U.S. patent application number 16/385670 was filed with the patent office on 2019-08-08 for laminate structures with enhanced damping properties.
The applicant listed for this patent is CORNING INCORPORATED. Invention is credited to Michael Edward DeRosa, Jennifer Lynn Lyon, James Robert Matthews, Michael Lesley Sorensen, Arlin Lee Weikel.
Application Number | 20190240958 16/385670 |
Document ID | / |
Family ID | 56611612 |
Filed Date | 2019-08-08 |
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United States Patent
Application |
20190240958 |
Kind Code |
A1 |
DeRosa; Michael Edward ; et
al. |
August 8, 2019 |
LAMINATE STRUCTURES WITH ENHANCED DAMPING PROPERTIES
Abstract
Described herein are laminate structures with enhanced
sound-damping properties and mechanical properties. The laminates
are composed of an interlayer stucture disposed between a first
glass substrate and a second glass substrate, wherein the
interlayer is composed of a polymer layer designed such that sound
attenuation or damping by the laminate is optimized. The laminates
described herein may be used in vehicles or architectural panels.
In one or more embodiments, the laminate may be disposed in an
opening of a vehicle body. Where the vehicle body is an automobile,
the laminate could be used as a windshield, a side window, sunroof
or rear windshield. The body of some embodiments may include
railcar body, or an airplane body. In other embodiments, the
laminate may be used in architectural panels, which may include a
window, an interior wall panel, a modular furniture panel, a
backsplash, a cabinet panel, or an appliance panel.
Inventors: |
DeRosa; Michael Edward;
(Painted Post, NY) ; Lyon; Jennifer Lynn; (Painted
Post, NY) ; Matthews; James Robert; (Painted Post,
NY) ; Sorensen; Michael Lesley; (Waverly, NY)
; Weikel; Arlin Lee; (Mansfield, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CORNING INCORPORATED |
CORNING |
NY |
US |
|
|
Family ID: |
56611612 |
Appl. No.: |
16/385670 |
Filed: |
April 16, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15219664 |
Jul 26, 2016 |
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16385670 |
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62199285 |
Jul 31, 2015 |
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62339152 |
May 20, 2016 |
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62349425 |
Jun 13, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 17/10761 20130101;
C08F 226/06 20130101; B32B 2607/00 20130101; B32B 2250/03 20130101;
B64C 1/00 20130101; B32B 2255/26 20130101; B32B 17/10036 20130101;
C08L 33/08 20130101; Y10T 428/2495 20150115; C08F 220/30 20130101;
C08F 220/28 20130101; Y02T 50/40 20130101; B64C 2001/0072 20130101;
C08F 220/1811 20200201; C08L 33/10 20130101; C08F 220/18 20130101;
C08F 220/301 20200201; B32B 2509/00 20130101; B32B 2605/00
20130101; B64C 1/14 20130101; B32B 17/10743 20130101; B64D
2011/0046 20130101; Y02T 50/46 20130101; B32B 7/022 20190101; B32B
2307/102 20130101; B32B 2419/00 20130101; B32B 2479/00 20130101;
C08F 220/282 20200201; C08L 33/14 20130101; B32B 2307/732 20130101;
B32B 17/10119 20130101; C08F 220/285 20200201; B64C 1/066 20130101;
B32B 17/10137 20130101; Y10T 428/24967 20150115; B32B 7/02
20130101; Y02T 50/43 20130101 |
International
Class: |
B32B 17/10 20060101
B32B017/10; B32B 7/022 20060101 B32B007/022; C08L 33/14 20060101
C08L033/14; B32B 7/02 20060101 B32B007/02; B64C 1/14 20060101
B64C001/14; C08L 33/10 20060101 C08L033/10; C08F 220/28 20060101
C08F220/28; C08F 220/30 20060101 C08F220/30; C08F 226/06 20060101
C08F226/06; C08L 33/08 20060101 C08L033/08; B64C 1/06 20060101
B64C001/06 |
Claims
1. A polymer that is the polymerization product of a first
constituent and a second constituent with an optional crosslinking
agent, initiator, or combination thereof, wherein the first
constituent is one or more compounds having the structure I
##STR00002## wherein R.sup.1 is hydrogen or an alkyl group; R.sup.2
is an alkylene group; R.sup.3 is an alkyl group, a cycloalkyl
group, or an unsubstituted aryl group; and n is from 1 to 20, and
the second constituent is selected from the group consisting of
lauryl acrylate, laurylethoxylated(4) acrylate, 2-propylheptyl
acrylate, ethoxylatednonylphenol acrylate, caprolactone acrylate,
isooctyl acrylate, tridecylacrylate, phenoxyglycidyl acrylate,
laurloxyglycidyl acrylate, isobornylacrylate, tetrahydrofurfuryl
acrylate, stearyl acrylate, isodecyl acrylate,
trimethylcyclohexylacrylate, adamatylmethacrylate,
N-vinylcaprolactam, cyclic trimethylolpropane formal acrylate,
tetrahydrofurfuryl acrylate, or any combination thereof.
2. The polymer of claim 1, wherein the first constituent is
selected from the group consisting of phenoxyethoxyethylacrylate,
phenoxyethylacrylate, phenoxyethoxyethoxyethoxyethylacrylate,
ethoxyethoxyethylacrylate, or ethoxyethoxyethylacrylate.
3. The polymer of claim 1, wherein R.sup.1 is hydrogen and R.sup.2
is ethylene.
4. The polymer of claim 1, wherein R.sup.1 is hydrogen, R.sup.2 is
ethylene, and R.sup.3 is an aryl group.
5. The polymer of claim 1, wherein R.sup.1 is hydrogen, R.sup.2 is
ethylene, R.sup.3 is an unsubstituted phenyl group, and n is from 1
to 10.
6. The polymer of claim 1, wherein the first constituent is
phenoxyethoxyethylacrylate, phenoxyethoxyethoxyethoxyethylacrylate,
or a combination thereof.
7. The polymer of claim 1, wherein the first polymer is further at
least partially crosslinked with a crosslinking agent.
8. The polymer of claim 1, wherein the first constituent is
phenoxyethoxyethylacrylate, phenoxyethylacrylate,
phenoxyethoxyethoxyethoxyethylacrylate, ethoxyethoxyethylacrylate,
ethoxyethoxyethylacrylate, or any combination thereof and the
second constituent is isobornyl acrylate.
9. The polymer of claim 1, wherein the first constituent is
phenoxyethoxyethylacrylate, phenoxyethylacrylate,
phenoxyethoxyethoxyethoxyethylacrylate, ethoxyethoxyethylacrylate,
ethoxyethoxyethylacrylate, or any combination thereof and the
second constituent is trimethylcyclohexylacrylate.
10. The polymer of claim 1, wherein the first constituent is
phenoxyethoxyethylacrylate, phenoxyethylacrylate,
phenoxyethoxyethoxyethoxyethylacrylate, ethoxyethoxyethylacrylate,
ethoxyethoxyethylacrylate, or any combination thereof and the
second constituent is N-vinylcaprolactam.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation and claims the benefit of
priority under 35 U.S.C .sctn. 120 of U.S. application Ser. No.
15/219,664, filed on Jul. 26, 2016, which claims the benefit of
priority under 35 U.S.C. .sctn. 119 of U.S. Provisional Application
Ser. No. 62/199,285 filed on Jul. 31, 2015, U.S. Provisional
Application Ser. No. 62/339,152, filed on May 20, 2016, and U.S.
Provisional Application Ser. No. 62/349,425, filed on Jun. 13,
2016, the contents of which are relied upon and incorporated herein
by reference in their entirety.
BACKGROUND
[0002] Acoustic performance of lighter window laminates is below
that of thicker laminates of equivalent construction, which permits
the passage of sound and noise through the laminate. The frequency
of this sound or noise occurs from approximately 1,000 Hz to 10,000
Hz. This is relevant for vehicle windows, as this sound or noise is
in the range of human speech and is very prominent and distracting
to passengers. Therefore, it is desirable to have a material that
will absorb and dissipate mechanical frequencies in this range so
that external sound or noise can be attenuated.
[0003] Efforts have been made to address noise attenuation. For
example, improved noise attenuation has been achieved with an
acoustic grade of polyvinyl butyral PVB. Acoustic PVB (APVB)
consists of three layers of material: two outer layers of standard
PVB (SPVB) and a core layer of PVB in the middle that is
plasticized with triethylene glycol bis-2-ethylhexanoate. However,
even acoustic grade of PVB is not sufficient for some window
laminate designs and therefore even greater noise attenuation is
needed.
[0004] In many transportation applications, fuel economy is a
function of vehicle weight. It is desirable, therefore, to reduce
the weight of laminates for such applications without compromising
their strength and sound-attenuating properties. In view of the
foregoing, thinner laminates that possess or exceed the
sound-damping, durability, and breakage performance properties
associated with thicker, heavier laminates are desirable.
SUMMARY
[0005] Described herein are laminate structures with enhanced
sound-damping properties and mechanical properties. The laminates
are composed of an interlayer structure disposed between a first
glass substrate and a second glass substrate, wherein the
interlayer is composed of a polymer layer designed to optimize
sound attenuation or damping. The laminates described herein may be
used in vehicles, architectural panels or any application that
requires high strength but lightweight windows, which also dampen
or attenuate sound in the desirable frequency range. In one or more
embodiments, the laminate may be disposed in an opening of a
vehicle body. Where the vehicle body is an automobile, the laminate
could be used as a windshield, a side window, a sunroof, or a rear
windshield. The vehicle body of some embodiments may include a
railcar, an aircraft, or seacraft. In other embodiments, the
laminate may be used in architectural panels, which may include a
window, an interior wall panel, a modular furniture panel, a
backsplash, a cabinet panel, or an appliance panel.
[0006] A first aspect of this disclosure pertains to a laminate
comprising a first substrate, an interlayer structure and a second
substrate where the interlayer structure is disposed between the
first and second substrates. In one or more embodiments, the
interlayer structure comprises a first polymer. In one or more
embodiments, the interlayer structure comprises a first layer
comprising the first polymer, wherein the first layer is disposed
between a second layer and a third layer. In some embodiments, the
second layer and the third layer comprise the same polymeric
material. In some embodiments, the second layer and the third layer
comprise different polymeric materials from one another. In one or
more embodiments, either one or both of the second layer and the
third layer comprise a polymeric material selected from the group
consisting of polyvinyl butyral (PVB), ethylene-vinyl acetate (EVA)
and thermoplastic polyurethane (TPU), polyester (PE), and
polyethylene terephthalate (PET). In one or more specific
embodiments, the second layer and the third layer comprise
polyvinyl butyral (PVB).
[0007] In one or more embodiments, the first polymer comprises a
tan .delta. value greater than 1.0 at a temperature a range from
about -20.degree. C. to about 40.degree. C. and a frequency in a
range from about 1 Hz to about 20,000 Hz. In some embodiments, the
first polymer comprises a tan .delta. value greater than 1.0 at a
temperature in a range from about -20.degree. C. to about
40.degree. C. when measured at mechanical frequency of 1 Hz and a
heating rate of 2.degree. C./minute. In one or more embodiments,
the first polymer comprises a glass transition temperature, as
indicated by a peak in tan .delta., in a range from about 0.degree.
C. to about -20.degree. C. at a mechanical frequency of 1 Hz with a
heating rate of 2.degree. C./minute. In some embodiments, the first
polymer comprises a tan .delta. value greater than 1.0 at a
temperature of 20.degree. C. at a frequency in a range from about
1,000 Hz to about 20,000 Hz. In one or more embodiments, the first
polymer exhibits a tan .delta. value greater than 2.0 or from about
2.0 to about 4.0, at a temperature in a range from about
-20.degree. C. to about 40.degree. C. when measured at mechanical
frequency of 1 Hz and a heating rate of 2.degree. C./min. In one or
more embodiments, the first polymer comprises a tan .delta. value
in a range from about 2.0 to about 4.0 at a temperature in a range
from about -20.degree. C. to about 40.degree. C. and at a frequency
in a range from about 1,000 Hz to about 10,000 Hz. In one or more
embodiments, the first polymer has a tan .delta. value greater than
1.25 at all temperatures in a range from -20.degree. C. to about
40.degree. C. and at all frequencies in a range from about 100 Hz
to about 100,000 Hz.
[0008] In some embodiments, the first polymer may be described with
respect to a known acoustic PVB material having a core layer, or
more specifically to that core material. For example, in one or
more embodiments, the first polymer as having a tan .delta. value
greater than the core layer of acoustic PVB within a frequency
range of 1 Hz to 20,000 Hz. In some instances, the first polymer
has a tan .delta. value that is 1.2 to 4 times greater than the
core layer of acoustic PVB within a frequency range of 1,000 Hz to
20,000 Hz.
[0009] In one or more embodiments, the first polymer is produced by
the polymerization of one or more ethylenically unsaturated
compounds. In some instances, the first polymer is produced by the
polymerization of one or more monomers comprising an allyl
compound, a vinyl compound, an acrylate, a methacrylate, an
acrylamide, or a methacrylamide, or any combination thereof. In
some examples, the first polymer is the polymerization product of
two or more acrylate monomers. In one or more embodiments, the
first polymer is the polymerization product of phenoxyethylacrylate
and ethoxylated(8)nonylphenol acrylate. In one or more embodiments,
the first polymer is the polymerization product of
phenoxyethylacrylate and phenoxyethoxyethylacrylate.
[0010] In one or more embodiments, the first polymer is further at
least partially crosslinked with a crosslinking agent. Exemplary
crosslinking agents include a diacrylate compound or dimethacrylate
compound. Other exemplary crosslinking agents include a
polyalkylene oxide diacrylate compound or a polyalkylene oxide
dimethacrylate compound. In one or more embodiments, the
crosslinking agent is an oligo-propylene glycol diacrylate.
[0011] The first and second substrates used in the embodiments of
the laminate described herein may further be characterized. In this
disclosure, when the laminate is used in a vehicle body, the first
substrate may face the exterior of the vehicle body and the second
substrate may face the interior of the vehicle body or vice versa
(i.e., the first substrate may face the interior of the vehicle
body and the second substrate may face the exterior of the vehicle
body). When the laminate is used in architectural panels such as a
window, the first substrate may face the exterior of the building
or the exterior environment, and the second substrate may face the
interior of the building or the interior environment or vice versa
(i.e., the first substrate may face the interior of the building or
the interior environment, and the second substrate may face the
exterior of the building or the exterior environment). When the
laminate is used in architectural panels such as a modular
furniture, a backsplash, a cabinet panel or an appliance panel, the
first substrate may face away from a user, and the second substrate
may face the user or vice versa (i.e., the first substrate may face
the user, and the second substrate may face away from the
user).
[0012] In one or more embodiments, the first substrate has a
thickness of 2.1 mm or less. In one or more embodiments, the first
substrate has a thickness in the range from about 1.6 mm to about 4
mm. In one or more embodiments, the first substrate is an
unstrengthened glass and may optionally comprise soda lime glass.
In one or more embodiments, the first substrate may comprise a
strengthened glass. In one or more embodiments, second substrate
has a thickness less than the thickness of the first substrate. In
some embodiments, the second substrate is a strengthened glass,
which may comprise a compressive stress in the range from about 50
MPa to about 800 MPa and a depth of compression in the range from
about 35 micrometers to about 200 micrometers. In one or more
embodiments, the first substrate has a thickness and the ratio of
the thickness of the second substrate to the thickness of the first
substrate is greater than about 0.33, or is about 0.39 or greater,
or is about 0.5 or greater.
[0013] The laminate and/or any one or more components thereof
(i.e., the first substrate, the second substrate, the interlayer
structure, the first polymer, the first layer, the second layer and
the third layer) may be characterized as transparent. For example,
the laminate and/or any one or more components thereof (i.e., the
first substrate, the second substrate, the interlayer structure,
the first polymer, the first layer, the second layer and the third
layer) may exhibit a transmittance of greater than 80% in the range
of 400 to 700 nm at a thickness of a 1 mm. The transmittance may be
measured under a CIE illuminant, such as D65, or F02.
