U.S. patent application number 15/226261 was filed with the patent office on 2016-11-24 for interlayer film for laminated glass and laminated glass.
The applicant listed for this patent is Sekisui Chemical Co., Ltd.. Invention is credited to Jiro Miyai.
Application Number | 20160341960 15/226261 |
Document ID | / |
Family ID | 38693870 |
Filed Date | 2016-11-24 |
United States Patent
Application |
20160341960 |
Kind Code |
A1 |
Miyai; Jiro |
November 24, 2016 |
INTERLAYER FILM FOR LAMINATED GLASS AND LAMINATED GLASS
Abstract
It is an object of the present invention to provide an
interlayer film for a laminated glass excellent in a
sound-insulating property, which is preferably usable for a head up
display and the like wherein a driver can look at the front view
and an instrument display simultaneously without requiring to look
down, and to provide a laminated glass. The present invention is
directed to interlayer film for a laminated glass, which comprises
at least a pair of protection layers and a sound-insulating layer
sandwiched between the pair of the protection layers, and which has
a wedge shape as a cross-sectional shape, a wedge angle e of 0.1 to
0.7 mrad, the maximum thickness of 2000 .mu.m or thinner, and the
minimum thickness of 400 .mu.m or thicker, the minimum thickness of
the sound-insulating layer being 20 .mu.m or thicker.
Inventors: |
Miyai; Jiro; (Koka-shi,
JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Sekisui Chemical Co., Ltd. |
Osaka-shi |
|
JP |
|
|
Family ID: |
38693870 |
Appl. No.: |
15/226261 |
Filed: |
August 2, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14715774 |
May 19, 2015 |
9427932 |
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15226261 |
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14193458 |
Feb 28, 2014 |
9067386 |
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14715774 |
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13230400 |
Sep 12, 2011 |
8695756 |
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14193458 |
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12983376 |
Jan 3, 2011 |
8033360 |
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13230400 |
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11883177 |
Aug 31, 2007 |
7886871 |
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PCT/JP2007/059759 |
May 11, 2007 |
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12983376 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 27/06 20130101;
G10K 11/168 20130101; B32B 27/42 20130101; B32B 2307/412 20130101;
Y10T 428/24612 20150115; G02B 27/0101 20130101; B32B 27/30
20130101; B32B 3/263 20130101; B32B 2605/08 20130101; B32B 17/10853
20130101; B32B 27/08 20130101; B32B 2307/102 20130101; G02B
2027/0121 20130101; Y10T 428/3163 20150401; B32B 17/10 20130101;
B32B 17/10036 20130101; B32B 2457/20 20130101; B32B 17/10761
20130101; Y10T 428/24479 20150115; B32B 17/06 20130101; B32B 27/306
20130101; E04B 1/88 20130101; Y10T 428/31627 20150401; Y10T
428/24967 20150115; B32B 17/10568 20130101; G02B 2027/012 20130101;
G02B 27/01 20130101 |
International
Class: |
G02B 27/01 20060101
G02B027/01; B32B 17/10 20060101 B32B017/10; G10K 11/168 20060101
G10K011/168; B32B 27/30 20060101 B32B027/30; B32B 27/42 20060101
B32B027/42; B32B 3/26 20060101 B32B003/26; B32B 27/08 20060101
B32B027/08 |
Foreign Application Data
Date |
Code |
Application Number |
May 12, 2006 |
JP |
2006-134200 |
Claims
1. An interlayer film for a laminated glass, which comprises at
least a pair of protection layers and a sound-insulating layer
sandwiched between the pair of the protection layers, and which has
a wedge shape as a cross-sectional shape, a wedge angle .theta. of
0.1 to 0.7 mrad, the maximum thickness of 2000 pm or thinner, and
the minimum thickness of 400 .mu.m or thicker, the minimum
thickness of the sound-insulating layer being 20 .mu.m or
thicker.
2. The interlayer film for a laminated glass according to claim 1,
which further comprises a shape assisting layer laminated on at
least one layer of the pair of the protection layers.
3. The interlayer film for a laminated glass according to claim 1,
wherein the protection layer, and/or the sound-insulating layer
contain a heat-insulating agent
4. The interlayer film for a laminated glass according to claim 2,
wherein the shape assisting layer contains a heat-insulating
agent.
5. A laminated glass, which is obtained by using the interlayer
film for a laminated glass according to claim 1.
6. A laminated glass, which is obtained by using the interlayer
film for a laminated glass according to claim 2.
7. A laminated glass, which is obtained by using the interlayer
film for a laminated glass according to claim 3.
8. A laminated glass, which is obtained by using the interlayer
film for a laminated glass according to claim 4.
Description
TECHNICAL FIELD
[0001] The present invention relates to an interlayer film for a
laminated glass excellent in a sound-insulating property, which is
preferably usable for a head up display and the like wherein a
driver can look at the front view and an instrument display
simultaneously without requiring to look down, and relates to a
laminated glass.
BACKGROUND ART
[0002] As so-called front glass, generally laminated glass composed
of two opposed plate-like glass sheets and an interlayer film for a
laminated glass sandwiched between the glass sheets has been used
for the front face of an automobile, an aircraft or the like.
[0003] In recent years, from a viewpoint of safety improvement,
with respect to, for example, a front glass for an automobile, it
has been highly required to display an instrument display such as a
speed information, which is automotive driving data, as a head up
display (HUD) in the same visible field as the front glass.
[0004] Various kinds of HUD mechanisms have been developed so far.
For example, there is a HUD mechanism whose HUD display part is not
in the front glass surface and by which the speed information and
the like transmitted from a control unit is reflected to the front
glass from a display unit on an instrumental panel to enable a
driver to see the information at the same position as the front
glass (that is, in the same visible field). For such a mechanism,
since the laminated glass composing the front glass comprises two
parallel glass sheets, there is a defective point that the
instrument display reflected in the visible field of the driver is
seen double.
