该PET片材是6.5～7.0密耳厚。计算损失因子并报告于表1中。
比较例1(C1)
遵照实施例1的程序，所不同的是本实例的层压体包括2层离聚物夹层和该PET层。计算损失因子并报告于表1中。
比较例2(C2)
构建一种结构为玻璃/90密耳离聚物/玻璃的层压体并测定其损失因子。结构报告于表1中。
比较例3(C3)
构建一种结构为玻璃/90密耳PVB/玻璃的层压体并测定其损失因子。结果报告于表1中。
比较例4(C4)
构建一种结构为玻璃/90密耳声学PVB/玻璃的层压体并测定其损失因子。结果报告于表1中。
实施例2
遵照实施例1的程序，所不同的是构建一种结构为玻璃/60密耳离聚物/PET/40密耳声学PVB/玻璃的层压体并测定其损失因子。结果报告于表1中。
实施例3
遵照实施例2的程序，所不同的是构建一种结构为玻璃/60密耳离聚物/PET/30密耳声学PVB/玻璃的层压体并测定其损失因子。结构报告于表1中。
实施例4
遵照实施例3的程序，所不同的是构建一种结构为玻璃/60密耳PVB/PET/30密耳PVB/玻璃的层压体并测定其损失因子。结果报告于表1中。
实施例5
遵照实施例4的程序，所不同的是构建一种结构为玻璃/60密耳声学PVB/PET/30密耳声学PVB/玻璃的层压体并测定其损失因子。结果报告于表1中。
实施例6
遵照实施例5的程序，所不同的是构建一种结构为玻璃/60密耳PVB/PET/30密耳声学PVB玻璃的层压体并测定其损失因子。结果报告于表1中。
实施例7
遵照实施例6的程序，所不同的是构建一种结构为玻璃/60密耳彩色PVB/PET/40密耳声学PVB/玻璃的层压体并测定其损失因子。结果报告于表1中。
比较例5(C5)
构建一种结构为玻璃/40密耳声学PVB/玻璃的层压体并测定其损失因子。结果报告于表1中。
比较例6(C6)
构建一种结构为玻璃/30密耳声学PVB/玻璃的层压体并测定其损失因子。结果报告于表1中。
  实施例                                        表1不同频率(Hz)时的损失因子(20℃)
  260   1000   1500   2500   3500   4500   5000   5500   6000   6500
  1   0.058   0.062   0.064   0.074   0.077   0.072   0.070
  2   0.109   0.151   0.166   0.174   0.170   0.163   0.163   0.163   0.162   0.162
  3   0.088   0.121   0.138   0.159   0.159   0.146
  4   0.084   0.130   0.150   0.170   0.178   0.178
  5   0.332   0.323   0.329   0.321   0.290   0.247   0.219
  6   0.194   0.269   0.279   0.285   0.271   0.260   0.255   0.252   0.248
  7   0.204   0.272   0.272   0.270   0.262   0.260   0.255   0.246   0.240
  C1   0.048   0.028   0.018   0.021   0.028   0.038   0.043
  C2   0.044   0.029   0.021   0.024   0.028   0.026   0.024   0.025   0.027   0.028
  C3   0.096   0.134   0.153   0.181   0.189   0.184
  C4   0.255   0.294   0.291   0.283   0.275   0.253   0.243   0.232
  C5   0.204   0.270   0.270   0.269   0.264   0.252   0.243   0.237
  C6   0.185   0.260   0.260   0.261   0.270   0.269   0.266   0.261

Claims (15)

1.一种隔音层压体物品，包含：在复合聚合物夹层中的至少三(3)个聚合物层，其中该复合夹层中至少一层是一种聚酯(PET)聚合物，它配置于至少2个与该PET层不类似的聚合物层之间，且其中该不类似聚合物是选自下列一组的聚合物：聚乙烯醇缩丁醛(PVB)；ionoplast树脂(离聚物)；聚氨酯(PU)；乙烯-乙酸乙烯酯共聚物(EVA)；聚氯乙烯；聚碳酸酯、聚缩醛；乙烯酸共聚物，包括乙烯酸三元共聚物(酸共聚物)；和聚烯烃，包括聚乙烯和聚丙烯。
2.权利要求1的层压体，其中该不类似聚合物是选自下列一组的聚合物：PVB；PU；离聚物；和酸共聚物。
3.权利要求2的层压体，其中该不类似聚合物中至少一种是PVB。
4.权利要求3的层压体，其中这些层中至少一层是声学PVB。
5.权利要求4的层压体，其中这些不类似聚合物中至少一种是一种离聚物。
6.权利要求5的层压体，其中该复合夹层中的不类似聚合物层选自：声学PVB和离聚物。
7.权利要求6的层压体，其中该层压体有至少约10磅/英寸2的粘合强度。
8.权利要求7的层压体，其中该层压体未经火焰处理。
9.权利要求8的层压体，其中该PET层包含一个烯丙基胺涂层，该涂层在与至少一个不类似聚合物表面接触的至少一个表面上。
10.一种隔音层压体物品，包含在复合聚合物夹层中至少三(3)个聚合物层，其中：(1)该复合夹层中至少一层是一种聚酯(PET)聚合物，该层配置于至少2个与该PET层不类似的聚合物层之间；(2)该PET层包含在与至少一个不类似聚合物表面接触的至少一个表面上的烯丙基胺涂层；(3)该复合夹层中的不类似聚合物层是要么声学PVB和/或离聚物；和(4)该层压体在50～10,000Hz范围内在20℃测定的损失因子为至少约0.080。
11.一种物品，包含权利要求1的层压体。
12.权利要求11的物品，其中该物品是一种汽车。
13.权利要求12的物品，其中该层压体是汽车的风挡、侧窗、夜间顶开窗、或白天顶开窗。
14.权利要求11的物品，其中该物品是一种建筑物。
15.权利要求14的物品，其中该层压体是一种窗、门、地板、天花板、楼梯、墙、挡板、或其它结构性建筑物部件。
CNA2005800314563A 2004-09-20 2005-09-20 减少声透射用玻璃层压体 Pending CN101031419A (zh)

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