[0014] The embodiments of the laminates described herein may be
described in terms of sound transmission loss. In one or more
embodiments, the laminate has a sound transmission loss of
transmission loss of greater than about 38 dB over a frequency
range from about 2500 Hz to about 6000 Hz.
[0015] A second aspect of this disclosure pertains to a vehicle
comprising a body, an opening and a laminate (according to one or
more embodiments disclosed herein) disposed in the opening. In one
or more embodiments, the vehicle body comprises an automobile, a
railcar, aircraft or seacraft.
[0016] A third aspect of this disclosure pertains to an
architectural panel comprising the laminate (according to one or
more embodiments disclosed herein). In one or more embodiments, the
architectural panel comprises a window, an interior wall panel, a
modular furniture panel, a backsplash, a cabinet panel, or an
appliance panel.
[0017] A Fourth aspect of this disclosure pertains to a polymer
comprising a polymerization product of one or more ethylenically
unsaturated compounds. In one or more embodiments, the polymer is
produced by the polymerization of one or more monomers comprising
an allyl compound, a vinyl compound, an acrylate, a methacrylate,
an acrylamide, or a methacrylamide, or any combination thereof. In
some embodiments, the polymer is the polymerization product of two
or more acrylate monomers. In one or more embodiments, the polymer
is the polymerization product of phenoxyethylacrylate and
ethoxylated(8)nonylphenol acrylate. In one or more embodiments, the
first polymer is the polymerization product of phenoxyethylacrylate
and phenoxyethoxyethylacrylate.
[0018] In one or more embodiments, the polymer is at least
partially crosslinked with a crosslinking agent. In one specific
embodiment, the crosslinking agent is a diacrylate compound or
dimethacrylate compound. In another specific embodiment, the
crosslinking agent is a polyalkylene oxide diacrylate compound or a
polyalkylene oxide dimethacrylate compound. In yet another specific
embodiment, the crosslinking agent is an oligo-propylene glycol
diacrylate.
[0019] A fifth aspect of this disclosure pertains to a laminate
comprising an interlayer structure (according to one or more
embodiments described herein) disposed between a first substrate
and a second substrate, wherein the first polymer is produced by
the polymerization of one or more ethylenically unsaturated
compounds, wherein the laminate exhibits a sound transmission loss
of greater than about 38 dB over a frequency range from about 2500
Hz to about 6000 Hz. The first polymer may be produced by the
polymerization of one or more monomers comprising an allyl
compound, a vinyl compound, an acrylate, a methacrylate, an
acrylamide, or a methacrylamide, or any combination thereof. The
first polymer may include the polymerization product of two or more
acrylate monomers. The first polymer may optionally include the
polymerization product of phenoxyethylacrylate and
ethoxylated(8)nonylphenol acrylate. In one or more embodiments, the
first polymer is the polymerization product of phenoxyethylacrylate
and phenoxyethoxyethylacrylate.
[0020] In one or more embodiments, the first polymer may be at
least partially crosslinked with a crosslinking agent (such as
those described herein).
[0021] Additional features and advantages will be set forth in the
detailed description which follows, and in part will be readily
apparent to those skilled in the art from that description or
recognized by practicing the embodiments as described herein,
including the detailed description which follows, the claims, as
well as the appended drawings.
[0022] It is to be understood that both the foregoing general
description and the following detailed description are merely
exemplary, and are intended to provide an overview or framework to
understanding the nature and character of the claims. The
accompanying drawings are included to provide a further
understanding, and are incorporated in and constitute a part of
this specification. The drawings illustrate one or more
embodiment(s), and together with the description serve to explain
principles and operation of the various embodiments.
BRIEF DESCRIPTION OF DRAWINGS
[0023] FIG. 1 is a side view of an exemplary laminate described
herein.
[0024] FIG. 2 is a side view of an exemplary laminate described
herein.
[0025] FIG. 3 is a perspective view of a vehicle where a laminate
described herein can be incorporated.
[0026] FIG. 4a shows the dynamic shear temperature ramp curve for
the core middle layer of a known APVB polymer laminate showing the
storage modulus (G'), loss modulus (G'') and tan .delta. as a
function of temperature.
[0027] FIG. 4b shows the dynamic shear mastercurve plot of the core
layer of the known APVB material, shown in FIG. 4a, as a function
of frequency at a reference temperature of 20.degree. C.
[0028] FIG. 5 shows the dynamic shear temperature ramp curves of
standard known SPVB, a known APVB core layer, and a polymer
according to one or more embodiments described herein.
[0029] FIG. 6 shows mastercurves of the SPVB, APVB core layer and a
polymer described according to one or more embodiments herein at a
reference temperature of 20.degree. C.
[0030] FIG. 7 shows the acoustic modeling of laminates with
different damping layers.
[0031] FIG. 8 shows the tan delta during a dynamic shear
temperature ramp test of several polymer formulations described
herein compared to a known APVB core layer.
[0032] FIG. 9 shows the tan delta mastercurve at a reference
temperature of 20.degree. C. of several polymer formulations
described herein compared to a known APVB core layer.
DETAILED DESCRIPTION
[0033] Before the present articles and methods are disclosed and
described, it is to be understood that the aspects described below
are not limited to specific devices or methods, or uses as such
may, of course, vary. It is also to be understood that the
terminology used herein is for the purpose of describing particular
aspects only and is not intended to be limiting.
[0034] It must be noted that, as used in the specification and the
appended claims, the singular forms "a," "an" and "the" include
plural referents unless the context clearly dictates otherwise.
Thus, for example, reference to "a monomer" includes one or more
monomers.
[0035] As used herein, the term "about" provides flexibility to a
numerical range endpoint by providing that a given value may be "a
little above" or "a little below" the endpoint without affecting
the desired result. Ranges may be expressed herein from "about" one
particular value, and/or to "about" another particular value. When
such a range is expressed, another aspect includes from the one
particular value and/or to the other particular value. Similarly,
when values are expressed as approximations, by use of the
antecedent "about," it will be understood that the particular value
forms another aspect. It will be further understood that the
endpoints of each of the ranges are significant both in relation to
the other endpoint and independently of the other endpoint.
[0036] Optional other "about" language: Finally, when the term
"about" is used in describing a value or an end-point of a range,
the disclosure should be understood to include the specific value
or end-point referred to. When a numerical value or end-point of a
range does not recite "about," the numerical value or end-point of
a range is intended to include two embodiments: one modified by
"about," and one not modified by "about." As used herein, the term
"about" means that amounts, sizes, formulations, parameters, and
other quantities and characteristics are not and need not be exact,
but may be approximate and/or larger or smaller, as desired,
reflecting tolerances, conversion factors, rounding off,
measurement error and the like, and other factors known to those of
skill in the art.
[0037] As used herein, the term "dispose" includes placing or
stacking a material onto a surface using any known method in the
art. The disposed material may constitute a substrate, an
interlayer, an interlayer structure or a layer, as used herein. The
phrase "disposed on" includes the instance of forming a material
onto a surface such that the material is in direct contact with the
surface and also includes the instance where the material is formed
on a surface, with one or more intervening material(s) is between
the disposed material and the surface. The intervening material(s)
may constitute a substrate, an interlayer, an interlayer structure
or a layer, as used herein.
[0038] The term "alkyl group" as used herein is a branched or
unbranched saturated hydrocarbon group of 1 to 25 carbon atoms,
such as methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl,
t-butyl, pentyl, hexyl, heptyl, octyl, decyl, tetradecyl,
hexadecyl, eicosyl, tetracosyl and the like. Examples of longer
chain alkyl groups include, but are not limited to, an oleate group
or a palmitate group. A "lower alkyl" group is an alkyl group
containing from one to eight carbon atoms.
[0039] The term "cycloalkyl group" as used herein is a non-aromatic
carbon-based ring composed of at least three carbon atoms. Examples
of cycloalkyl groups include, but are not limited to, cyclopropyl,
cyclobutyl, cyclopentyl, cyclohexyl, etc. The term
"heterocycloalkyl group" is a cycloalkyl group as defined above
where at least one of the carbon atoms of the ring is substituted
with a heteroatom such as, but not limited to, nitrogen, oxygen,
sulphur, or phosphorus.
[0040] The term "aryl group" as used herein is any carbon-based
aromatic group including, but not limited to, benzene, naphthalene,
etc. The term "aromatic" also includes "heteroaryl group," which is
defined as an aromatic group that has at least one heteroatom
incorporated within the ring of the aromatic group. Examples of
heteroatoms include, but are not limited to, nitrogen, oxygen,
sulfur, and phosphorus. The aryl group can be substituted or
unsubstituted. The aryl group can be substituted with one or more
groups including, but not limited to, alkyl, alkynyl, alkenyl,
aryl, halide, nitro, amino, ester, ketone, aldehyde, hydroxy,
carboxylic acid, or alkoxy.
[0041] The term "alkylene group" as used herein is represented by
the general formula --(CH.sub.2).sub.m--, where m is from 1 to
10.
[0042] Unless otherwise indicated, all numbers such as those
expressing weight percents of ingredients, dimensions, and values
for certain physical properties used in the specification and
claims are to be understood as being modified in all instances by
the term "about." It should also be understood that the precise
numerical values used in the specification and claims form
additional embodiments of the invention. Efforts have been made to
ensure the accuracy of the numerical values disclosed in the
Examples. Any measured numerical value, however, can inherently
contain certain errors resulting from the standard deviation found
in its respective measuring technique.
[0043] Each component used to prepare the laminates described
herein as well as methods of making and using the laminates is
described below.
Interlayer Structure
[0044] FIG. 1 provides an example of a laminate structure described
herein. Laminate structure 100 has an interlayer structure 120
disposed between a first substrate 110 and a second substrate 130.
In one or more embodiments, the interlayer structure 120 in FIG. 1
comprises a single polymer layer composed of a first polymer
described herein.
[0045] In one or more embodiments, the interlayer structure can be
composed of two or more layers. An example of this is depicted in
FIG. 2. Referring to FIG. 2, the interlayer structure comprises
layers 120, 122, and 124, where first layer 120 comprises a first
polymer described herein, and is disposed between second and third
layers 122 and 124, respectively. The second and third layers 122
and 124 can be made of the same or different material as one
another. In one or more embodiments, any one or both the second and
third layers 122 and 124 may have the same or different material as
the first layer. In some embodiments, all three of the first,
second and third layers 120, 122, 124 may comprise the same first
polymer as described herein but may have different properties from
any one or more of the other layers. Additionally, the second and
third layers 122, 124 can have the same or different thickness. In
one or more embodiments, the second and third layers 122, 124 are
composed of polyvinyl butyral (PVB), ethylene-vinyl acetate (EVA),
a thermoplastic polyurethane (TPU), a polyester (PE), or
polyethylene terephthalate (PET). In some other embodiments, the
second and third layers 122, 124 are each composed of polyvinyl
butyral (PVB). In one or more embodiments, the interlayer structure
or the individual layers (and/or any sub-layers) of the interlayer
structure may include any one or more of pigments, UV absorbers,
infrared absorbers, adhesion promoting silane compounds, or other
stabilizers.
[0046] In one or more embodiments, the first polymer is composed of
a material that has a tan delta (.delta.) value greater than that
of the core layer present in known APVB in the frequency range of
interest and the temperature range of interest. By increasing the
tan .delta. value of the first polymer, the damping properties of a
laminate incorporating such first polymer also increase. In
addition to the tan .delta. value being greater than that of the
core layer of currently available APVB, the storage shear modulus
(G') value of the first polymer described herein is ideally
equivalent to or less than that of the core layer of the APVB in
the frequency range of interest at the temperature of interest. As
demonstrated in the Examples, acoustic modeling results indicate
that a laminate including an interlayer structure as described
herein using a first polymer described herein exhibits
significantly improved noise attenuation over an identical laminate
that utilizes a known APVB material in the desired frequency range
at the temperature of interest. Here, the tan .delta. value of the
first polymer was significantly higher than the core layer present
in APVB.
[0047] A rheometer can be used to quantify the dynamic mechanical
shear properties of the first polymer that is ultimately used to
calculate the tan .delta. value. Using a parallel plate
configuration the rheometer measures the elastic portion of the
viscoelastic response, storage shear modulus (G'), and the viscous
portion of the response, loss shear modulus (G'') during sinusoidal
oscillatory shear deformation. Both G' and G'' change significantly
as a function of frequency and temperature. The ratio G''/G' is
called tan .delta. and is a measure of the damping behavior of the
material.
[0048] There are other considerations when selecting the components
used to produce the first polymer useful herein possessing high tan
.delta. values. Not wishing to be bound by theory, the first
polymer should be composed of a network that is as uniform as
possible. This can be accomplished achieved by using the fewest
number of different monomers as possible to produce the first
polymer while still maximizing the peak tan .delta. at the desired
frequency and temperature of operation. Therefore, monomers can be
selected such that they have peak tan .delta. of their cured
homo-polymers that are at frequencies as close as possible to the
desired final value. Mixtures are then made from these monomers to
create a combined composition, whose peak tan .delta. after curing
is at the correct frequency. By selecting monomers that have
homo-polymers with peak tan .delta. as close as possible to the
desired frequency, the first polymer can be produced substantially
from one single monomer, but can include additional monomers if
necessary to shift the peak tan .delta. to the correct frequency.
In one aspect, the monomers selected to produce the first polymer
possess structures are as close to each other as possible so as to
reduce deviation from a uniform network once polymerized.
[0049] Another consideration when selecting the monomers to produce
the first polymer is the miscibility of the monomers. The monomers
should all be miscible with each other. The monomers should not
preferentially segregate during the polymerization process, but
instead react with one another as equally as possible in their
relative proportions to produce a uniform a network. As well as
monomer miscibility, the cured polymer network and partially cured
network fragments should not phase separate from the whole in order
to maintain the closest possible adherence to network
uniformity.
[0050] The viscosity of the monomer(s) prior to polymerization is
another feature to consider when selecting the monomers to produce
the first polymer. Different viscosity ranges lend themselves
better to different processing conditions. For example, low
viscosity materials flow more easily and de-air more quickly.
However, higher viscosity materials are more easily manipulated
into films where they are required to maintain film thickness for a
period of time before polymerization. In certain aspects, viscosity
modifiers such as, for example, polymeric materials, can be
combined with the monomer(s) in order to adjust viscosity,
performance and other related properties. For example, the polymer
selected can provide a film that meets the desired use requirements
for clarity and temperature performance that is also miscible or
compatible with the monomer(s). In one aspect, the final viscosity
of the monomer(s) (with or without viscosity modifier) prior to
polymerization is from 10 cPs to 20,000 cPs. In another aspect, the
monomer mixture has a viscosity of from 100 cPs to 5,000 cPs, 150
cPs to 4,000, or 200 cPs to 3,000 cPs.
[0051] Other factors to consider include surface tension and
surface chemistry. The selection of the monomers for producing the
first polymer can be varied depending upon the degree of wetting of
the surface the monomers are applied to. For example, the pre-cured
monomer mixture can wet a surface to a greater or lesser extent.
Alternatively, the monomer mixture can wet one surface
preferentially over another. It may also be necessary for the cured
polymer composition to adhere or not adhere to a given surface.
Additives such as surface tension modifiers can be incorporated
into the monomer mixture to modify the surface tension properties.
Examples of surface tension modifiers include, but are not limited
to, surfactants and adhesion promoters, such as silanes for glass
or other hydroxylated inorganic surfaces, or acids or bases to
create ionic interactions. Where additives are used, they were used
at levels small enough to provide minimal disruption to the
uniformity of the polymer network. Here the additives
preferentially segregate to the surfaces to have maximum effect at
the interface with minimum impact on the bulk.