[0005] To deal with such a problem, Patent Document 1 discloses a
laminated glass using an interlayer film for a laminated glass with
a wedge shape having a prescribed wedge angle.
[0006] Such a laminated glass enables a convergence of the
instrument display reflected by one glass sheet and the instrument
display reflected by the other glass sheet upon one point in the
visible field of the driver by adjusting the wedge angle, and the
laminated glass can solve the conventional problem that the
instrument display is seen double, and the driver's visible field
is never interfered.
[0007] However, such a laminated glass has a problem of inferior
sound-insulating property in particular. Patent Document 1:
Japanese Kokai Publication Hei-4-502525
DISCLOSURE OF THE INVENTION
Problems to be Solved by the Invention
[0008] In view of the above-mentioned state of the art, the present
invention aims to provide an interlayer film for a laminated glass
excellent in a sound-insulating property, which is preferably
usable for a head up display and the like wherein a driver can look
at the front view and an instrument display simultaneously without
requiring to look down, and aims to provide a laminated glass.
Means for Solving the Problems
[0009] The present invention provides interlayer film for a
laminated glass, which comprises at least a pair of protection
layers and a sound-insulating layer sandwiched between the pair of
the protection layers, and which has a wedge shape as a
cross-sectional shape, a wedge angle 0 of 0.1 to 0.7 mrad, the
maximum thickness of 2000 .mu.m or thinner, and the minimum
thickness of 400 .mu.m or thicker, the minimum thickness of the
sound-insulating layer being 20 .mu.m or thicker.
[0010] Hereinafter, the present invention will be described in
detail.
[0011] The present inventors made various investigations concerning
causes of the inferiority of the sound-insulating property of the
laminated glass using the interlayer film for a laminated glass
with a wedge shape and accordingly have found that since the
interlayer film for a laminated glass has a wedge angle, the
thickness of the end forming the wedge angle is extremely thin as
compared with the other end and sound vibration is transmitted to
the inside of a vehicle through the thin portion. Further, the
inventors of the present invention have found that the problem that
the instrument display reflected to the visible field of a driver
is seen double cannot be solved only by making the thickness of the
end forming the edge angle in the interlayer film for a laminated
glass thick enough not to transmit the sound vibration. Therefore,
the inventors of the present invention have made further
investigations to find that an interlayer film for a laminated
glass having a sound-insulating layer and a protection layer with
prescribed thickness and having a wedge angle in a prescribed range
and a specified shape overcomes the problems in terms of the
lightweight, cost and the like, has sufficient sound-insulating
property and penetration resistance, enables a driver to
simultaneously see the front view, a speed display and the like
with no need for the driver to look down, and is preferably usable
for a head up display. These findings have now led to completion of
the present invention.
[0012] An interlayer film for a laminated glass of the present
invention comprises at least a pair of protection layers and a
sound-insulating layer sandwiched between the pair of the
protection layers.
[0013] The minimum thickness of the sound-insulating layer is 20
.mu.m in the lower limit. If it is thinner than 20 .mu.m,
sufficient sound-insulating property cannot be obtained. The lower
limit is preferably 30 .mu.m and more preferably 40 .mu.m. The
upper limit is preferably 300 .mu.m and more preferably 200
.mu.m.
[0014] As the thickness of the sound-insulating layer becomes
thicker, a higher sound-insulating property can be obtained. The
cross-sectional shape of the sound-insulating layer may be a wedge
shape in consideration of the easiness in terms of formation and
the like. In the case where the sound-insulating layer of the
interlayer film for a laminated glass has a wedge shape, it has an
excellent defoaming property of preventing foaming in the laminated
glass.
[0015] In this description, the wedge shape means a shape which is
wide in one end and becomes narrower toward the other end.
Practical examples of the shape may be a trapezoidal shape and a
triangular shape.
[0016] The sound-insulating layer may have partially a colored
band.
[0017] The colored band can be obtained, for example, by inserting
a polyvinyl acetal resin mixed with a coloring agent in a layer and
extrusion-molding the resin at the time of extrusion-molding the
sound-insulating layer.
[0018] The sound-insulating layer is not particularly limited,
however it is preferably to form the layer, for example, by using a
plasticizer and a polyvinyl acetal resin.
[0019] The plasticizer is not particularly limited and may include,
for example, organic plasticizers such as monobasic organic acid
esters and polybasic organic acid esters; and organic phosphoric
acid ester plasticizers such as organic phosphoric acid esters and
organic phosphorous acid esters.
[0020] The monobasic organic acid ester plasticizers are not
particularly limited and may include, for example, glycol esters
obtained by reaction with glycols such as triethylene glycol,
tetraethylene glycol, and tripropylene glycol and monobasic organic
acids such as butyric acid, isobutyric acid, caproic acid,
2-ethylbutyric acid, heptylic acid, n-octylic acid, 2-ethylhexylic
acid, pelargonic acid (n-nonylic acid), and decylic acid. Among
them, triethylene glycol esters such as triethylene glycol
dicaproate, triethylene glycol di-2-ethylbutanoate, triethylene
glycol di-n-octanoate, triethylene glycol di-2-ethylhexanoate (3GO)
are preferable.
[0021] The polybasic organic acid ester plasticizers are not
particularly limited and may include, for example, esters obtained
by reaction of straight chain or branched alcohols having 4 to 8
carbon atoms and polybasic organic acids such as adipic acid,
sebacic acid, and azelaic acid. Among them, dibutyl sebacate,
dioctyl azelate, and dibutylcarbitol adipate are preferable.
[0022] The organic phosphoric acid ester plasticizers are not
particularly limited and may include, for example, tributoxyethyl
phosphate, isodecylphenyl phosphate, and triisopropyl
phosphate.
[0023] Among the plasticizers, triethylene glycol
di-2-ethylbutanoate and triethylene glycol di-2-ethylhexanoate
(3GO) are preferably usable in particular.
[0024] The content of the plasticizer in the sound-insulating layer
is not particularly limited, however since a higher
sound-insulating property can be obtained by adding a large
quantity of a plasticizer and thereby softening the resin layer and
absorbing the vibration of sound, it is preferably 40 parts by
weight in the lower limit and 80 parts by weight in the upper limit
to 100 parts by weight of a polyvinyl acetal resin. If it is less
than 40 parts by weight, the sound-insulating property for the
sound in a range about 5000 Hz may sometimes become insufficient
and if it exceeds 80 parts by weight, bleeding out of the
plasticizer occurs to lower the transparency and the adhesive
property of the interlayer film for a laminated glass and the
optical distortion of the obtained laminated glass may become
significant in some cases. It is more preferably 50 parts by weight
in the lower limit and 70 parts by weight in the upper limit.
[0025] The polyvinyl acetal resin is not particularly limited,
however the sound-insulating layer contains a large quantity of the
plasticizer as described above, and therefore, the polyvinyl acetal
resin is preferable to have high affinity even for a large quantity
of the plasticizer.. Particularly preferable examples to be used
are a polyvinyl acetal resin having an acetal group having 4 to 5
carbon atoms and having an acetylation .degree of 4 to 30% by mole,
a polyvinyl acetal resin having an acetal group having 6 to 10
carbon atoms, and a polyvinyl acetal resin having an acetalization
degree of 70 to 85% by mole.
[0026] The polyvinyl acetal resin can be obtained by acetalization
of polyvinyl alcohol with aldehyde and generally includes an acetal
group, an acetyl group, and a hydroxy group as side chains in an
ethylene chain, which is a main chain.
[0027] The average polymerization degree of the polyvinyl alcohol,
which is a raw material for producing the polyvinyl acetal resin,
is preferably 200 in the lower limit and 5000 in the upper limit.
If it is lower than 200, the interlayer film for a laminated glass
may sometimes be inferior in the penetration resistance and if it
exceeds 5000, the strength of the laminated glass may sometimes
become too high to use the glass for a front glass for a vehicle.
It is more preferably 500 in the lower limit and 4000 in the upper
limit and even more preferably 1000 in the lower limit and 3500 in
the upper limit.
[0028] An aldehyde having 4 to 5 carbon atoms to be used for
producing the polyvinyl acetal resin having an acetal group having
4 to 5 carbon atoms is not particularly limited and may include,
for example, n-butyraldehyde, isobutyraldehyde, and valeraldehyde.
These aldehydes may be used alone or two or more of them may be
used in combination. Among them, n-butyraldehyde and
isobutyraldehyde are preferable to be used and n-butyraldehyde is
even more preferable to be used in particular. Use of
n-butyraldehyde strengthens the adhesive strength between
neighboring layers. Further, resins may be synthesized in the same
methods as those for producing commonly used polyvinyl butyral
resin.
[0029] With respect to the polyvinyl acetal resin having an acetal
group having 4 to 5 carbon atoms, the acetylation degree is
preferably 4% by mole in the lower limit and 30% by mole in the
upper limit. If it is lower than 4% by mole, the sound-insulating
property is not exhibited sufficiently in some cases and if it
exceeds 30% by mole, the reaction ratio of the aldehyde is
considerably lowered in some cases.
[0030] It is more preferably 8% by mole in the lower limit and 24%
by mole in the upper limit and even more preferably 10% by mole in
the lower limit.
[0031] The acetylation degree is a mole fraction calculated by
dividing the average value of the quantity of ethylene groups to
which the acetyl group is bonded by the total quantity of ethylene
groups in the main chain.
[0032] With respect to the polyvinyl acetal resin having an acetal
group having 4 to 5 carbon atoms, the acetalization degree is
preferably 40% by mole in the lower limit and 69% by mole in the
upper limit. If it is lower than 40% by mole, the compatibility for
the plasticizer is worsened to make it impossible to add a
necessary amount of the plasticizer to exhibit the sound-insulating
property in some cases. On the other hand, a polyvinyl acetal resin
having the acetalization degree exceeding 69% by mole is inferior
in the production efficiency, and becomes costly. It is more
preferably 50% by mole in the lower limit and 68% by mole in the
upper limit.
[0033] With respect to the polyvinyl acetal resin having an acetal
group having 4 to 5 carbon atoms, a mixture of two or more kind
polyvinyl acetal resins obtained by acetalization of polyvinyl
alcohol with aldehydes having 4 carbon atoms or aldehydes having 5
carbon atoms. Alternatively, a polyvinyl acetal resin obtained by
acetalization of an aldehyde mixture containing an aldehyde other
than the aldehyde having 4 to 5 carbon atoms in a range of lower
than 30% by weight may be used.
[0034] An aldehyde having 6 to 10 carbon atoms to be used for
producing the polyvinyl acetal resin containing an acetal group
having 6 to 10 carbon atoms is not particularly and may include,
for example, aliphatic, aromatic, or alicyclic aldehydes such as
n-hexyl aldehyde, 2-ethylbutyraldehyde, n-heptaldehyde, n-octyl
aldehyde, n-nonyl aldehyde, n-decyl aldehyde, benzaldehyde, and
cinnamaldehyde. These aldehydes may be used alone or two or more of
them may be used in combination. Among them, aldehydes having 6 to
8 carbon atoms are preferably usable.
[0035] If the number of carbon atoms of the aldehyde exceeds 10,
the rigidity of the polyvinyl acetal to be obtained becomes low and
the sound-insulating property may be deteriorated in some
cases.