[0052] The first polymers described herein possess very high tan
.delta. values when measured in the frequency range audible to
human beings at a temperature within a range of operation. For
example, such tan .delta. values may be greater than 1, about 1.2
or greater, about 1.4 or greater, about 1.6 or greater, about 1.8
or greater, about 2 or greater, about 2.2 or greater, about 2.4 or
greater, about 2.6 or greater, about 2.8 or greater, about 3 or
greater, about 3.2 or greater, about 3.4 or greater, about 3.5 or
greater, or about 4 or greater. The upper limit of the tan .delta.
value may be about 5, or about 4.5. In some embodiments, the tan
.delta. value may be in a range from about 1.1 to about 4, from
about 1.2 to about 4, from about 1.4 to about 4, from about 1.5 to
about 4, from about 1.6 to about 4, from about 1.8 to about 4, from
about 2 to about 4, from about 2.2 to about 4, from about 2.4 to
about 4, from about 2.5 to about 4, from about 2.6 to about 4, from
about 2.8 to about 4, from about 3 to about 4, from about 1.1 to
about 3.8, from about 1.1 to about 3.6, from about 1.1 to about
3.5, from about 1.1 to about 3.4, from about 1.1 to about 3.2, from
about 1.1 to about 3, from about 1.5 to about 4, from about 1.5 to
about 3.5, or from about 2 to about 3.5.
[0053] In one or more embodiments, the first polymer may exhibit
the tan .delta. values provided herein at a temperature in a range
from about -20.degree. C. to about 40.degree. C. In some
embodiments, the first polymer may exhibit the tan .delta. values
provided herein a temperature in a range from about -18.degree. C.
to about 40.degree. C., from about -16.degree. C. to about
40.degree. C., from about -15.degree. C. to about 40.degree. C.,
from about -14.degree. C. to about 40.degree. C., from about
-12.degree. C. to about 40.degree. C., from about -10.degree. C. to
about 40.degree. C., from about -8.degree. C. to about 40.degree.
C., from about -6.degree. C. to about 40.degree. C., from about
-5.degree. C. to about 40.degree. C., from about -4.degree. C. to
about 40.degree. C., from about -2.degree. C. to about 40.degree.
C., from about 0.degree. C. to about 40.degree. C., from about
-20.degree. C. to about 38.degree. C., from about -20.degree. C. to
about 36.degree. C., from about -20.degree. C. to about 35.degree.
C., from about -20.degree. C. to about 34.degree. C., from about
-20.degree. C. to about 32.degree. C., from about -20.degree. C. to
about 30.degree. C., from about -20.degree. C. to about 28.degree.
C., from about -20.degree. C. to about 26.degree. C., from about
-20.degree. C. to about 25.degree. C., from about -20.degree. C. to
about 24.degree. C., from about -20.degree. C. to about 22.degree.
C., from about -20.degree. C. to about 20.degree. C., from about
-20.degree. C. to about 18.degree. C., from about -20.degree. C. to
about 16.degree. C., from about -20.degree. C. to about 15.degree.
C., from about -20.degree. C. to about 14.degree. C., from about
-20.degree. C. to about 12.degree. C., from about -20.degree. C. to
about 10.degree. C., from about -15.degree. C. to about 5.degree.
C., or from about -5.degree. C. to about 5.degree. C., and all
ranges and sub-ranges therebetween.
[0054] In some embodiments, the first polymer exhibits the tan
.delta. values provided herein at all temperatures along the range
from about -20.degree. C. to about 40.degree. C., from about
-18.degree. C. to about 40.degree. C., from about -16.degree. C. to
about 40.degree. C., from about -15.degree. C. to about 40.degree.
C., from about -14.degree. C. to about 40.degree. C., from about
-12.degree. C. to about 40.degree. C., from about -10.degree. C. to
about 40.degree. C., from about -8.degree. C. to about 40.degree.
C., from about -6.degree. C. to about 40.degree. C., from about
-5.degree. C. to about 40.degree. C., from about -4.degree. C. to
about 40.degree. C., from about -2.degree. C. to about 40.degree.
C., from about 0.degree. C. to about 40.degree. C., from about
-20.degree. C. to about 38.degree. C., from about -20.degree. C. to
about 36.degree. C., from about -20.degree. C. to about 35.degree.
C., from about -20.degree. C. to about 34.degree. C., from about
-20.degree. C. to about 32.degree. C., from about -20.degree. C. to
about 30.degree. C., from about -20.degree. C. to about 28.degree.
C., from about -20.degree. C. to about 26.degree. C., from about
-20.degree. C. to about 25.degree. C., from about -20.degree. C. to
about 24.degree. C., from about -20.degree. C. to about 22.degree.
C., from about -20.degree. C. to about 20.degree. C., from about
-20.degree. C. to about 18.degree. C., from about -20.degree. C. to
about 16.degree. C., from about -20.degree. C. to about 15.degree.
C., from about -20.degree. C. to about 14.degree. C., from about
-20.degree. C. to about 12.degree. C., from about -20.degree. C. to
about 10.degree. C., from about -15.degree. C. to about 5.degree.
C., or from about -5.degree. C. to about 5.degree. C. In some
embodiments, the first polymer exhibits the tan .delta. values
provided herein at all temperatures along more extreme temperature
range combinations, for example, at all temperatures from about
-20.degree. C. to about -15.degree. C. and at all temperatures from
about -5.degree. C. to about 5.degree. C., and all ranges and
sub-ranges therebetween.
[0055] In one or more embodiments, the first polymer may exhibit
the tan .delta. values provided herein at a frequency within a
range from about 1 Hz to about 20,000 Hz. In one or more
embodiments, the frequency at which the first polymer exhibits the
tan .delta. values provided herein is in the range from about 5 Hz
to about 100,000 Hz, from about 10 Hz to about 100,000 Hz, from
about 100 Hz to about 100,000 Hz, from about 500 Hz to about
100,000 Hz, from about 1,000 Hz to about 100,000 Hz, from about
2,000 Hz to about 100,000 Hz, from about 3,000 Hz to about 100,000
Hz, from about 4,000 Hz to about 100,000 Hz, from about 5,000 Hz to
about 100,000 Hz, from about 6,000 Hz to about 100,000 Hz, from
about 7,000 Hz to about 100,000 Hz, from about 8,000 Hz to about
100,000 Hz, from about 9,000 Hz to about 100,000 Hz, from about
10,000 Hz to about 100,000 Hz, from about 15,000 Hz to about
100,000 Hz, from about 20,000 Hz to about 100,000 Hz, from about
25,000 Hz to about 100,000 Hz, from about 30,000 Hz to about
100,000 Hz, from about 40,000 Hz to about 100,000 Hz, from about
50,000 Hz to about 100,000 Hz, from about 5 Hz to about 90,000 Hz,
from about 5 Hz to about 80,000 Hz, from about 5 Hz to about 70,000
Hz, from about 5 Hz to about 60,000 Hz, from about 5 Hz to about
50,000 Hz, from about 5 Hz to about 40,000 Hz, from about 5 Hz to
about 30,000 Hz, from about 5 Hz to about 20,000 Hz, from about 5
Hz to about 18,000 Hz, from about 5 Hz to about 16,000 Hz, from
about 5 Hz to about 15,000 Hz, from about 5 Hz to about 14,000 Hz,
from about 5 Hz to about 12,000 Hz, from about 5 Hz to about 10,000
Hz, from about 5 Hz to about 5,000 Hz, or from about 5 Hz to about
1,000 Hz, and all ranges and sub-ranges therebetween.
[0056] In one or more embodiments, the first polymer may exhibit
the tan .delta. values provided herein at all frequencies within a
range from about 1 Hz to about 20,000 Hz, from about 5 Hz to about
100,000 Hz, from about 10 Hz to about 100,000 Hz, from about 100 Hz
to about 100,000 Hz, from about 500 Hz to about 100,000 Hz, from
about 1,000 Hz to about 100,000 Hz, from about 2,000 Hz to about
100,000 Hz, from about 3,000 Hz to about 100,000 Hz, from about
4,000 Hz to about 100,000 Hz, from about 5,000 Hz to about 100,000
Hz, from about 6,000 Hz to about 100,000 Hz, from about 7,000 Hz to
about 100,000 Hz, from about 8,000 Hz to about 100,000 Hz, from
about 9,000 Hz to about 100,000 Hz, from about 10,000 Hz to about
100,000 Hz, from about 15,000 Hz to about 100,000 Hz, from about
20,000 Hz to about 100,000 Hz, from about 25,000 Hz to about
100,000 Hz, from about 30,000 Hz to about 100,000 Hz, from about
40,000 Hz to about 100,000 Hz, from about 50,000 Hz to about
100,000 Hz, from about 5 Hz to about 90,000 Hz, from about 5 Hz to
about 80,000 Hz, from about 5 Hz to about 70,000 Hz, from about 5
Hz to about 60,000 Hz, from about 5 Hz to about 50,000 Hz, from
about 5 Hz to about 40,000 Hz, from about 5 Hz to about 30,000 Hz,
from about 5 Hz to about 20,000 Hz, from about 5 Hz to about 18,000
Hz, from about 5 Hz to about 16,000 Hz, from about 5 Hz to about
15,000 Hz, from about 5 Hz to about 14,000 Hz, from about 5 Hz to
about 12,000 Hz, from about 5 Hz to about 10,000 Hz, from about 5
Hz to about 5,000 Hz, or from about 5 Hz to about 1,000 Hz, and all
ranges and sub-ranges therebetween.
[0057] In one or more embodiments, the first polymer has a tan
.delta. value greater than 1.0 or greater than about 1.25 at a
temperature in a range from about -20.degree. C. to about
40.degree. C. and at a frequency in a range from about 1 Hz to
about 20,000 Hz. In one or more embodiments, the first polymer has
a tan .delta. value greater than 1.0 or greater than about 1.25 at
a temperature in a range from about -20.degree. C. to about
40.degree. C. and at a frequency in a range from about 100 Hz to
about 100,000 Hz. In one or more embodiments, the first polymer has
a tan .delta. value greater than 1.0 or greater than about 1.25 at
a temperature in a range from about -20.degree. C. to about
5.degree. C. and at a frequency in a range from about 100 Hz to
about 100,000 Hz. In one or more embodiments, the first polymer has
a tan .delta. value greater than 1.0 or greater than about 1.25 at
a temperature in a range from about -15.degree. C. to about
5.degree. C. and at a frequency in a range from about 100 Hz to
about 100,000 Hz.
[0058] In one or more embodiments, the first polymer has a tan
.delta. value greater than 1.0 or greater than about 1.25 at all
temperatures in a range from about -20.degree. C. to about
40.degree. C. and at all frequencies in a range from about 1 Hz to
about 20,000 Hz. In one or more embodiments, the first polymer has
a tan .delta. value greater than 1.0 or greater than about 1.25 at
all temperatures in a range from about -20.degree. C. to about
40.degree. C. and at all frequencies in a range from about 100 Hz
to about 100,000 Hz. In one or more embodiments, the first polymer
has a tan .delta. value greater than 1.0 or greater than about 1.25
at all temperatures in a range from about -20.degree. C. to about
5.degree. C. and at all frequencies in a range from about 100 Hz to
about 100,000 Hz. In one or more embodiments, the first polymer has
a tan .delta. value greater than 1.0 or greater than about 1.25 at
all temperatures in a range from about -15.degree. C. to about
5.degree. C. and at all frequencies in a range from about 100 Hz to
about 100,000 Hz.
[0059] In another aspect, the first polymer has storage shear
modulus (G') of less than 100 MPa, less than 75 MPa, or less than
50 MPa. In one or more embodiments, the first polymer has such
shear modulus (G') values at a single temperature or all
temperatures within a temperature range from about -20.degree. C.
to about 40.degree. C. In one or more embodiments, the first
polymer has such shear modulus (G') values at a single frequency or
all frequencies within a frequency range from about 1 Hz to about
20,000 Hz (or from about 1,000 Hz to about 10,000 Hz). In one
aspect, the first polymer has storage shear modulus (G') of less
than 100 MPa, less than 75 MPa, or less than 50 MPa at both a
temperature within a temperature range from about -20.degree. C. to
about 40.degree. C. and a frequency within a frequency range from
about 1,000 Hz to about 20,000 Hz (or from about 1,000 Hz to about
10,000 Hz). In one aspect, the first polymer has storage shear
modulus (G') of less than 100 MPa, less than 75 MPa, or less than
50 MPa at all temperatures along a temperature range from about
-20.degree. C. to about 40.degree. C. and all frequencies within a
frequency range from about 1,000 Hz to about 20,000 Hz (or from
about 1,000 Hz to about 10,000 Hz).
[0060] In another aspect, the first polymer has a tan .delta. value
greater than 1.0, greater than 1.25, greater than 1.5 or greater
than 2, at a single temperature or all temperatures along a
temperature range from about -20.degree. C. to about 40.degree. C.,
when measured at a mechanical frequency of 1 Hz and a heating rate
of 2.degree. C./min. In one aspect, the first polymer has a tan
.delta. value greater than 1.0 at a temperature of 20.degree. C.
within a frequency range of 1 Hz to 20,000 Hz.
[0061] In another aspect, wherein the first polymer has a tan
.delta. value greater than the core layer of acoustic PVB within a
frequency or all frequencies along the range from about 1 Hz to
about 20,000 Hz when compared at the same temperature. For example,
the first polymer has a tan .delta. value that is 1.2, 1.5, 2.0,
2.5, 3.0, 3.5, or 4 times greater than the core layer of acoustic
PVB within a frequency or all frequencies along the range from
about 1 Hz to about 20,000 Hz, where any value can form a lower and
upper endpoint of the frequency range.
[0062] In another aspect, the first polymer has a tan .delta. value
from 2.0 to 4.0 at a single temperature or all temperatures along
the temperature range from about -20.degree. C. to about 40.degree.
C. when measured at a mechanical frequency of 1 Hz and a heating
rate of 2.degree. C./min. In a further aspect, the first polymer
has a tan .delta. value from about 2.0 to about 4.0 at single
temperature or all temperatures along the a temperature range from
about -20.degree. C. to about 40.degree. C. at a single frequency
or all frequencies along a frequency range from about 1,000 Hz to
about 10,000 Hz. In another aspect, the first polymer has a tan
.delta. value greater than 2.0 at a temperature of 20.degree. C. at
a single frequency or all frequencies along a frequency range from
about 1,000 Hz to about 10,000 Hz.
[0063] By increasing the tan .delta. value of the first polymer,
the damping properties of a laminate including the first polymer
increase as well. For example, the laminates described herein have
a greater sound transmission loss than a laminate composed of an
interlayer of APVB, at the same thickness and temperature. In one
aspect, the laminates described have a sound transmission loss that
is 1.2, 1.5, 2.0, 2.5, 3.0, 3.5, or 4 times greater than a laminate
having an APVB interlayer at the same thickness, where any value
can form a lower and upper endpoint of the frequency range.
[0064] In one or more embodiments, the first polymer has a glass
transition temperature in a range from about -10.degree. C. to
about 10.degree. C., when measured at mechanical frequency of 1 Hz
and a heating rate of 2.degree. C./minute. In one or more specific
embodiments, the first polymer has a glass transition temperature,
when measured at mechanical frequency of 1 Hz and a heating rate of
2.degree. C./minute, from about -10.degree. C. to about 9.degree.
C., from about -10.degree. C. to about 8.degree. C., from about
-10.degree. C. to about 7.degree. C., from about -10.degree. C. to
about 6.degree. C., from about -10.degree. C. to about 5.degree.
C., from about -10.degree. C. to about 4.degree. C., from about
-10.degree. C. to about 3.degree. C., from about -10.degree. C. to
about 2.degree. C., from about -10.degree. C. to about 9.degree.
C., from about -10.degree. C. to about 0.degree. C., from about
-9.degree. C. to about 10.degree. C., from about -8.degree. C. to
about 10.degree. C., from about -8.degree. C. to about 10.degree.