[0036] With respect to the polyvinyl acetal resin having an
acetalization degree of 70 to 85% by mole, the acetalization degree
is preferably 70% by mole in the lower limit and 85% by mole in the
upper limit. If it is lower than 70% by mole, the sound-insulating
property is not exhibited sufficiently in some cases and if it
exceeds 85% by mole, the reaction ratio of the aldehyde to be used
at the time of producing the polyvinyl acetal resin may be
considerably decreased in some cases. It is more preferably 72% by
mole in the lower limit and 82% by mole in the upper limit.
[0037] The acetalization degree is a mole fraction calculated by
dividing the average value of the quantity of ethylene groups to
which the acetal group is bonded by the total quantity of ethylene
groups in the main chain.
[0038] A production method of the polyvinyl acetal resin is not
particularly limited and may be, for example, a method for
obtaining a resin powder by dissolving polyvinyl alcohol in hot
water, keeping the obtained aqueous polyvinyl alcohol solution at a
prescribed temperature, adding the aldehyde and a catalyst to the
solution, promoting acetalization reaction, keeping the reaction
solution at a prescribed high temperature, and thereafter carrying
out steps of neutralization, washing with water, and drying.
[0039] The sound-insulating layer is sandwiched between a pair of
protection layers.
[0040] The protection layer prevents the adhesive property between
the interlayer film for a laminated glass and glass from lowering
because of bleeding out of a large quantity of the plasticizer
contained in the sound-insulating layer. Further, the protection
layer has a role to provide the penetration resistance to the
interlayer film for a laminated glass to be obtained. Further, the
protection layer also has a function of adjusting the shape of the
entire interlayer film for a laminated glass to be a wedge
shape.
[0041] The thickness of the protection layer may be adjusted in a
manner that the film thickness of the entire interlayer film for a
laminated glass is to be in a range as described below and is thus
not particularly limited.
[0042] The cross-sectional shape of the pair of the protection
layers is preferably the wedge shape or a combination of the wedge
shape and a rectangular shape.
[0043] The protection layer is not particularly limited, however it
preferably comprises a polyvinyl acetal resin containing a
plasticizer.
[0044] The polyvinyl acetal resin to be used for the protection
layer is not particularly limited and may be, for example, a
polyvinyl acetal resin having an acetylation degree of 3% by mole
or lower, 3 to 4 carbon atoms of an acetal group, and an
acetalization degree of 60 to 70% by mole.
[0045] The plasticizer to be used for the protection layer is not
particularly limited and the plasticizers same as those to be used
for the sound-insulating layer may be used.
[0046] The content of, the plasticizer in the protection layer is
not particularly limited, however it is preferably 25 parts by
weight in the lower limit and 55 parts by weight in the upper limit
to 100 parts by weight of the polyvinyl acetal resin. If it is
lower than 25 parts by weight, the adhesive property to the glass
may become insufficient in some cases. Further, if it exceeds 55
parts by weight, bleeding out occurs to lower the transparency and
the adhesive property of the interlayer film for a laminated glass
and the optical distortion of the obtained laminated glass may
become significant. It is more preferably 30 parts by weight in the
lower limit and 50 parts by weight in the upper limit.
[0047] Further, the protection layer may have partially a colored
band.
[0048] The colored band can be obtained by inserting a polyvinyl
acetal resin and the like mixed with a coloring agent in a layer
and extrusion-molding the resin at the time of extrusion-molding
the protection layer.
[0049] In order to adjust the convenience and the shape in the
production method, a shape assisting layer may be layered on at
least one layer of the pair of the protection layers.
[0050] The shape assisting layer is not particularly limited and
the resin same as that of the protection layer may be used.
[0051] The thickness of the shape assisting layer may be adjusted
in a manner that the film thickness, the wedge angle and the like
of the interlayer film for a laminated glass to be obtained are to
be in a range as described below.
[0052] The sound-insulating layer, the protection layer, and/or the
shape assisting layer may contain, if necessary, conventionally
known additives such as an ultraviolet ray absorbent, an adhesive
strength control agent, a photostabilizer, a surfactant, a flame
retardant, an antistatic agent, a moisture prevention agent, and a
coloring agent.
[0053] The sound-insulating layer, the protection layer, and/or the
shape assisting layer are preferable to contain a heat insulating
agent.
[0054] If the interlayer film for a laminated glass contains the
heat insulating agent in any one of the layers, the interlayer film
for a laminated glass is provided with an excellent heat insulating
property.
[0055] The heat insulating agent is not particularly limited and
may include, for example, inorganic heat insulating agents such as
tin-doped indium oxide, antimony-doped tin oxide, and lanthanum
hexaboride; and organic heat insulating agents such as copper
complex compounds and phthalocyanine-metal complexes.
[0056] Practical Examples of cross-sectional drawings of the
interlayer film for a laminated glass of the present invention
comprising at least the protection layers and the sound-insulating
layer may be those shown in the schematic drawings of FIGS. 1 to
4.
[0057] The interlayer film for a laminated glass shown in FIG. 1
comprises the sound-insulating layer 2 with a cross-sectional shape
of the rectangular shape sandwiched between the protection layers 1
with a cross-sectional shape of the wedge shape.
[0058] The interlayer film for a laminated glass shown in FIG. 2
comprises the sound-insulating layer 2 with a cross-sectional shape
of the wedge shape sandwiched between the protection layers 1 with
a cross-sectional shape of the wedge shape.
[0059] The interlayer film for a laminated glass shown in FIG. 3
comprises the sound-insulating layer 2 with a cross-sectional shape
of the rectangular shape sandwiched between the protection layer 1
with a cross-sectional shape of the wedge shape and the protection
layer 1 with a cross-sectional shape of the rectangular shape.
[0060] The interlayer film for a laminated glass shown in FIG. 4
comprises the sound-insulating layer 2 with a cross-sectional shape
of the rectangular shape sandwiched between the protection layers 1
with a cross-sectional shape of the rectangular shape and further a
shape assisting layer 3 with a cross-sectional shape of the wedge
shape laminated on the surface of one of the protection layer.
[0061] Among them, the interlayer film for a laminated glass shown
in FIG. 2 is preferably since it has an excellent defoaming
property of generating no foam at the time of producing a laminated
glass.
[0062] The interlayer film for a laminated glass of the present
invention comprising at least the protection layers and
sound-insulating layer has a wedge angle .theta. of the
cross-section of 0.1 mrad in the lower limit and 0.7 mrad in the
upper limit. The wedge angle .theta. of the cross-section of the
interlayer film for a laminated glass means an acute angle formed
at the crossing point of extended two sides as shown as the wavy
lines in the cross-sectional drawings of FIGS. 1 to 4.
[0063] If the wedge angle .theta. is lower than 0.1 mrad, an
instrument display for speed information and the like transmitted
from a control unit is seen double and thus cannot display well and
if it exceeds 0.7 mrad, the instrument display is seen double in
the visible field of a driver. It is more preferably 0.2 mrad in
the lower limit and 0.6 mrad in the upper limit
[0064] The maximum thickness of the interlayer film for a laminated
glass of the present invention is 2000 .mu.m in the upper limit.
The maximum thickness is the portion 4 as shown in FIG. 1.
[0065] If the maximum thickness exceeds 2000 .mu.m, the thickness
is too thick to install the laminated glass easily as the front
glass in a vehicular body in some cases. It is more preferably 1500
.mu.m in the upper limit.
[0066] The minimum thickness of the interlayer film for a laminated
glass of the present invention is 400 .mu.m in the lower limit. The
minimum thickness is the portion 5 as shown in FIG. 1.
[0067] If the minimum thickness is thinner than 400 .mu.m, it
becomes impossible to obtain a sufficient sound-insulating property
and the penetration resistance to impact becomes weak. It is more
preferably 500 .mu.m in the lower limit.
[0068] A method for producing the sound-insulating layer, the
protection layer, and the shape assisting layer is not particularly
limited and may be, for example, methods involving adding a
plasticizer and additives, added based on the necessity, to a
polyvinyl acetal resin, kneading the mixture, and molding the
mixture. The kneading method is not particularly limited and may
be, for example, methods using an extruder, a Plastograph, a
kneader, a Bumbury's mixer, a calender roll, or the like. Among
them, a method using an extruder is preferable since it is suitable
for continuous production.
[0069] A method for producing the interlayer film for a laminated
glass of the present invention comprising at least the
sound-insulating layers and protection layer is not particularly
limited and may be methods involving producing the protection
layers and the sound-insulating layer and thermally laminating the
layers; molding the protection layers and the sound-insulating
layer by co-extrusion; and molding the protection layers and the
sound-insulating layer by co-extrusion, layering the shape
assisting layer on the surface of at least one of the protection
layers, and thermally laminating the layers.
[0070] Since the cross-sectional shape of the interlayer film for a
laminated glass is formed in a wedge shape by combining at least
shapes of the sound-insulating layers and the protection layer, the
sound-insulating property is provided and the speed information and
the like transmitted from the control unit can be reflected on the
front glass from the display unit of a instrumental panel and
therefore, a driver can simultaneously see the front view, speed
display and the like without looking down and the interlayer film
for a laminated glass can be used preferably for a head up
display.
[0071] A laminated glass obtained using the interlayer film for a
laminated glass of the present invention is also an aspect of the
present invention.
[0072] The laminated glass of the present invention comprises at
least the interlayer film for a laminated glass of the present
invention sandwiched between a pair of glass sheets.
[0073] The glass sheets to be used are not particularly limited and
may be conventionally known transparent plate glass. Further,
organic glass of polycarbonate, polymethyl methacrylate or the like
may be used in place of inorganic glass.
[0074] A method for producing laminated glass of the present
invention is not particularly limited and conventionally known
methods can be employed.
[0075] It is preferable to sandwich only one interlayer film for a
laminated glass between a pair of glass sheets since the laminated
glass production is easy, however in terms of the properties and
functions such as stability, a plurality of interlayer films for a
laminated glass may be sandwiched between a pair of glass sheets to
produce a laminated glass.
EFFECTS OF THE INVENTION
[0076] According to the present invention, it is made possible to
provide an interlayer film for a laminated glass excellent in a
sound-insulating property, which is preferably usable for a head up
display and the like wherein a driver can look at the front view
and an instrument display simultaneously without requiring to look
down, and to provide a laminated glass.
BEST MODE FOR CARRYING OUT THE INVENTION
[0077] Hereinafter, the present invention will be described in
details with reference to examples, however the present invention
is not limited to these examples.
EXAMPLE 1
(1) Production of a Sound-Insulating Layer
[0078] A sound-insulating layer was produced by adding 65 parts by
weight of triethylene.glycol di-2-ethylhexanoate (3GO) as a
plasticizer to 100 parts by weight of a polyvinyl acetal resin
having an acetylation degree of 12% by mole, 4 as the number of
carbon atoms of the acetal group, and an acetalization degree of
65% by mole, sufficiently kneading the mixture by a mixing roll,
and extrusion-molding the mixture. The thickness of the
sound-insulating layer was as shown in Table 1.
(2) Production of a Protection Layer
[0079] A protection layer was produced by adding 38 parts by weight
of triethylene glycol di-2-ethylhexanoate (3GO) as a plasticizer to
100 parts by weight of a polyvinyl acetal resin having an
acetylation degree of 1% by mole, 4 as the number of carbon atoms
of the acetal group, and an acetalization degree of 68% by mole,
sufficiently kneading the mixture by a mixing roll, and
extrusion-molding the mixture.