C., from about -7.degree. C. to about 10.degree. C., from about
-6.degree. C. to about 10.degree. C., from about -5.degree. C. to
about 10.degree. C., from about -4.degree. C. to about 10.degree.
C., from about -3.degree. C. to about 10.degree. C., from about
-2.degree. C. to about 10.degree. C., from about -1.degree. C. to
about 10.degree. C., or from about 0.degree. C. to about 10.degree.
C., and all ranges and sub-ranges therebetween.
[0065] In one or more embodiments, the first polymer is produced by
the polymerization of one or more ethylenically unsaturated
compounds. The phrase "ethylenically unsaturated compound" is
defined herein as a compound that possesses at least one
carbon-carbon double bond. Examples of ethylenically unsaturated
compounds include, but are not limited to, an allyl compound, a
vinyl compound, an acrylate, a methacrylate, an acrylamide, or a
methacrylamide. Depending upon the application, the first polymer
can be a homopolymer or a copolymer.
[0066] In one or more embodiments, the ethylenically unsaturated
compound includes acrylic acid, lauryl acrylate (e.g., SR335
available from Sartomer Company, Inc., Agellex FA12 available from
CPS Chemical Co. (Old Bridge, N.J.), and Photomer 4812 available
from Cognis f.k.a. Henkel (Ambler, Pa.)), laurylethoxylated(4)
acrylate (e.g., CD9075 manufactured by Sartomer), 2-propylheptyl
acrylate manufactured by BASF, ethoxylatednonylphenol acrylate
(e.g., SR504 available from Sartomer Company, Inc. and Photomer
4003 available from Cognis), caprolactone acrylate (e.g., SR495
available from Sartomer Company, Inc., and Tone M100 available from
Union Carbide Company (Danbury, Conn.)), phenoxyethyl acrylate
(e.g., SR339 available from Sartomer Company, Inc., Ageflex PEA
available from CPS Chemical Co., Photomer 4035 available from
Cognis, and M140 manufactured by Miwon), phenoxyethoxyethyl
acrylate (e.g., M142 manufactured by Miwon),
phenoxyethoxethoxyethoxyyethyl acrylate (e.g., M144 manufactured by
Miwon), isooctyl acrylate (e.g., SR440 available from Sartomer
Company, Inc. and Ageflex FA8 available from CPS Chemical Co.),
tridecyl acrylate (e.g., SR489 available from Sartomer Company,
Inc.), phenoxyglycidyl acrylate (e.g., CN131 available from
Sartomer Company, Inc.), lauryloxyglycidyl acrylate (e.g., CN130
available from Sartomer Company, Inc.), isobornyl acrylate SR506
available from Sartomer Company, Inc., Ageflex IBOA available from
CPS Chemical Co., and M1140 manufactured by Miwon),
tetrahydrofurfuryl acrylate (e.g., SR285 available from Sartomer
Company, Inc.), stearyl acrylate (e.g., SR257 available from
Sartomer Company, Inc.), isodecyl acrylate (e.g., SR395 available
from Sartomer Company, Inc. and Ageflex FA10 available from CPS
Chemical Co.), 2-(2-ethoxyethoxy)ethyl acrylate SR256 available
from Sartomer Company, Inc.), trimethylcyclohexylacrylate (e.g.,
M1130 manufactured by Miwon), adamatylmethacrylate,
N-vinylcaprolactam, cyclic trimethylolpropane formal acrylate
(e.g., M1110 manufactured by Miwon), tetrahydrofurfuryl acrylate
(e.g., M150 manufactured by Miwon) and any combination thereof.
[0067] In some embodiments, the first polymer can be crosslinked.
In one aspect, a crosslinking agent composed of two or more
olefinic groups can be mixed with one or more monomers to produce a
crosslinked first polymer. In one aspect, the crosslinking agent is
a polyalkylene oxide diacrylate compound or a polyalkylene oxide
dimethacrylate compound. For example, the polyalkylene can be a
polymer of ethylene glycol, propylene glycol, or block co-polymers
thereof. In one aspect, the crosslinking agent is a polypropylene
glycol diacrylate having a molecular weight of about 400 (e.g.,
M2040 manufactured by Miwon Specialty Chemical Co.) or a
tripropylene glycol diacrylate. In one or more embodiments, the
crosslinking agent is 0.05%, 0.1%, 0.5%, 1.0%, 1.5%, 2.0, 3%, 5%,
or 10% by weight of the first polymer, where any value can form a
lower and upper endpoint of a range.
[0068] In one or more embodiments, the first polymer can include a
number of processing and stabilizing molecules such as
anti-oxidants (primary and secondary), photo-stabilizers,
lubricants, or plasticizers.
[0069] In one or more embodiments, the first polymer is produced by
the polymerization of one or more monomers having the formula
I:
##STR00001##
wherein R.sup.1 is hydrogen or an alkyl group; [0070] R.sup.2 is an
alkylene group; [0071] R.sup.3 is an alkyl group, a cycloalkyl
group, or an aryl group; and [0072] n is from 1 to 20.
[0073] In one embodiment, R.sup.1 is hydrogen and R.sup.2 is
ethylene. In one or more specific embodiments, R.sup.1 is hydrogen,
R.sup.2 is ethylene, and R.sup.3 is an aryl group. In yet other
specific embodiments, R.sup.1 is hydrogen, R.sup.2 is ethylene,
R.sup.3 is a substituted or unsubstituted phenyl group, and n is
from 1 to 10.
[0074] In one or more embodiments, the first polymer is the
polymerization product of two monomers having formula I. In one or
more specific embodiments, the first polymer is the polymerization
product of a first constituent and a second constituent. In one or
more embodiments, the first polymer is a polymerization of a first
constituent, a second constituent and a third constituent. In one
or more embodiments, the first constituent, second constituent
and/or the third constituent is selected from the group consisting
of ethoxylated nonylphenolacrylate, phenoxyethoxyethylacrylate,
phenoxyethylacrylate, Trimethylcyclohexylacrylate, isobornyl
acrylate, phenoxyethoxyethoxyethoxyethylacrylate,
ethoxyethoxyethylacrylate, isooctyl acrylate,
laurylethoxylated(4)acrylate, isodecyl acrylate,
ethoxyethoxyethylacrylate, N-Vinylcaprolactam, 2-propylheptyl
acrylate, heptadecyl acrylate, acrylic acid, isobornyl acrylate,
and adamatylmethacrylate. In one or more embodiments, the first
polymer is a polymerization product of phenoxyethylacrylate (e.g.,
M140 in an amount in a range from about 40 wt % to about 60 wt %)
and phenoxyethoxyethylacrylate (e.g., M142 in an amount in a range
from about 40 wt % to about 60 wt %). In one or more embodiments,
the first polymer is a polymerization product of isobornyl acrylate
(e.g., M1140 in an amount in a range from about 25 to about 45 wt
%) and phenoxyethoxyethoxyethoxyethylacrylate (e.g., M144 in an
amount in a range from about 50 wt % to about 75 wt %). In one or
more embodiments, the first polymer is a polymerization product of
phenoxyethylacrylate (e.g., M140 in an amount in a range from about
40 wt % to about 60 wt %) and
phenoxyethoxyethoxyethoxyethylacrylate (e.g., M144 in an amount in
a range from about 40 wt % to about 60 wt %). In one or more
embodiments, the first polymer is a polymerization product of
phenoxyethylacrylate (e.g., M140 in an amount in a range from about
10 wt % to about 25 wt %) and phenoxyethoxyethylacrylate (e.g.,
M142 in an amount in a range from about 75 wt % to about 90 wt %).
In one or more embodiments, the first polymer is a polymerization
product of isobornyl acrylate (e.g., M1140 in an amount in a range
from about 35 wt % to about 55 wt %) and ethoxyethoxyethylacrylate
(e.g., SR256 in an amount in a range from about 45 wt % to about 65
wt %). In one or more embodiments, the first polymer is a
polymerization product of isobornyl acrylate (e.g., M1140 in an
amount in a range from about 30 wt % to about 50 wt %) and
phenoxyethoxyethoxyethoxyethylacrylate (e.g., M144 in an amount in
a range from about 40 wt % to about 70 wt %). In one or more
embodiments, the first polymer is a polymerization product of
isobornyl acrylate (e.g., M1140 in an amount in a range from about
35 wt % to about 55 wt %) and laurylethoxylated(4)acrylate (e.g.,
CD9075 in an amount in a range from about 45 wt % to about 65 wt
%). In one or more embodiments, the first polymer is a
polymerization product of isobornyl acrylate (e.g., M1140 in an
amount in a range from about 40 wt % to about 60 wt %) and isodecyl
acrylate (e.g., SR395 in an amount in a range from about 40 wt % to
about 60 wt %). In one or more embodiments, the first polymer is a
polymerization product of isobornyl acrylate (e.g., M1140 in an
amount in a range from about 20 wt % to about 40 wt %),
henoxyethylacrylate (e.g., M140 in an amount in a range from about
20 wt % to about 40 wt %) and ethoxyethoxyethylacrylate (e.g.,
SR256 in an amount in a range from about 30 wt % to about 50 wt %).
In one or more embodiments, the first polymer is a polymerization
product of isobornyl acrylate (e.g., M1140 in an amount in a range
from about 40 wt % to about 60 wt %) and
laurylethoxylated(4)acrylate (e.g., CD9075 in an amount in a range
from about 40 wt % to about 60 wt %). In one or more embodiments,
the first polymer is a polymerization product of isobornyl acrylate
(e.g., M1140 in an amount in a range from about 20 wt % to about 40
wt %) and isodecyl acrylate (e.g., SR395 in an amount in a range
from about 60 wt % to about 80 wt %). In one or more embodiments,
the first polymer is a polymerization product of
phenoxyethylacrylate (e.g., M140 in an amount in a range from about
20 wt % to about 40 wt %) and phenoxyethoxyethylacrylate (e.g.,
M142 in an amount in a range from about 60 wt % to about 80 wt %).
In one or more embodiments, the first polymer is a polymerization
product of trimethylcyclohexylacrylate (e.g., M1130 in an amount in
a range from about 5 wt % to about 25 wt %) and
phenoxyethoxyethylacrylate (e.g., M142 in an amount in a range from
about 75 wt % to about 95 wt %). In one or more embodiments, the
first polymer is a polymerization product of isobornyl acrylate
(e.g., M1140 in an amount in a range from about 5 wt % to about 25
wt %) and phenoxyethoxyethylacrylate (e.g., M142 in an amount in a
range from about 75 wt % to about 95 wt %). In one or more
embodiments, the first polymer is a polymerization product of
N-Vinylcaprolactam (e.g., NVC in an amount in a range from about 1
wt % to about 20 wt %) and phenoxyethoxyethylacrylate (e.g., M142
in an amount in a range from about 80 wt % to about 99 wt %). In
one or more embodiments, the first polymer is a polymerization
product of 2-propylheptyl acrylate (e.g., 2-PHA in an amount in a
range from about 50 wt % to about 80 wt %) and isobornyl acrylate
(e.g., IBOA in an amount in a range from about 20 wt % to about 50
wt %). In one or more embodiments, the first polymer is a
polymerization product of heptadecyl acrylate (e.g., C17A in an
amount in a range from about 50 wt % to about 80 wt %) and
isobornyl acrylate (e.g IBOA in an amount in a range from about 20
wt % to about 50 wt %). In one or more embodiments, the first
polymer is a polymerization product of acrylic acid (e.g., AA in an
amount in a range from about 1 wt % to about 20 wt %) and
laurylethoxylated(4)acrylate (e.g., CD9075 in an amount in a range
from about 80 wt % to about 99 wt %). In one or more embodiments,
the first polymer is a polymerization product of acrylic acid
(e.g., AA in an amount in a range from about 5 wt % to about 25 wt
%) and isodecyl acrylate (e.g., SR395 in an amount in a range from
about 75 wt % to about 95 wt %). In one or more embodiments, the
first polymer is a polymerization product of acrylic acid (e.g., AA
in an amount in a range from about 5 wt % to about 25 wt %) and
isooctyl acrylate (e.g., SR440 in an amount in a range from about
75 wt % to about 95 wt %). In one or more embodiments, the first
polymer is a polymerization product of isobornyl acrylate (e.g.,
IBOA in an amount in a range from about 5 wt % to about 25 wt %)
and isooctyl acrylate (e.g., SR440 in an amount in a range from
about 75 wt % to about 95 wt %). In one or more embodiments, the
first polymer is a polymerization product of isobornyl acrylate
(e.g., IBOA in an amount in a range from about 5 wt % to about 25
wt %), isooctyl acrylate (e.g., SR440 in an amount in a range from
about 75 wt % to about 90 wt %) and acrylic acid (e.g., AA in an
amount in a range from about 1 wt % to about 15 wt %). In one or
more embodiments, the first polymer is a polymerization product of
ethoxylated nonylphenolacrylate (e.g., M111 in an amount in a range
from about 15 wt % to about 35 wt %) and adamatylmethacrylate
(e.g., ADMA in an amount in a range from about 25 wt % to about 45
wt %). In one or more embodiments, the first polymer is a
polymerization product of ethoxylated nonylphenolacrylate (e.g.,
M111 in an amount in a range from about 15 wt % to about 35 wt %)
and isobornyl acrylate (e.g., IBOA in an amount in a range from
about 25 wt % to about 45 wt %).
[0075] In one or more embodiments, the first polymer is a
polymerization product of phenoxyethylacrylate (e.g., M140
manufactured by Miwon Specialty Chemical Co.) and
ethoxylated(8)nonylphenol acrylate (e.g., M166 manufactured by
Miwon Specialty Chemical Co.). In one or more embodiments, the
phenoxyethylacrylate is 70%, 75%, 80%, 85%, 90%, or 95% by weight
of the first polymer, where any value can form a lower and upper
endpoint of a range, and ethoxylated(8)nonylphenol acrylate is 5%,
10%, 15%, 20%, 25%, or 30% by weight of the first polymer, where
any value can form a lower and upper endpoint of a range. In one or
more embodiments, the first polymer is further crosslinked with
0.5% to 2% polypropylene glycol diacrylate having a molecular
weight of about 400 (e.g., M2040 manufactured by Miwon Specialty
Chemical Co.).
[0076] In one or more embodiments, the first polymer is the
polymerization product of phenoxyethoxyethylacrylate (R.sup.1 is H,
R.sup.2 is CH.sub.2CH.sub.2, and R.sup.3 is unsubstituted phenyl in
formula I) (e.g., M142 manufactured by Miwon Specialty Chemical
Co.) and one or more ethylenically unsaturated compounds. In one or
more embodiments, the phenoxyethoxyethylacrylate is 50%, 55%, 60%,
65%, 70%, 75%, 80%, 85%, 90%, or 95% by weight of the first
polymer, where any value can form a lower and upper endpoint of a
range, and the ethylenically unsaturated compound is 5%, 10%, 15%,
20%, 25%, 30%, 35%, 40%, 45%, or 50% by weight of the first
polymer, where any value can form a lower and upper endpoint of a
range.
[0077] In one or more embodiments, the first polymer is the
polymerization product between 95% to 99%
phenoxyethoxyethylacrylate (e.g., M142 manufactured by Miwon
Specialty Chemical Co.) and 0.5% to 2% polypropylene glycol
diacrylate having a molecular weight of about 400 (e.g., M2040
manufactured by Miwon Specialty Chemical Co.) In one or more
specific embodiments, the first polymer is the polymerization
product between 40% to 70% phenoxyethoxyethylacrylate (e.g., M142
manufactured by Miwon Specialty Chemical Co.), 30% to 60%
phenoxyethoxyethylacrylate (e.g., M140 manufactured by Miwon
Specialty Chemical Co.) and 0.5% to 2% polypropylene glycol
diacrylate having a molecular weight of about 400 (e.g., M2040
manufactured by Miwon Specialty Chemical Co.). In a further aspect,
the first polymer is the polymerization product between 50% to 80%
phenoxyethoxyethoxyethoxyethylacrylate (e.g., M144 manufactured by
Miwon Specialty Chemical Co.), 20% to 80% isobornyl acrylate (e.g.,
M1140 manufactured by Miwon Specialty Chemical Co.) and 0.5% to 2%
polypropylene glycol diacrylate having a molecular weight of about
400 (e.g., M2040 manufactured by Miwon Specialty Chemical Co.).