(3) Production of an Interlayer Film for a Laminated Glass
[0080] The obtained sound-insulating layer was sandwiched between a
pair of protection layers and thermally laminated to produce an
interlayer film for a laminated glass with a cross-sectional shape
of the wedge shape. The thickness of the interlayer film for a
laminated glass and the wedge angle of the cross-section were as
shown in Table 1. The cross-sectional shape was as shown in FIG.
2.
EXAMPLE 2
[0081] A sound-insulating layer was produced by adding 65 parts by
weight of triethylene glycol di-2-ethylhexanoate (3GO) as a
plasticizer to 100 parts by weight of a polyvinyl acetal resin
having an acetylation degree of 1% by mole, 6 as the number of
carbon atoms of the acetal group, and an acetalization degree of
65% by mole, sufficiently kneading the mixture by a mixing roll,
and extrusion-molding the mixture. The thickness of the
sound-insulating layer was as shown in Table 1.
[0082] Thereafter, a protection layer was produced and successively
an interlayer film for a laminated glass was produced in the same
manner as Example 1. The thickness of the interlayer film for a
laminated glass and the wedge angle of the cross-section were as
shown in Table 1. The cross-sectional shape was as shown in FIG.
2.
Example 3
[0083] A sound-insulating layer was produced by adding 63 parts by
weight of triethylene glycol di-2-ethylhexanoate (3GO) as a
plasticizer to 100 parts by weight of a polyvinyl acetal resin
having an acetylation degree of 1% by mole, 4 as the number of
carbon atoms of the acetal group, and an acetalization degree of
78% by mole, sufficiently kneading the mixture by a mixing roll,
and extrusion-molding the mixture. The thickness of the
sound-insulating layer was as shown in Table 1.
[0084] Thereafter, a protection layer was produced and successively
an interlayer film for a laminated glass was produced in the same
manner as Example 1. The thickness of the interlayer film for a
laminated glass and the wedge angle of the cross-section were as
shown in Table 1. The cross-sectional shape was as shown in FIG.
2.
COMPARATIVE EXAMPLE 1
[0085] A sound-insulating layer was produced by adding 65 parts by
weight of triethylene glycol di-2-ethylhexanoate (3GO) as a
plasticizer to 100 parts by weight of a polyvinyl acetal resin
having an acetylation degree of 12% by mole, 4 as the number of
carbon atoms of the acetal group, and an acetalization degree of
65% by mole, sufficiently kneading the mixture by a mixing roll,
and extrusion-molding the mixture. The thickness of the
sound-insulating layer was as shown in Table 1.
[0086] Thereafter, a protection layer was produced and successively
an interlayer film for a laminated glass was produced in the same
manner as Example 1. The thickness of the interlayer film for a
laminated glass and the wedge angle of the cross-section were as
shown in Table 1. The cross-sectional shape was as shown in FIG.
2.
COMPARATIVE EXAMPLE 2
[0087] A sound-insulating layer was produced by adding 65 parts by
weight of triethylene glycol di-2-ethylhexanoate (3GO) as a
plasticizer to 100 parts by weight of a polyvinyl acetal resin
having an acetylation degree of 12% by mole, 4 as the number of
carbon atoms of the acetal group, and an acetalization degree of
65% by mole, sufficiently kneading the mixture by a mixing roll,
and extrusion-molding the mixture. The thickness of the
sound-insulating layer was as shown in Table 1.
[0088] Thereafter, a protection layer was produced and successively
an interlayer film for a laminated glass was produced in the same
manner as Example 1. The thickness of the interlayer film for a
laminated glass and the wedge angle of the cross-section were as
shown in Table 1. The cross-sectional shape was as shown in FIG.
2.
COMPARATIVE EXAMPLE 3
[0089] A sound-insulating layer was produced.by adding 65 parts by
weight of triethylene glycol di-2-ethylhexanoate (3GO) as a
plasticizer to 100 parts by weight of a polyvinyl acetal resin
having an acetylation degree of 12% by mole, 4 as the number of
carbon atoms of the acetal group, and an acetalization degree of
65% by mole, sufficiently kneading the mixture by a mixing roll,
and extrusion-molding the mixture. The thickness of the
sound-insulating layer was as shown in Table 1.
[0090] Thereafter, a protection layer was produced and successively
an interlayer film for a laminated glass was produced in the same
manner as Example 1. The thickness of the interlayer film for a
laminated glass and the wedge angle of the cross-section were as
shown in Table 1. The cross-sectional shape was as shown in FIG.
2.
COMPARATIVE EXAMPLE 4
[0091] A sound-insulating layer was produced by adding 65 parts by
weight of triethylene glycol di-2-ethylhexanoate (3GO) as a
plasticizer to 100 parts by weight of a polyvinyl acetal resin
having an acetylation degree of 12% by mole, 4 as the number of
carbon atoms of the acetal group, and an acetalization degree of
65% by mole, sufficiently kneading the mixture by a mixing roll,
and extrusion-molding the mixture. The thickness of the
sound-insulating layer was as shown in Table 1.
[0092] Thereafter, a protection layer was produced and successively
an interlayer film for a laminated glass was produced in the same
manner as Example 1. The thickness of the interlayer film for a
laminated glass and the wedge angle of the cross-section were as
shown in Table 1. The cross-sectional shape was as shown in FIG.
2.
<Evaluation>
[0093] The following evaluations were carried out for the
interlayer films for a laminated glass obtained in Examples 1 to 3
and Comparative Examples 1 to 4. The results are shown in Table
1.
(1) Sound-Insulating Property
[0094] Each sample obtained by cutting obtained laminated glass
into a size of 300 mm.times.25 mm was vibrated by a vibration
generating apparatus for a damping test (a vibrator G21-005D,
manufactured by Shinken Co., Ltd.) and the vibration property
obtained at that time was amplified by a mechanical impedance
amplifier (XG-81, manufactured by RION Co., Ltd.) and the vibration
spectrum was analyzed by an FFT spectrum analyzer (FFT analyzer
HP3582A, manufactured by Yokogawa Hewlett Packard).
[0095] A graph showing the relation between sound frequency (Hz)
and sound transmission loss (dB) at 20.degree. C. was produced from
the ratio of loss factor and the resonance frequency of the glass
measured in the manner to measure the minimum sound transmission
loss (TL value) around a sound frequency of 2000 Hz and the
evaluation was carried out based on the following standard. As the
TL value is higher, the sound-insulating property is higher. [0096]
.largecircle.: 35 dB or higher [0097] .times.: lower than 35
dB.
(2) Occurrence of Double Image
[0098] Each obtained laminated glass was disposed at a position of
a front glass and display information was reflected upon the
laminated glass from a display unit installed in a lower part and
occurrence of a double image at a prescribed position was confirmed
by eye observation and the evaluation was carried out based on the
following standard. [0099] .largecircle.: No double image was
confirmed. [0100] .times.: A double image was confirmed.
(3) Defoaming Property Evaluation
[0101] A laminate body was produced by sandwiching each interlayer
film for a laminated glass between two transparent float glass
plates (length 30 cm, width 30 cm, thickness 3 mm).
[0102] The obtained laminate body was put in a rubber bag and held
at a reduced pressure of -60 kPa (absolute pressure 16 kPa} for 10
minutes and heated in order that the temperature of the laminate
body reach 100.degree. C. and then taken out of the rubber bag.
Next, it was put in an autoclave and held at a temperature of
140.degree. C. and a pressure of 1.3 MPa for 10 minutes and then
taken out of the autoclave after the temperature of the inside of
the autoclave was decreased to 50.degree. C. In such a manner, a
laminated glass was produced.
[0103] The obtained laminated glass was heated in an oven at
200.degree. C. for 2 hours. Next, the laminated glass was taken out
of the oven and after 3 hours, the appearance of the laminated
glass was observed with eyes. The number of sheets of the laminated
glass in which foams with an outer diameter of 1 mm or larger were
formed was investigated. The number of the sheets of the laminated
glass to be used in the test was 20. As the number of the sheets in
which foams were formed was lower, the interlayer film for a
laminated glass was found having a more excellent defoaming
property. The results of the test were evaluated based on the
following standard. [0104] {circle around (.smallcircle.)}: One
sheet of laminated glass was found foaming. [0105] .largecircle.:
Four sheets of laminated glass were found foaming.
TABLE-US-00001 [0105] TABLE 1 Sound- Interlayer insulating film for
a layer laminated glass Evaluation Minimum Maximum Minimum Maximum
Cross- Occurrence thickness thickness thickness thickness Wedge
angle sectional TL value of Defoaming (.mu.m) (.mu.m) (.mu.m)
(.mu.m) (mrad) shape (dB) double image property Example 1 100 150
800 1200 0.40 FIG. 2 37 .largecircle. .largecircle.
.circleincircle. Example 2 100 150 700 1100 0.30 FIG. 2 36
.largecircle. .largecircle. .circleincircle. Example 3 80 200 600
1200 0.58 FIG. 2 35 .largecircle. .largecircle. .circleincircle.
Comparative 100 120 700 800 0.08 FIG. 2 37 .largecircle. X
.circleincircle. Example 1 Comparative 15 30 800 1200 0.40 FIG. 2
31 X .largecircle. .circleincircle. Example 2 Comparative 20 30 300
450 0.30 FIG. 2 31 X .largecircle. .circleincircle. Example 3
Comparative 100 150 800 1600 0.80 FIG. 2 37 .largecircle. X
.circleincircle. Example 4
EXAMPLES 4 AND 5
[0106] Each interlayer film for a laminated glass was produced in
the same manner as Example 1, except that the cross-sectional shape
was adjusted to be the wedge shape as shown in FIG. 1 and the
thickness of the sound-insulating layer, the thickness of the
interlayer film for a laminated glass, and the wedge angle were
changed as shown in Table 2.
COMPARATIVE EXAMPLES 5 AND 6
[0107] Each interlayer film for a laminated glass was produced in
the same manner as Example 1, except that the cross-sectional shape
was adjusted to be the wedge shape as shown in FIG. 1 and the
thickness of the sound-insulating layer, the thickness of the
interlayer film for a laminated glass, and the wedge angle were
changed as shown in Table 2.
<Evaluation>
[0108] With respect to each interlayer film for a laminated glass
obtained in Examples 4 and 5 and Comparative Examples 5 and 6, same
evaluations carried out for Examples 1 to 3 and Comparative
Examples 1 to 4 were carried out. The results are shown in Table
2.
TABLE-US-00002 TABLE 2 Sound- Interlayer insulating film for a
layer laminated glass Evaluation Minimum Maximum Minimum Maximum
Cross- Occurrence thickness thickness thickness thickness Wedge
angle sectional TL value of Defoaming (.mu.m) (.mu.m) (.mu.m)
(.mu.m) (mrad) shape (dB) double image property Example 4 100 100
800 1200 0.40 FIG. 1 36 .largecircle. .largecircle. .largecircle.
Example 5 110 110 600 1200 0.58 FIG. 1 35 .largecircle.
.largecircle. .largecircle. Comparative 100 100 800 890 0.08 FIG. 1
36 .largecircle. X .largecircle. Example 5 Comparative 15 15 800
1200 0.40 FIG. 1 30 X .largecircle. .largecircle. Example 6
EXAMPLE 6
[0109] An interlayer film for a laminated glass was produced in the
same manner as Example 1, except that the cross-sectional shape was
adjusted to be the wedge shape as shown in FIG. 3 and the thickness
of the sound-insulating layer, the thickness of the interlayer film
for a laminated glass, and the wedge angle were changed as shown in
Table 3.