[0078] In one or more embodiments, the first polymer is the
polymerization product between 5% to 70% isobornyl acrylate (e.g.,
M1140 manufactured by Miwon Specialty Chemical Co.), 0.5% to 2%
polypropylene glycol diacrylate having a molecular weight of about
400 (e.g., M2040 manufactured by Miwon Specialty Chemical Co.) and
one of the following monomers: ethoxyethoxyethylacrylate (40% to
70%); phenoxyethoxyethoxyethoxyethylacrylate (40% to 70%);
laurylethoxylated(4) acrylate (40% to 80%); isodecyl acrylate (30%
to 80%); phenoxyethylacrylate (10% to 50%); and
phenoxyethoxyethylacrylate.
[0079] In one or more embodiments, the first polymer is the
polymerization product between phenoxyethoxyethylacrylate (60% to
95%), 0.5% to 2% polypropylene glycol diacrylate having a molecular
weight of about 400, and one of the following monomers:
phenoxyethylacrylate (5% to 50%); trimethylcyclohexylacrylate(5% to
30%); and N-vinylcaprolactam (1% to 20%). In one or more specific
embodiments, the first polymer is the polymerization product
between phenoxyethoxyethoxyethoxyethylacrylate (30% to 70%), 0.5%
to 2% polypropylene glycol diacrylate having a molecular weight of
about 400, and phenoxyethylacrylate (30% to 70%).
[0080] In one or more embodiments, the first polymer is the
polymerization product between 40% to 80% 2-propylheptyl acrylate,
20% to 60% isobornyl acrylate, and 0.01% to 1% tripropylene glycol
diacrylate. In one or more specific embodiments, the first polymer
is the polymerization product between 40% to 80% heptadecyl
acrylate, 20% to 60% isobornyl acrylate, and 0.01% to 1%
tripropylene glycol diacrylate. In yet even more specific
embodiments, the first polymer is the polymerization product
between 1% to 20% acrylic acid, 0.01% to 1% tripropylene glycol
diacrylate, and one of the following monomers: laurylethoxylated(4)
acrylate (80% to 99%) or isodecyl acrylate (80% to 99%).
[0081] In one or more embodiments, the first polymer is the
polymerization product between 1% to 20% acrylic acid, 80% to 99%
isooctyl acrylate, and one of the following crosslinkers: 0.5% to
2% polypropylene glycol diacrylate having a molecular weight of
about 400 or 0.01% to 1% tripropylene glycol diacrylate. In one or
more embodiments, the first polymer is the polymerization product
between 1% to 20% isobornyl acrylate, 80% to 99% isooctyl acrylate,
and one of the following crosslinkers: 0.5% to 2% polypropylene
glycol diacrylate having a molecular weight of about 400 or 0.01%
to 1% tripropylene glycol diacrylate. In one or more embodiments,
the first polymer is the polymerization product between 1% to 20%
isobornyl acrylate, 80% to 99% isooctyl acrylate, 1% to 10% acrylic
acid, and one of the following crosslinkers: 0.5% to 2%
polypropylene glycol diacrylate having a molecular weight of about
400 or 0.01% to 1% tripropylene glycol diacrylate.
[0082] In one or more embodiments, the first polymer is the
polymerization product between phenoxyethoxyethylacrylate (75% to
90%), 0.5% to 1.5% polypropylene glycol diacrylate having a
molecular weight of about 400, and 10% to 20%
phenoxyethylacrylate.
[0083] In one or more embodiments, the first polymer is the
polymerization product between phenoxyethoxyethylacrylate (65% to
80%), 0.5% to 1.5% polypropylene glycol diacrylate having a
molecular weight of about 400, and 20% to 30%
phenoxyethylacrylate.
[0084] In one or more embodiments, the first polymer is the
polymerization product between phenoxyethoxyethylacrylate (80% to
95%), 0.5% to 1.5% polypropylene glycol diacrylate having a
molecular weight of about 400, and 5% to 20% trimethylcyclohexyl
acrylate.
[0085] In one or more embodiments, an ethylenically unsaturated
oligomer can be polymerized with one or more unsaturated monomers
to produce the polymers described herein, Suitable ethylenically
unsaturated oligomers include polyether urethane acrylate oligomers
(e.g., CN986 available from Sartomer Company, Inc., (West Chester,
Pa.)) and BR3731 and STC3-149 available from Bomar Specialty Co.
(Winstead, Conn.)), acrylate oligomers based on
tris(hydroxyethyl)isocyanurate, (available from Sartomer Company,
Inc.), (meth)acrylated acrylic oligomers, (available from Cognis
(Ambler, Pa.), polyester urethane acrylate oligomers (e.g., CN966
and CN973 available from Sartomer Company, Inc. and BR7432
available from Bomar Specialty Co.), polyurea urethane acrylate
oligomers oligomers disclosed in U.S. Pat. Nos. 4,690,502 and
4,798,852 to Zimmerman et al., U.S. Pat. No. 4,609,718 to Bishop,
and U.S. Pat. No. 4,629,287 to Bishop et al.), polyether acrylate
oligomers (e.g., Genomer 3456 available from Rahn AG (Zurich,
Switzerland), polyester acrylate oligomers (e.g., Ebecryl 80, 584,
and 657 available from UCB Radcure (Atlanta, Ga.)), polyurea
acrylate oligomers oligomers disclosed in U.S. Pat. Nos. 4,690,502
and 4,798,852 to Zimmerman et al, U.S. Pat. No. 4,609,718 to
Bishop, and U.S. Pat. No. 4,629,287 to Bishop et al., the
specifications of which are hereby incorporated by reference),
epoxy acrylate oligomers (e.g., CN120 available from Sartomer
Company, Inc., and Ebecryl 3201 and 3604 available from UCB
Radcure), hydrogenated polybutadiene oligomers (e.g., Echo Resin
MBNX available from Echo Resins and Laboratory (Versailles Mo.)),
and combinations thereof. In one aspect, the oligomer is UC-102
manufactured by Kurray Co. (1,3-butadiene, 2-methyl-homopolymer,
maleated, 2-[(2-methyl-1-oxo-2-propenyl)oxy] ethyl esters).
[0086] In one or more embodiments, the first polymer is the
polymerization product between 10% to 30% ethoxylated
nonylphenolacrylate, 20% to 50 of an oligomer (e.g., UC-102
manufactured by Kurray Co.) and one of the following monomers:
isobornyl acrylate (20% to 50%) or adamatylmethacrylate (20% to
50%).
[0087] The first polymer can be produced using techniques known in
the art. In one aspect, the monomer(s) used to produce the first
polymer can include an initiator. Initiators useful herein include
a thermal initiator, a chemical initiator, or a photoinitiator to
promote polymerization of the monomer(s). In other aspects, chain
transfer agents (e.g., isooctyl 3-mercaptopropionate) can be used
to facilitate the production of the polymers.
[0088] In one or more embodiments, photoinitiators such as ketonic
photoinitiating and/or phosphine oxide additives can be used
herein. When used to produce the polymers described herein, the
photoinitiator is present in an amount sufficient to provide rapid
ultraviolet curing. Generally, this includes between about 0.1 to
about 10.0 percent by weight. Examples of photoinitiators useful
herein include, but not limited to, 1-hydroxycyclohexylphenyl
ketone (e.g., IRGACURE 184 available from Ciba Specialty Chemical
(Hawthorne, N.Y.);
bis(2,6-dimethoxybenzoyl)-2,4,4-trimethylpentylphosphine oxide
(e.g., commercial blends IRGACURE 1800, 1850, and 1700 available
from Ciba Specialty Chemical); 2,2-dimethoxy-2-phenylacetophenone
(e.g., IRGACURE 651, available from Ciba Specialty Chemical);
bis(2,4,6-trimethylbenzoyl)phenylphosphine oxide (IRGACURE 819);
(2,4,6-trimethylbenzoyl)diphenyl phosphine oxide (LUCIRIN TPO,
available from BASF (Munich, Germany));
ethoxy(2,4,6-trimethylbenzoyl)phenylphosphine oxide (LUCIRIN TPO-L
from BASF); and combinations thereof.
[0089] In one or more embodiments, the first polymer is produced
prior to laminate production. Here, the first polymer can be
manufactured to have specific dimensions prior to being disposed
between the first and second substrate. In one or more embodiments,
a mixture composed of one or more monomers, photoinitiator, and
optional crosslinking agent described herein can be applied to a
surface of the first and/or second substrate followed by bringing
the first and second substrate together so that a thin film of the
monomer is disposed between the first and second substrate. The
laminate is subsequently exposed to UV light in order to cure the
monomer(s) and produce the first polymer in situ.
[0090] In one or more embodiments, two or more polymers can be
admixed together to produce a final polymeric composition with the
properties described herein (e.g., tan .delta. value greater than
1.0). Thus, the combination of two or more polymers can be used to
modify the mechanical properties of the polymer composition in
order to optimize the damping properties of the resulting
laminate.
[0091] The thickness of the first polymer can vary depending upon
the application of the laminate. In one or more embodiments, the
thickness of the first polymer can be in the range from about 0.01
mm to about 2 mm. In another aspect, the thickness of the first
polymer is in the range from about 0.01 mm to about 1.8 mm, in the
range from about 0.01 mm to about 1.6 mm, in the range from about
0.01 mm to about 1.5 mm, in the range from about 0.01 mm to about
1.4 mm, in the range from about 0.01 mm to about 1.2 mm, in the
range from about 0.01 mm to about 1 mm, in the range from about
0.01 mm to about 0.8 mm, in the range from about 0.01 mm to about
0.6 mm, in the range from about 0.01 mm to about 0.5 mm, in the
range from about 0.01 mm to about 0.4 mm, in the range from about
0.01 mm to about 0.2 mm, in the range from about 0.05 mm to about 2
mm, in the range from about 0.1 mm to about 2 mm, in the range from
about 0.2 mm to about 2 mm, in the range from about 0.3 mm to about
2 mm, in the range from about 0.4 mm to about 2 mm, in the range
from about 0.5 mm to about 2 mm, in the range from about 0.6 mm to
about 2 mm, in the range from about 0.7 mm to about 2 mm, in the
range from about 0.8 mm to about 2 mm, in the range from about 0.9
mm to about 2 mm, or in the range from about 1 mm to about 2 mm,
and all ranges and sub-ranges therebetween. The interlayer
structure may have a thickness in the range from about 0.5 mm to
about 2.5 mm, from about 0.5 mm to about 2.4 mm, from about 0.5 mm
to about 2.2 mm, from about 0.5 mm to about 2 mm, from about 0.5 mm
to about 1.8 mm, from about 0.5 mm to about 1.6 mm, from about 0.5
mm to about 1.5 mm, from about 0.5 mm to about 1.4 mm, from about
0.5 mm to about 1.2 mm, from about 0.5 mm to about 1 mm, from about
0.6 mm to about 2.5 mm, from about 0.7 mm to about 2.5 mm, from
about 0.8 mm to about 2.5 mm, from about 0.9 mm to about 2.5 mm,
from about 1 mm to about 2.5 mm, from about 1.1 mm to about 2.5 mm,
from about 1.2 mm to about 2.5 mm, from about 1.3 mm to about 2.5
mm, from about 1.4 mm to about 2.5 mm, from about 1.5 mm to about
2.5 mm, from about 1 mm to about 2 mm, from about 1.1 mm to about 2
mm, from about 1.2 mm to about 2 mm, from about 1.3 mm to about 2
mm, from about 1.4 mm to about 2 mm, from about 1 mm to about 1.9
mm, from about 1 mm to about 1.8 mm, or from about 1 mm to about
1.7 mm, and all ranges and sub-ranges therebetween.
First and Second Substrate
[0092] The first and second substrates 110 and 130 may have the
same thickness or differing thicknesses. In some embodiments, the
thickness of the first substrate 110 may be in the range from about
0.3 mm to about 4 mm (e.g., from about 0.4 mm to about 4 mm, from
about 0.5 mm to about 4 mm, from about 0.55 mm to about 4 mm, from
about 0.6 mm to about 4 mm, from about 0.7 mm to about 4 mm, from
about 0.8 mm to about 1 mm, from about 0.9 mm to about 4 mm, from
about 1 mm to about 4 mm, from about 1.2 mm to about 4 mm, from
about 1.5 mm to about 4 mm, from about 1.8 mm to about 4 mm, from
about 2 mm to about 4 mm, from about 2.1 mm to about 4 mm, from
about 2.5 mm to about 4 mm, from about from about 1 mm to about 4
mm, from about 0.3 mm to about 3 mm, from about 0.3 mm to about 2.1
mm, from about 0.3 mm to about 2 mm, from about 0.3 mm to about 1.8
mm, from about 0.3 mm to about 1.5 mm, from about 0.3 mm to about 1
mm, from about 0.3 mm to about 0.7 mm, or from about 1.2 mm to
about 1.8 mm, and all ranges and sub-ranges therebetween.
[0093] In one or more embodiments, the thickness of the second
substrate 130 may be less than the thickness of the first substrate
110. In some embodiments, the second substrate 230 is about 1.6 mm
or less, less than 1.6 mm, 1.5 mm or less, 1.4 mmo or less, 1.3 mm
or less, 1.2 mm or less, 1.1 mm or less, 1 mm or less, 0.7 mm or
less, 0.5 mm or less or about 0.4 mm or less. In some embodiments,
the thickness of the second substrate 230 may be in the range from
about 0.3 mm to about 4 mm (e.g., from about 0.4 mm to about 4 mm,
from about 0.5 mm to about 4 mm, from about 0.55 mm to about 4 mm,
from about 0.6 mm to about 4 mm, from about 0.7 mm to about 4 mm,
from about 0.8 mm to about 1 mm, from about 0.9 mm to about 4 mm,
from about 1 mm to about 4 mm, from about 1.2 mm to about 4 mm,
from about 1.5 mm to about 4 mm, from about 1.8 mm to about 4 mm,
from about 2 mm to about 4 mm, from about 2.1 mm to about 4 mm,
from about 2.5 mm to about 4 mm, from about from about 1 mm to
about 4 mm, from about 0.3 mm to about 3 mm, from about 0.3 mm to
about 2.1 mm, from about 0.3 mm to about 2 mm, from about 0.3 mm to
about 1.8 mm, from about 0.3 mm to about 1.5 mm, from about 0.3 mm
to about 1 mm, from about 0.3 mm to about 0.7 mm, and all ranges
and sub-ranges therebetween.
[0094] In embodiments in which the first substrate 110 has a
thickness greater than the second substrate, the second substrate
may have a thickness of about 1.5 mm or less, about 1 mm or less or
about 0.7 mm or less. The difference in thickness between the first
substrate 110 and the second substrate 130 may be about 0.5 mm or
greater, 0.7 mm or greater, 0.8 mm or greater, 1 mm or greater or
about 1.4 mm or greater. Some exemplary thickness combinations for
the first substrate 110 and the second substrate 130 may be
(written in the form of first substrate thickness in
millimeters/second substrate thickness in millimeters) 2.1/1.8,
2.1/1.5, 2.1/1, 2.1/0.7, 2.1/0.55, 2.1/0.4, 1.8/1.8, 1.8/1.5,
1.8/1, 1.8/0.7, 1.8/0.55, 1.8/0.4, 1.5/1.5, 1.5/1, 1.5/0.7,
1.5/0.55, 1.5/0.4, 1/1, 1/0.7, 1/0.55,1/0.4, 0.7/0.7, 0.7/0.55,
0.55/0.55, 0.55/0.5, 0.55/0.4, 0.5/0.5, 0.5/0.4, and 0.4/0.4.
[0095] The thickness of the first substrate 110 and the second
substrate 130 may be described by a ratio. In some embodiments, the
ratio of the thickness of the second substrate to the thickness of
the first substrate is greater than about 0.33. In some cases the
ratio may be about 0.35 or greater, 0.37 or greater, 0.39 or
greater, 0.4 or greater, 0.42 or greater, 0.44 or greater, 0.46 or
greater, 0.48 or greater, about 0.5 or greater, or about 0.55 or
greater. The upper limit of the ratio of the thickness of the
second substrate to the thickness of the first substrate may be
about 1. In some embodiments, the first and second substrates 110,
130 may each have a thickness of about 1.5 mm or less, 1 mm or
less, or even 0.7 mm or less, and still exhibit a ratio that is
greater than 0.33. In one or more embodiments, such thin laminates
may still exhibit the transmission loss performance described
herein at frequencies of about 2500 Hz or greater.
[0096] In one or more embodiments, either one or both of the first
and second substrates 110, 130 exhibits a refractive index in the
range from about 1.45 to about 1.55. In specific embodiments,
either one or both of the first and second substrates 110, 130 may
exhibit an average strain-to-failure at a surface on one or more
opposing major surface that is 0.5% or greater, 0.6% or greater,
0.7% or greater, 0.8% or greater, 0.9% or greater, 1% or greater,
1.1% or greater, 1.2% or greater, 1.3% or greater, 1.4% or greater
1.5% or greater or even 2% or greater, as measured using
ball-on-ring testing using at least 5, at least 10, at least 15, or
at least 20 samples. In specific embodiments, either one or both of
the first and second substrates 110, 130 may exhibit an average
strain-to-failure at its surface on one or more opposing major
surface of about 1.2%, about 1.4%, about 1.6%, about 1.8%, about
2.2%, about 2.4%, about 2.6%, about 2.8%, or about 3% or
greater.
[0097] Either one or both of the first and second substrates 110,
130 may exhibit an elastic modulus (or shear modulus) in the range
from about 30 GPa to about 120 GPa. In some instances, the elastic
modulus of either one or both of the first and second substrates
210, 230 may be in the range from about 30 GPa to about 110 GPa,
from about 30 GPa to about 100 GPa, from about 30 GPa to about 90
GPa, from about 30 GPa to about 80 GPa, from about 30 GPa to about
70 GPa, from about 40 GPa to about 120 GPa, from about 50 GPa to
about 120 GPa, from about 60 GPa to about 120 GPa, from about 70
GPa to about 120 GPa, and all ranges and sub-ranges
therebetween.
[0098] The materials used in the laminate may vary according to
application or use. In one or more embodiments, the first substrate
110 and second layer 130 may be characterized as having a greater
modulus than the interlayer structure 120. In some embodiments, the
first and second substrates 110 and 130 may be described as
inorganic and may include an amorphous substrate, a crystalline
substrate or a combination thereof. Either one or both the first
and second substrates 110 and 130 may be formed from man-made
materials and/or naturally occurring materials. In some specific
embodiments, the substrate 110 may specifically exclude plastic
and/or metal substrates.
[0099] In some embodiments, either one or both of the first and
second substrates 110 and 130 may be organic and specifically
polymeric. Examples of suitable polymers include, without
limitation: thermoplastics including polystyrene (PS) (including
styrene copolymers and blends), polycarbonate (PC) (including
copolymers and blends), polyesters (including copolymers and
blends, including polyethyleneterephthalate and
polyethyleneterephthalate copolymers), polyolefins (PO) and
cyclopolyolefins (cyclic-PO), polyvinylchloride (PVC), acrylic
polymers including polymethyl methacrylate (PMMA) (including
copolymers and blends), thermoplastic urethanes (TPU),
polyetherimide (PEI) and blends of these polymers with each other.
Other exemplary polymers include epoxy, styrenic, phenolic,
melamine, and silicone resins.
[0100] In one or more embodiments, either one or both of the first
and second substrates 110, 130 may be amorphous and may include
glass, which may be strengthened or non-strengthened. Examples of
suitable glass include soda lime glass, alkali aluminosilicate
glass, alkali containing borosilicate glass and alkali
aluminoborosilicate glass. In some variants, the glass may be free
of lithia. In one or more alternative embodiments, either one or
both of the first and second substrates 110, 130 may include
crystalline substrates such as glass ceramic substrates (which may
be strengthened or non-strengthened) or may include a single
crystal structure, such as sapphire. In one or more specific
embodiments, the substrate 110 includes an amorphous base (e.g.,
glass) and a crystalline cladding (e.g., sapphire layer, a
polycrystalline alumina layer and/or or a spinel
(MgAl.sub.2O.sub.4) layer).
[0101] Either one or both of the first and second substrates 110,
130 may be substantially planar or sheet-like, although other
embodiments may utilize a curved or otherwise shaped or sculpted
substrate. Either one or both of the first and second substrates
110, 130 may be substantially optically clear, transparent and free
from light scattering.
[0102] Additionally or alternatively, the physical thickness of
either one or both of the first and second substrates 110, 130 may
vary along one or more of its dimensions for aesthetic and/or
functional reasons. For example, the edges of a substrate may be
thicker as compared to more central regions. The length, width and
physical thickness dimensions of either one or both of the first
and second substrates 110, 130 may also vary according to the
application or use.
[0103] The first and second substrate 110, 130 may be provided
using a variety of different processes. For instance, where the
substrate includes an amorphous substrate such as glass, various
forming methods can include float glass processes and down-draw
processes such as fusion draw and slot draw.
[0104] Once formed, either one or both of the first and second
substrates 110, 130 may be strengthened to form a strengthened
substrate. As used herein, the term "strengthened substrate" may
refer to a substrate that has been chemically strengthened, for
example through ion-exchange of larger ions for smaller ions in the
surface of the substrate. However, other strengthening methods
known in the art, such as thermal tempering, or utilizing a
mismatch of the coefficient of thermal expansion between portions
of the substrate to create compressive stress and central tension
regions, may be utilized to form strengthened substrates.
[0105] Where the substrate is chemically strengthened by an ion
exchange process, the ions in the surface layer of the substrate
are replaced by--or exchanged with--larger ions having the same
valence or oxidation state. Ion exchange processes are typically
carried out by immersing a substrate in a molten salt bath
containing the larger ions to be exchanged with the smaller ions in
the substrate. It will be appreciated by those skilled in the art
that parameters for the ion exchange process, including, but not
limited to, bath composition and temperature, immersion time, the
number of immersions of the substrate in a salt bath (or baths),
use of multiple salt baths, additional steps such as annealing,
washing, and the like, are generally determined by the composition
of the substrate and the desired compressive stress (CS), and depth
of compressive stress layer (DOC) of the substrate that result from
the strengthening operation. By way of example, ion exchange of
alkali metal-containing glass substrates may be achieved by
immersion in at least one molten bath containing a salt such as,
but not limited to, nitrates, sulfates, and chlorides of the larger
alkali metal ion. The temperature of the molten salt bath typically
is in a range from about 380.degree. C. up to about 450.degree. C.,
while immersion times range from about 15 minutes up to about 40
hours. However, temperatures and immersion times different from
those described above may also be used.
[0106] The degree of strengthening exhibited by either one or both
the first and second substrates may be quantified by the parameters
of central tension (CT), surface compressive stress (CS), and depth
of compression (DOC). CT and CS are provided in units of MPa and
DOC is typically provided in units of micrometers or as a fraction
of the total thickness of the substrate. As used herein, the terms
"depth of compression" and "DOC" refer to the depth at which the
stress within the substrate changes from compressive to tensile
stress. At the DOC, the stress crosses from a positive
(compressive) stress to a negative (tensile) stress and thus
exhibits a stress value of zero.
[0107] Where strengthened glass is used for the substrate, surface
CS may be measured near the surface or within the strengthened
glass substrate at various depths. A maximum CS value may include
the measured CS at the surface (CSs) of the strengthened substrate.
CS and DOC are measured using those means known in the art. Such
means include, but are not limited to, measurement of surface
stress using a surface stress meter, such as the commercially
available instrument the FSM-6000, manufactured by Luceo Co., Ltd.
(Tokyo, Japan). Surface stress measurements rely upon the accurate
measurement of the stress optical coefficient (SOC), which is
related to the birefringence of the glass substrate. SOC in turn is
measured according to a modified version of Procedure C described
in ASTM standard C770-98 (2013), entitled "Standard Test Method for
Measurement of Glass Stress-Optical Coefficient," the contents of
which are incorporated herein by reference in their entirety. The
modification includes using a glass disc as the specimen with a
thickness of 5 to 10 mm and a diameter of 12.7 mm, wherein the disc
is isotropic and homogeneous and core drilled with both faces
polished and parallel. The modification also includes calculating
the maximum force, Fmax to be applied. The force should be
sufficient to produce at least 20 MPa compression stress. Fmax is
calculated as follows:
F max=7.854*D*h
[0108] Where:
[0109] F max=Force in Newtons
[0110] D=the diameter of the disc
[0111] h=the thickness of the light path
For each force applied, the stress is computed as follows:
.sigma..sub.MPa=8F/(.pi.t*D*h)
[0112] Where:
[0113] F=Force in Newtons
[0114] D=the diameter of the disc
[0115] h=the thickness of the light path
[0116] In some embodiments, the CT, which is computed for the inner
region adjacent the compressive stress layer within a glass
substrate, can be calculated from the CS, the physical thickness t,
and the DOC. The relationship between CS and CT is given by the
expression (1):
CT=(CSDOC)/(t-2 DOC) (1),
wherein t is the physical thickness (.mu.m) of the glass
article.
[0117] In one embodiment, a strengthened substrate can have a
surface CS in the range from about 50 MPa to about 800 MPa (e.g.,
about 100 MPa or greater, about 150 MPa or greater, about 200 MPa
or greater, of 250 MPa or greater, 300 MPa or greater, e.g., 400
MPa or greater, 450 MPa or greater, 500 MPa or greater, 550 MPa or
greater, 600 MPa or greater, 650 MPa or greater, 700 MPa or
greater, or 750 MPa or greater). The strengthened substrate may
have a DOC in the range from about 35 .mu.m to about 200 .mu.m
(e.g., 45 .mu.m, 60 .mu.m, 75 .mu.m, 100 .mu.m, 125 .mu.m, 150
.mu.m or greater). In one or more specific embodiments, the
strengthened substrate has one or more of the following: a surface
CS of about 50 MPa to about 200 MPa, and a DOC in the range from
about 100 .mu.m to about 200 .mu.m; a surface CS of about 600 MPa
to about 800 MPa and a DOC in the range from about 35 .mu.m to
about 70 .mu.m.
[0118] The strengthened substrate may have a DOC in the range from
about 35 .mu.m to about 200 .mu.m (e.g., 45 .mu.m, 60 .mu.m, 75
.mu.m, 100 .mu.m, 125 .mu.m, 150 .mu.m or greater). In one or more
specific embodiments, the strengthened substrate has one or more of
the following: a surface CS of about 50 MPa to about 200 MPa, and a
DOC in the range from about 100 .mu.m to about 200 .mu.m; a surface
CS of about 600 MPa to about 800 MPa and a DOC in the range from
about 35 .mu.m to about 70 .mu.m.
[0119] Example glasses that may be used in the substrate may
include alkali aluminosilicate glass compositions or alkali
aluminoborosilicate glass compositions, though other glass
compositions are contemplated. Such glass compositions are capable
of being chemically strengthened by an ion exchange process. One
example glass composition comprises SiO.sub.2, B.sub.2O.sub.3 and
Na.sub.2O, where (SiO.sub.2+B.sub.2O.sub.3).gtoreq.66 mol. %, and
Na.sub.2O.gtoreq.9 mol. %. In an embodiment, the glass composition
includes at least 6 wt. % aluminum oxide. In a further embodiment,
the substrate includes a glass composition with one or more
alkaline earth oxides, such that a content of alkaline earth oxides
is at least 5 wt. %. Suitable glass compositions, in some
embodiments, further comprise at least one of K.sub.2O, MgO, and
CaO. In a particular embodiment, the glass compositions used in the
substrate can comprise 61-75 mol. % SiO2; 7-15 mol. %
Al.sub.2O.sub.3; 0-12 mol. % B.sub.2O.sub.3; 9-21 mol. % Na.sub.2O;
0-4 mol. % K.sub.2O; 0-7 mol. % MgO; and 0-3 mol. % CaO.
[0120] A further example glass composition suitable for the
substrate comprises: 60-70 mol. % SiO.sub.2; 6-14 mol. %
Al.sub.2O.sub.3; 0-15 mol. % B.sub.2O.sub.3; 0-15 mol. % Li.sub.2O;
0-20 mol. % Na.sub.2O; 0-10 mol. % K.sub.2O; 0-8 mol. % MgO; 0-10
mol. % CaO; 0-5 mol. % ZrO.sub.2; 0-1 mol. % SnO.sub.2; 0-1 mol. %
CeO.sub.2; less than 50 ppm As.sub.2O.sub.3; and less than 50 ppm
Sb.sub.2O.sub.3; where 12 mol.
%.ltoreq.(Li.sub.2O+Na.sub.2O+K.sub.2O).ltoreq.20 mol. % and 0 mol.
%.ltoreq.(MgO+CaO).ltoreq.10 mol. %.
[0121] A still further example glass composition suitable for the
substrate comprises: 63.5-66.5 mol. % SiO.sub.2; 8-12 mol. %
Al.sub.2O.sub.3; 0-3 mol. % B.sub.2O.sub.3; 0-5 mol. % Li.sub.2O;
8-18 mol. % Na.sub.2O; 0-5 mol. % K.sub.2O; 1-7 mol. % MgO; 0-2.5
mol. % CaO; 0-3 mol. % ZrO.sub.2; 0.05-0.25 mol. % SnO.sub.2;
0.05-0.5 mol. % CeO.sub.2; less than 50 ppm As.sub.2O.sub.3; and
less than 50 ppm Sb.sub.2O.sub.3; where 14 mol.
%.ltoreq.(Li.sub.2O+Na.sub.2O+K.sub.2O).ltoreq.18 mol. % and 2 mol.
%.ltoreq.(MgO+CaO).ltoreq.7 mol. %.
[0122] In a particular embodiment, an alkali aluminosilicate glass
composition suitable for the substrate comprises alumina, at least
one alkali metal and, in some embodiments, greater than 50 mol. %
SiO.sub.2, in other embodiments at least 58 mol. % SiO.sub.2, and
in still other embodiments at least 60 mol. % SiO.sub.2, wherein
the ratio
Al 2 O 3 + B 2 O 3 modifiers > 1 ##EQU00001##
, where in the ratio the components are expressed in mol. % and the
modifiers are alkali metal oxides. This glass composition, in
particular embodiments, comprises: 58-72 mol. % SiO.sub.2; 9-17
mol. % Al.sub.2O.sub.3; 2-12 mol. % B.sub.2O.sub.3; 8-16 mol. %
Na.sub.2O; and 0-4 mol. % K.sub.2O, wherein the ratio
Al 2 O 3 + B 2 O 3 modifiers > 1 ##EQU00002##
[0123] In still another embodiment, the substrate may include an
alkali aluminosilicate glass composition comprising: 64-68 mol. %
SiO.sub.2; 12-16 mol. % Na.sub.2O; 8-12 mol. % Al.sub.2O.sub.3; 0-3
mol. % B.sub.2O.sub.3; 2-5 mol. % K.sub.2O; 4-6 mol. % MgO; and 0-5
mol. % CaO, wherein: 66 mol.
%.ltoreq.SiO.sub.2+B.sub.2O.sub.3+CaO.ltoreq.69 mol. %;
Na.sub.2O+K.sub.2O+B.sub.2O.sub.3+MgO+CaO+SrO>10 mol. %; 5 mol.