COMPARATIVE EXAMPLE 7
[0110] An interlayer film for a laminated glass was produced in the
same manner as Example 1, except that the cross-sectional shape was
adjusted to be the wedge shape as shown in FIG. 3 and the thickness
of the sound-insulating layer, the thickness of the interlayer film
for a laminated glass, and the wedge angle were changed as shown in
Table 3.
<Evaluation>
[0111] With respect to each interlayer film for a laminated glass
obtained in Example 6 and Comparative Example 7, same evaluations
carried out for Examples 1 to 3 and Comparative Examples 1 to 4
were carried out. The results are shown in Table 3.
TABLE-US-00003 TABLE 3 Sound- Interlayer insulating film for a
layer laminated glass Evaluation Minimum Maximum Minimum Maximum
Wedge Cross- Occurrence thickness thickness thickness thickness
angle sectional TL value of Defoaming (.mu.m) (.mu.m) (.mu.m)
(.mu.m) (mrad) shape (dB) double image property Example 6 100 100
800 1200 0.40 FIG. 3 36 .largecircle. .largecircle. .largecircle.
wedge shape wedge shape protection protection layer: 350 layer: 750
rectangular shape rectangular shape protection layer: 350
protection layer: 350 Comparative 100 100 800 900 0.08 FIG. 3 36
.largecircle. X .largecircle. Example 7 wedge shape wedge shape
protection protection layer: 350 layer: 450 rectangular shape
rectangular shape protection layer: 350 protection layer: 350
EXAMPLES 7 AND 8
[0112] An interlayer film for a laminated glass was produced in the
same manner as Example 1, except that the cross-sectional shape was
adjusted to be the wedge shape as shown in FIG. 4 and the thickness
of the sound-insulating layer, the thickness of the interlayer film
for a laminated glass, and the wedge angle were changed as shown in
Table 4. The shape assisting layer was produced by using the resin
with the same composition as that of the resin used for producing
the protection layer in Example 1.
COMPARATIVE EXAMPLES 8 AND 9
[0113] An interlayer film for a laminated glass was produced in the
same manner as Example 1, except that the cross-sectional shape was
adjusted to be the wedge shape as shown in FIG. 4 and the thickness
of the sound-insulating layer, the thickness of the, interlayer
film for a laminated glass, and the wedge angle were changed as
shown in Table 4. The shape assisting layer was produced by using
the resin with the same composition as that of the resin used for
producing the protection layer in Example 1.
<Evaluation>
[0114] With respect to each interlayer film for a laminated glass
obtained in Examples 7 and 8 and Comparative Examples 8 and 9, same
evaluations carried out for Examples 1 to 3 and Comparative
Examples 1 to 4 were carried out. The results are shown in Table
4.
TABLE-US-00004 TABLE 4 Sound- Interlayer insulating film for a
layer laminated glass Evaluation Minimum Maximum Minimum Maximum
Wedge Cross- Occurrence thickness thickness thickness thickness
angle sectional TL value of Defoaming (.mu.m) (.mu.m) (.mu.m)
(.mu.m) (mrad) shape (dB) double image property Example 7 100 100
900 1300 0.40 FIG. 4 36 .largecircle. .largecircle. .largecircle.
wedge shape wedge shape protection protection layer: 200 layer: 200
rectangular shape rectangular shape protection protection layer:
200 layer: 200 shape assisting shape assisting layer: 400 layer:
800 Example 8 100 100 900 1550 0.58 FIG. 4 36 .largecircle.
.largecircle. .largecircle. wedge shape wedge shape protection
protection layer: 200 layer: 200 rectangular shape rectangular
shape protection protection layer: 200 layer: 200 shape assisting
shape assisting layer: 400 layer: 1050 Comparative 100 100 900 1100
0.08 FIG. 4 36 .largecircle. X .largecircle. Example 8 wedge shape
wedge shape protection protection layer: 200 layer: 200 rectangular
shape rectangular shape protection protection layer: 200 layer: 200
shape assisting shape assisting layer: 400 layer: 600 Comparative
15 15 900 1300 0.40 FIG. 4 30 X .largecircle. .largecircle. Example
9 wedge shape wedge shape protection protection layer: 200 layer:
200 rectangular shape rectangular shape protection protection
layer: 285 layer: 285 shape assisting shape assisting layer: 400
layer: 800
INDUSTRIAL APPLICABILITY
[0115] According to the present invention, it is made possible to
provide an interlayer film for a laminated glass excellent in a
sound-insulating property, which is preferably usable for a head up
display and the like wherein a driver can look at the front view
and an instrument display simultaneously without requiring to look
down, and to provide a laminated glass.
BRIEF DESCRIPTION OF THE DRAWINGS
[0116] FIG. 1 is a drawing schematically showing a cross-sectional
drawing of an interlayer film for a laminated glass of the present
invention.
[0117] FIG. 2 is a drawing schematically showing a cross-sectional
drawing of an interlayer film for a laminated glass of another
embodiment of the present invention.
[0118] FIG. 3 is a drawing schematically showing a cross-sectional
drawing of an interlayer film for a laminated glass of another
embodiment of the present invention.
[0119] FIG. 4 is a drawing schematically showing a cross-sectional
drawing of an interlayer film for a laminated glass of another
embodiment of the present invention.
EXPLANATION OF SYMBOLS
[0120] 1 a protection layer [0121] 2 a sound-insulating layer
[0122] 3 a shape assisting layer [0123] 4 the maximum thickness
[0124] 5 the minimum thickness
* * * * *