%.ltoreq.MgO+CaO+Sr.ltoreq.8 mol. %;
(Na.sub.2O+B.sub.2O.sub.3)-Al.sub.2O.sub.3.ltoreq.2 mol. %; 2 mol.
%.ltoreq.Na.sub.2O-Al.sub.2O.sub.3.ltoreq.6 mol. %; and 4 mol.
%.ltoreq.(Na.sub.2O+K.sub.2O)-Al.sub.2O.sub.3.ltoreq.10 mol. %.
[0124] In an alternative embodiment, the substrate may comprise an
alkali aluminosilicate glass composition comprising: 2 mol % or
more of Al.sub.2O.sub.3 and/or ZrO.sub.2, or 4 mol % or more of
Al.sub.2O.sub.3 and/or ZrO.sub.2.
[0125] Where a substrate 110, 130 includes a crystalline substrate,
the substrate may include a single crystal, which may include
Al.sub.2O.sub.3. Such single crystal substrates are referred to as
sapphire. Other suitable materials for a crystalline substrate
include polycrystalline alumina layer and/or spinel
(MgAl.sub.2O.sub.4).
[0126] Optionally, the crystalline substrate 110, 130 may include a
glass ceramic substrate, which may be strengthened or
non-strengthened. Examples of suitable glass ceramics may include
Li.sub.2O--Al.sub.2O.sub.3--SiO.sub.2 system (i.e. LAS-System)
glass ceramics, MgO--Al.sub.2O.sub.3--SiO.sub.2 system (i.e.
MAS-System) glass ceramics, and/or glass ceramics that include a
predominant crystal phase including .beta.-quartz solid solution,
.beta.-spodumene ss, cordierite, and lithium disilicate. The glass
ceramic substrates may be strengthened using the chemical
strengthening processes disclosed herein. In one or more
embodiments, MAS-System glass ceramic substrates may be
strengthened in Li.sub.2SO.sub.4 molten salt, whereby an exchange
of 2Li.sup.+ for Mg.sup.2+ can occur.
[0127] In one or more embodiments, the first substrate is
unstrengthened, while the second substrate is strengthened. In some
embodiments, the first substrate may include a soda lime glass.
Optionally, the first substrate may include a soda lime glass that
is strengthened. In another embodiment, the first substrate may
include an alkali aluminosilicate glass that is strengthened.
[0128] The substrate composition may include a colorant to provide
darkening for privacy glass, and/or reducing the transmission of
infrared radiation for solar glass.
Applications of the Laminates
[0129] The laminates described herein can be used as windows and
glazing in architectural and transportation applications. The
laminates can also be used as panels in balustrades and stairs, and
as decorative panels or covering for walls, columns, elevator cabs,
kitchen appliances and other applications. The laminates may be
transparent, semi-transparent, translucent or opaque and may
comprise part of a window, panel, wall, enclosure, sign or other
structure. Common types of such laminates may also be tinted or
colored or include a component that is tinted or colored.
[0130] An example of a vehicle that includes a laminate as
described herein is shown in FIG. 3. The vehicle 300 includes a
body 310 with at least one opening 320. The laminate 100 is
disposed in the at least one opening 320. As used herein, the term
"vehicle" may include automobiles (e.g., cars, vans, trucks,
semi-trailer trucks, motorcycles, and buses), rolling stock,
locomotives, train cars, aircraft (e.g., helicopters, planes,
gliders, drones, etc.), and seacraft (ships, boats, etc.) and the
like. The opening 320 is a window within which a laminate is
disposed to provide a transparent covering.
[0131] The laminate may be disposed in an opening of a vehicle or
within an architectural panel by adhesives and other means (e.g.,
clamps, fasteners, etc.) to secure the laminate thereto.
[0132] Depending upon the application of the laminate (e.g.,
windows in an automobile), it is desirable that the laminate be
transparent. The selection of the first material and the first
polymer can affect the transparency of the laminate. In one aspect,
the first polymer has an average transmittance of greater than 80%,
over a wavelength range from about 400 nm to about 700 nm, at a
first polymer thickness of 1 mm. In another aspect, the laminates
described herein exhibit an average transmittance of greater than
80%, over a wavelength range from about 400 nm to about 700 nm. The
laminate may exhibit such average transmittance values over any one
or more of the thicknesses disclosed herein. The transmittance
values provided herein may be measured using a CIE illuminant such
as D65 or F02 and may be measured at normal incidence.
[0133] In one or more embodiments, the laminate may have a
thickness in a range from about 1 mm to about 10 mm. For example,
the laminate may have a thickness in a range from about 1.2 mm to
about 10 mm, from about 1.4 mm to about 10 mm, from about 1.5 mm to
about 10 mm, from about 1.6 mm to about 10 mm, from about 1.8 mm to
about 10 mm, from about 2 mm to about 10 mm, from about 2.2 mm to
about 10 mm, from about 2.4 mm to about 10 mm, from about 2.5 mm to
about 10 mm, from about 2.6 mm to about 10 mm, from about 2.8 mm to
about 10 mm, from about 3 mm to about 10 mm, from about 3.2 mm to
about 10 mm, from about 3.4 mm to about 10 mm, from about 3.5 mm to
about 10 mm, from about 3.6 mm to about 10 mm, from about 3.8 mm to
about 10 mm, from about 4 mm to about 10 mm, from about 1 mm to
about 9 mm, from about 1 mm to about 8 mm, from about 1 mm to about
7 mm, from about 1 mm to about 6 mm, from about 1 mm to about 5 mm,
from about 1 mm to about 4 mm, from about 1 mm to about 3.8 mm,
from about 1 mm to about 3.6 mm, from about 1 mm to about 3.5 mm,
from about 1 mm to about 3.4 mm, from about 1 mm to about 3.2 mm,
from about 1.6 mm to about 2.2 mm, from about 1.6 mm to about 2.4
mm, from about 1.6 mm to about 2.5 mm, from about 1.6 mm to about
2.6 mm, from about 1.6 mm to about 2.8 mm, from about 1.6 mm to
about 3 mm, from about 1.6 mm to about 3.2 mm, from about 3.7 mm to
about 5.7 mm, from about 3.5 mm to about 5.5 mm, and all ranges and
sub-ranges therebetween.
[0134] In one or more embodiments, the laminates described herein
exhibit a sound transmission loss of about 38 dB or greater, over a
frequency range from about 2500 Hz to about 6000 Hz. For example, a
laminate according to one or more embodiments described herein
exhibits a sound transmission loss of about 38.2 dB or greater,
about 38.4 dB or greater, about 38.5 dB or greater, about 38.6 dB
or greater, about 38.8 dB or greater, about 39 dB or greater, about
39.2 dB or greater, about 39.4 dB or greater, about 39.5 dB or
greater, about 39.6 dB or greater, about 39.8 dB or greater, about
40 dB or greater, about 40.2 dB or greater, about 40.4 dB or
greater, about 40.5 dB or greater, about 40.6 dB or greater, about
40.8 dB or greater, or about 41 dB or greater, all over a frequency
range from about 2500 Hz to about 6000 Hz. In some embodiments, the
sound transmission loss values described herein may be exhibited
over a frequency range from about 4000 Hz to about 6000 Hz, from
about 4200 Hz to about 6000 Hz, from about 4500 Hz to about 6000
Hz, or from about 5000 Hz to about 6000 Hz.
[0135] In the case when the laminates described herein are used as
windows in automobiles or other vehicles, the laminates will meet
the FMVSS 205 standards under 49 CFR 571.205, which includes the
standards approved by American National Standards Institute (e.g.,
ANSI/SAE Z26.1-1996) and Society of Automotive Engineers (e.g., SAE
J673).
[0136] The laminates described herein may include one or more
films, coatings or surface treatments to provide added
functionality. Examples of such films and/or coatings include
anti-reflective coatings, UV absorbing coatings, IR reflecting
coatings, anti-glare surface treatments, and the like.
[0137] In other aspects, the laminates described herein can be
photochromic. For example, the first substrate, the second
substrate, the interlayer structure (e.g., the first polymer), or
any combination thereof can be doped with one or more photochromic
agents known in the art to photochromic laminates.
EXAMPLES
[0138] The following examples are put forth so as to provide those
of ordinary skill in the art with a complete disclosure and
description of how the compounds, compositions, and methods
described and claimed herein are made and evaluated, and are
intended to be purely exemplary and are not intended to limit the
scope of what the inventors regard as their invention. Efforts have
been made to ensure accuracy with respect to numbers (e.g.,
amounts, temperature, etc.) but some errors and deviations should
be accounted for. Unless indicated otherwise, parts are parts by
weight, temperature is in .degree. C. or is at ambient temperature,
and pressure is at or near atmospheric. There are numerous
variations and combinations of reaction conditions, e.g., component
concentrations, desired solvents, solvent mixtures, temperatures,
pressures and other reaction ranges and conditions that can be used
to optimize the product purity and yield obtained from the
described process. Only reasonable and routine experimentation will
be required to optimize such process conditions.
[0139] Measurement of Dynamic Mechanical Shear Properties of
Polymer Samples
[0140] A film sample of polymer material having a thickness in the
range from about 0.8 to about 1.7 mm is loaded between circular
parallel plate fixtures (8 mm diameter) in a rheometer model DHR-3
(TA Instruments). Multiple layers of material were used to achieve
the desired specimen thickness between the plates. The instrument
was run with the following primary mechanical and environmental
settings for a temperature ramp test and a temperature sweep test
on the instrument. Some of the settings were adjusted depending on
individual material to get the optimum readings from the
instrument.
[0141] For the temperature ramp test, the axial force adjust mode
was set to active compression using a load in the range from 1N to
5N. The initial temperature was set in the range from -50.degree.
C. to 0.degree. C. depending on the glass transition temperature of
the sample and allowed to soak for up to 5 minutes before starting
the test. A frequency of 1 Hz and an initial strain in the range of
0.002%-0.01% was used while running in non-iterative sampling mode,
which enabled the instrument to adjust the strain during the test
during heating. An initial torque of 1000 microN-m and a lower
torque limit of 100 microN-m was used. A heating rate of 2.degree.
C./minute was used using with a nitrogen atmosphere and the test
was ended at an upper temperature of 50.degree. C. or as high as
100.degree. C.
[0142] A temperature sweep test was run by setting the axial force
adjustment mode to active compression using a load in the range
from 1N to 5N. The initial temperature was set in the range from
-50.degree. C. to 0.degree. C. depending on the glass transition
temperature of the specimen and allowed to soak for up to 5 minutes
before starting the test. The sample was sheared from 1-100 rad/s
at an initial strain in the range of 0.001% to 0.01% and 5 data
points per decade of frequency were collected. The instrument was
run in non-iterative sampling mode with an initial torque of 1000
microN-m and a lower torque limit of 100 microN-m. After the
frequency sweep was conducted, the temperature was increased by
5.degree. C., allowed to equilibrate for 5 min and then repeated
until reaching the final temperature, which could be as high as
60.degree. C.
[0143] The parallel plate fixtures and specimen were enclosed in a
temperature controlled oven and two experiments (i.e., the
temperature ramp test and the temperature sweep test) were
performed. First, a temperature ramp experiment was conducted. In
this experiment, the material was cooled to the starting
temperature and then sheared in a sinusoidal fashion at a fixed
frequency of 1 Hz while the temperature was increased at a heating
rate of 2.degree. C./min and the test was stopped once it reached
the final temperature. During the test the instrument measures the
elastic portion of the viscoelastic response, storage shear modulus
(G') and the viscous portion of the response, loss shear modulus
(G''). These two quantities change as a function of frequency and
temperature but in this experiment, since the frequency is held
constant, the temperature response of the material was measured.
The ratio of the viscous to elastic portion of the response is
called tan .delta., which equals G''/G' and is a measure of the
damping character of the polymeric material. Polymers typically
exhibit a peak in tan .delta. at the glass transition temperature
(T.sub.g) where maximum damping occurs. A temperature ramp of the
middle core layer of the APVB material is shown in FIG. 4a, where
the oscillation frequency is 1 Hz and temperature ramp rate at
2.degree. C./min. The tan .delta. peak occurs at approximately
-8.degree. C.
[0144] For sound transmission loss of a laminate, it is important
to characterize the damping performance of the damping polymer in
the frequency range of interest at the operating temperature of
interest. Since the rheometer instrument cannot directly conduct
measurements at frequencies of 1,000 Hz to 10,000 Hz the principle
of time-temperature superposition was used to make frequency
mastercurves at the desired reference operating temperature. This
principle is discussed in the reference book entitled Polymer
Viscoelasticity, 3.sup.rd Ed. by J. Ferry (John Wiley & Sons,
New York 1980). To make a mastercurve, a temperature sweep test is
conducted where the temperature is held constant and the specimen
is oscillated over a range of frequencies typically from 0.1 to100
rad/s which can be converted to frequency in Hertz using the
relationship that 1 Hz=2.pi. rad/s.). The specimen is cooled to the
initial temperature and allowed to equilibrate for at least 5
minutes. The samples are measured as a function of frequency at
five frequencies per decade. The temperature is increased by
5.degree. C., allowed to equilibrate for 5 minutes and the
frequency sweep is repeated. At the end of the experiment, one data
set is chosen as the reference temperature, usually a temperature
near the glass transition temperature, and all the other data sets
at different temperatures are connected to the data set at the
reference temperature by shifting them horizontally along the
x-axis by applying a multiplication factor to the frequency values,
called the shift factor. The entire mastercurve itself can then be
shifted to a different reference temperature desired by using the
shift factors obtained by making the mastercurve. This procedure of
shifting the data is called time-temperature superposition and is
routinely used in polymer analysis. The mastercurve provides
dynamic data (G', G'', tan .delta.) at the reference temperature
for many orders of magnitude of frequencies. It allows the user to
obtain data at high frequencies (e.g. 1,000-10,000 Hz), which the
instrument cannot measure directly. Ultimately, the data from the
mastercurve can be used to model the sound transmission loss
performance of glass/polymer laminates. A mastercurve of the core
layer of acoustic PVB material (SAFLEX.RTM. QE51 manufactured by
Eastman Chemical Company) is shown in FIG. 4b at a reference
temperature of 20.degree. C. The core layer was obtained by
mechanically separating it from between the two outer layers of
standard PVB.
[0145] The tan .delta. reaches a maximum value in the range of
1,000 Hz to 7,000 Hz.
Comparative Studies with Laminates
[0146] Several polymers were evaluated against the core layer of
acoustic PVB and standard PVB. Tables 1-6 provide the polymers
evaluated and the corresponding tan .delta. and G' values for each
polymer. Values of tan .delta. and G' are taken from mastercurves
constructed at a reference temperature of 20.degree. C. and at a
frequency as close to 6,300 Hz as possible (i.e. within 10%). If
outside that range tan .delta. and G' values were an average value
based on the two data points on either side of 6,300 Hz.
[0147] Table 7 provides the tan .delta. and G' values for standard
PVB (SAFLEX.RTM. RB41 manufactured by Eastman Chemical Company) and
the core layer of acoustic PVB (SAFLEX.RTM. QE51 manufactured by
Eastman Chemical Company) at 20.degree. C. and 6,300 Hz. The
following materials were used to produce the polymers in Tables
1-6. [0148] TPO is Lucirin TPO, a photoinitiator from BASF [0149]
Irgacure 651 is from BASF [0150] PPG400DA is the diacrylate of
polypropyleneglycol with an average molecular [0151] weight of 400
(M2040 supplied by Miwon) [0152] M140 is phenoxyethylacrylate from
Miwon [0153] M142 is phenoxyethoxyethylacrylate from Miwon [0154]
M144 is phenoxyethoxyethoxyethoxyethylacrylate from Miwon [0155]
M1140* is isobornyl acrylate from Miwon [0156] SR256 is
ethoxyethoxyethylacrylate (EOEOEA) from Sartomer [0157] M1130 is
Trimethylcyclohexylacrylate (TMCHA) from Miwon [0158] CD9075 is
laurylethoxylated(4)acrylate (L(EO).sub.4A) from Sartomer [0159]
SR395 is isodecyl acrylate from Sartomer [0160] NVC is
N-Vinylcaprolactam from Sigma-Aldrich [0161] AA is acrylic acid
from Arkema [0162] TPGDA is tripropylene glycol diacrylate from
Cytec [0163] SR440 is isooctyl acrylate from Sartomer [0164] TEGBEH
is triethyleneglycolbis(2-ethyl hexanoate) (Solusolv 2075) from
Eastman Chemical Company [0165] C17A is heptadecyl acrylate from
BASF [0166] 2-PHA is 2-propylheptyl acrylate from BASF [0167] UC102
is (1,3-butadiene, 2-methyl-homopolymer, maleated,
2-[(2-methyl-1-oxo-2-propenyl)oxy] ethyl esters) from Kurray Co.
[0168] M111 is Aronix M111 ethoxylated nonylphenolacrylate from
International Specialty Chemical [0169] ADMA is
adamatylmethacrylate from Bymax [0170] IOMP is isooctyl
3-mercaptopropionate from Sigma-Aldrich [0171] A-189 is Silquest
189 (mercaptopropyltrimethoxysilane) from Momentive [0172] D1173 is
Darocur.RTM. 1173 from BASF [0173] **IBOA is Ageflex isobornyl
acrylate from CPS Chemical Co.
TABLE-US-00001 [0173] TABLE 1 1 2 3 Function Material wt % wt % wt
% Photoinitiator TPO 1 1 1 Crosslinker M2040 1 1 1 PPG400DA Monomer
1 M142 M140 M1140 P(EO).sub.2A PEA IBOA* 98 40 32 Monomer 2 -- M142
M144 0 P(EO).sub.2A P(EO).sub.4A 58 66 tan .delta. 2.76 2.59 2.07
(at 20.degree. C., 6300 Hz) G' (MPa) 1.19 9.68 1.25 (at 20.degree.
C., 6300 Hz)
TABLE-US-00002 TABLE 2 4 5 6 7 8 9 10 Function Material wt % wt %
wt % wt % wt % wt % wt % Photo- TPO 1 1 1 1 1 1 1 initiator
Crosslinker M2040 1 1 1 1 1 1 1 PPG400DA Monomer 1 M140 M140 M1140
M1140 M1140 M1140 M1140 PEA PEA IBOA* IBOA* IBOA* IBOA* IBOA* 52 16
47 38 40 50 28 Monomer 2 M144 M142 SR256 M144 CD9075 SR395 M140
P(EO).sub.4A P(EO).sub.2A EOEOEA P(EO).sub.4A L(EO).sub.4A EDA PEA
46 82 51 60 58 48 28 Monomer 3 0 0 0 0 0 0 SR256 EOEOEA 42 tan
.delta. 2.45 3.04 1.72 2.29 (at 20.degree. C., 6300 Hz) G' (MPa)
9.16 4.47 19.6 9.69 (at 20.degree. C., 6300 Hz)
TABLE-US-00003 TABLE 3 11 12 13 14 15 16 Function Material wt % wt
% wt % wt % wt % wt % Photoinitiator TPO 1 1 1 1 1 1 Crosslinker
M2040 1 1 1 1 1 1 PPG400DA Monomer 1 various M1140 M1140 M140 M1130
M1140 NVC IBOA* IBOA* PEA TMCHA IBOA* 5 52 31 26 10 8 Monomer 2
various CD9075 SR395 M142 M142 M142 M142 L(EO).sub.4A IDA
P(EO).sub.2A P(EO).sub.2A P(EO).sub.2A P(EO).sub.2A 46 67 72 88 90
93 tan .delta. 1.93 2.08 3.18 2.97 2.93 2.78 (at 20.degree. C.,
6300 Hz) G' (MPa) 6.51 6.12 5.24 2.93 2.72 2.92 (at 20.degree. C.,
6300 Hz)
TABLE-US-00004 TABLE 4 17 18 19 20 21 22 Function Material wt % wt
% wt % wt % wt % wt % Photoinitiator TPO 0.3 0.3 0.3 0.3 0.3 0.3
Crosslinker TPGDA 0.15 0.15 0.15 0.15 0.15 0.15 Monomer 1 2-PHA
2-PHA C17A C17A AA AA 69.69 59.73 69.69 59.73 4.98 9.96 Monomer 2
IBOA** IBOA** IBOA** IBOA** CD9075 SR395 29.87 39.82 29.87 39.82
L(EO).sub.4A IDA 94.57 89.60 tan .delta. 1.91 1.68 2.03 1.68 1.31
1.02 (at 20.degree. C., 6300 Hz) G' (MPa) 3.60 14.2 3.35 13.1 2.1
9.3 (at 20.degree. C., 6300 Hz)
TABLE-US-00005 TABLE 5 23 24 25 26 27 28 Function Material wt % wt
% wt % wt % wt % wt % Photoinitiator Irgacure 0.3 0 0.3 0 0.3 0.3
651 Photoinitiator TPO 0 1 0 1 0 0 Crosslinker TPGDA 0.15 0 0.15 0
0.15 0.15 Crosslinker PPG400DA 0 1 0 1 0 0 Plasticizer TEGBEH 0 1 0
1 0 0 Monomer 1 AA AA IBOA** IBOA** IBOA** IBOA** 7.47 7.47 9.96
9.96 14.93 9.96 Monomer 2 SR440 SR440 SR440 SR440 SR440 SR440 92.09
92.09 89.60 89.60 84.62 84.62 Monomer 3 0 0 0 0 0 AA 4.98 tan
.delta. 1.06 1.13 1.83 1.72 2.06 1.42 (at 20.degree. C., 6300 Hz)
G' (MPa) 4.01 3.60 0.64 0.42 0.91 4.1 (at 20.degree. C., 6300
Hz)
TABLE-US-00006 TABLE 6 29 30 Function Material wt % wt %
Photoinitiator D1173 5 5 Silane Adhesion Promoter A-189 3 3 Liquid
Rubber UC102 35 35 Chain Transfer Agent IOMP 5 1 Monomer 1 M111
M111 21 21 Monomer 2 ADMA IBOA** 31 35 tan .delta. 1.71 1.41 (at
20.degree. C., 6300 Hz) G' (MPa) 4.0 4.7 (at 20.degree. C., 6300
Hz)
TABLE-US-00007 TABLE 7 Standard Core Layer PVB Acoustic PVB tan
.delta. 0.18 1.03 (at 20.degree. C., 6300 Hz) G' (MPa) 209 3.08 (at
20.degree. C., 6300 Hz)
[0174] As a non-limiting example, FIG. 5 shows the temperature ramp
DMA tan .delta. response of the UV cured material Sample 5 (Table
2) compared to the benchmark core layer of acoustic PVB material
and the standard PVB material. The peak in tan .delta. of Sample 5
occurs near the same temperature of the core layer of acoustic PVB
material but its magnitude is much larger and therefore has much
higher damping properties than the core layer of acoustic PVB
material. Mastercurves of the standard PVB, core layer acoustic
PVB, and Sample 5 at a reference temperature of 20.degree. C. are
shown in FIG. 6. As can be seen, Sample 5 has much higher damping
than the acoustic PVB core material. The mastercurve data was used
as an input to model the acoustic sound transmission loss (STL)
performance of a window laminate construction of various layers and
layer thicknesses shown in FIG. 7. The UV-curable Sample 5 in FIG.
5 had a significantly higher theoretical acoustic sound
transmission loss due to higher damping compared to the currently
used acoustic PVB material.
[0175] The temperature at which the tan .delta. peak occurs, or Tg,
can be adjusted in the formulation to better match that of the core
layer of acoustic PVB. The tan .delta. peak of Samples 5, 13, and
14 in Tables 2 and 3 were determined and compared to the core layer
of acoustic PVB, with the results in FIG. 8. As shown in FIG. 8,
the tan .delta. peak of samples 5, 13, and 14 was significantly
higher than that of acoustic PVB. Additionally, samples 5, 13, and
14 are clear once UV-cured.
[0176] Referring to FIG. 9, samples 5, 13, and 14 had peak tan
.delta. values near or above 3 at 20.degree. C. over the frequency
range of 1,000 Hz to 10,000 Hz. These values are substantially
higher than the core layer of QE51, which is an acoustic grade of
PVB (APVB) composed of two outer layers of standard PVB
(approximately 0.34 mm each) and a thin layer of highly plasticized
PVB (approximately 0.13 mm) in the middle.
[0177] Aspect (1) of this disclosure pertains to a laminate
comprising an interlayer structure comprising a first polymer
disposed between a first substrate and a second substrate, wherein
the first polymer comprises a tan .delta. value greater than 1.0 at
a temperature a range from about -20.degree. C. to about 40.degree.
C. and a frequency in a range from about 1 Hz to about 20,000
Hz.
[0178] Aspect (2) of this disclosure pertains to the laminate
according to Aspect (1), wherein the first polymer comprises a tan
.delta. value greater than 1.0 at a temperature in a range from
about -20.degree. C. to about 40.degree. C. when measured at
mechanical frequency of 1 Hz and a heating rate of 2.degree.
C./minute.
[0179] Aspect (3) of this disclosure pertains to the laminate
according to Aspect (1) or Aspect (2), wherein the first polymer
comprises a glass transition temperature, as indicated by a peak in
tan .delta., in a range from about 0.degree. C. to about
-20.degree. C. at a mechanical frequency of 1 Hz with a heating
rate of 2.degree. C./minute.
[0180] Aspect (4) of this disclosure pertains to the laminate
according to any one or more of Aspect (1) through Aspect (3),
wherein the first polymer comprises a tan .delta. value greater
than 1.0 at a temperature of 20.degree. C. at a frequency in a
range from about 1,000 Hz to about 20,000 Hz.
[0181] Aspect (5) of this disclosure pertains to the laminate
according to any one or more of Aspect (1) through Aspect (4),
wherein the first polymer comprises a tan .delta. value greater
than 2.0 at a temperature in a range from about -20.degree. C. to
about 40.degree. C. when measured at mechanical frequency of 1 Hz
and a heating rate of 2.degree. C./min.
[0182] Aspect (6) of this disclosure pertains to the laminate
according to any one or more of Aspect (1) through Aspect (5),
wherein the first polymer comprises a tan .delta. value in a range
from about 2.0 to about 4.0 at a temperature in a range from about
-20.degree. C. to about 40.degree. C. when measured at mechanical
frequency of 1 Hz and a heating rate of 2.degree. C./min.
[0183] Aspect (7) of this disclosure pertains to the laminate
according to any one or more of Aspect (1) through Aspect (6),
wherein the first polymer comprises a tan .delta. value in a range
from about 2.0 to about 4.0 at a temperature in a range from about
-20.degree. C. to about 40.degree. C. and at a frequency in a range
from about 1,000 Hz to about 20,000 Hz.
[0184] Aspect (8) of this disclosure pertains to the laminate
according to any one or more of Aspect (1) through Aspect (4),
wherein the first polymer has a tan .delta. value greater than 1.25
at 20.degree. C. and at all frequencies in a range from about 100
Hz to about 100,000 Hz.
[0185] Aspect (9) of this disclosure pertains to a laminate
comprising an interlayer structure comprising a first polymer
disposed between a first substrate and a second substrate, wherein
the first polymer has a tan .delta. value greater than a core layer
of an acoustic PVB within a frequency range of 1 Hz to 20,000
Hz.
[0186] Aspect (10) pertains to the laminate of Aspect (9), wherein
the first polymer has a tan .delta. value that is 1.2 to 4 times
greater than the core layer of the acoustic PVB within a frequency
range of 1,000 Hz to 20,000 Hz.
[0187] Aspect (11) pertains to the laminate of Aspect (9) or Aspect
(10), wherein the first polymer is produced by the polymerization
of one or more ethylenically unsaturated compounds.
[0188] Aspect (12) of this disclosure pertains to the laminate
according to any one or more of Aspect (1) through Aspect (10),
wherein the first polymer is produced by the polymerization of one
or more monomers comprising an allyl compound, a vinyl compound, an
acrylate, a methacrylate, an acrylamide, or a methacrylamide, or
any combination thereof
[0189] Aspect (13) of this disclosure pertains to the laminate
according to any one or more of Aspect (1) through Aspect (10),
wherein the first polymer is the polymerization product of two or
more acrylate monomers.
[0190] Aspect (14) of this disclosure pertains to the laminate
according to any one or more of Aspect (1) through Aspect (10),
wherein the first constituent and second constituent are selected
from the group consisting of ethoxylated nonylphenolacrylate,
phenoxyethoxyethylacrylate, phenoxyethylacrylate,
trimethylcyclohexylacrylate, isobornyl acrylate,
phenoxyethoxyethoxyethoxyethylacrylate, ethoxyethoxyethylacrylate,
isooctyl acrylate, laurylethoxylated(4)acrylate, isodecyl acrylate,
ethoxyethoxyethylacrylate, N-vinylcaprolactam, 2-propylheptyl
acrylate, heptadecyl acrylate, acrylic acid, isobornyl acrylate,
and adamatylmethacrylate.
[0191] Aspect (15) of this disclosure pertains to the laminate
according to any one or more of Aspect (1) through Aspect (10),
wherein the first polymer is further at least partially crosslinked
with a crosslinking agent.
[0192] Aspect (16) of this disclosure pertains to the laminate
according to Aspect (15), wherein the crosslinking agent is a
diacrylate compound or dimethacrylate compound.
[0193] Aspect (17) of this disclosure pertains to the laminate
according to Aspect (15), wherein the crosslinking agent is a
polyalkylene oxide diacrylate compound or a polyalkylene oxide
dimethacrylate compound.
[0194] Aspect (18) of this disclosure pertains to the laminate
according to Aspect (15), wherein the crosslinking agent is an
oligo-propylene glycol diacrylate.
[0195] Aspect (19) of this disclosure pertains to the laminate
according to any one or more of Aspect (1) through Aspect (18),
wherein the interlayer structure comprises a first layer and a
second layer, wherein the first layer comprises the first
polymer.
[0196] Aspect (20) of this disclosure pertains to the laminate
according to any one or more of Aspect (1) through Aspect (19),
wherein the first layer is disposed between a second layer and a
third layer.
[0197] Aspect (21) of this disclosure pertains to the laminate
according to Aspect (19) or Aspect (20), wherein the second layer
and the third layer comprise the same polymeric material.
[0198] Aspect (22) of this disclosure pertains to the laminate
according to Aspect (19) or Aspect (20), wherein the second layer
and the third layer comprise different polymeric materials from one
another.
[0199] Aspect (23) of this disclosure pertains to the laminate
according to any one or more of Aspect (19) through Aspect (22),
wherein either one or both of the second layer and the third layer
comprise a polymeric material selected from the group consisting of
polyvinyl butyral (PVB), ethylene-vinyl acetate (EVA) and
thermoplastic polyurethane (TPU), polyester (PE), and polyethylene
terephthalate (PET).
[0200] Aspect (24) of this disclosure pertains to the laminate
according to any one or more of Aspect (19) through Aspect (23),
wherein the second layer and the third layer comprise polyvinyl
butyral (PVB).
[0201] Aspect (25) of this disclosure pertains to the laminate
according to any one or more of Aspect (1) through Aspect (24),
wherein the first substrate has a thickness of 2.1 mm or less.
[0202] Aspect (26) of this disclosure pertains to the laminate
according to any one or more of Aspect (1) through Aspect (24),
wherein the first substrate has a thickness in the range from about
1.6 mm to about 4 mm.
[0203] Aspect (27) of this disclosure pertains to the laminate
according to any one or more of Aspect (1) through Aspect (26),
wherein the first substrate comprises an unstrengthened glass.
[0204] Aspect (28) of this disclosure pertains to the laminate
according to any one or more of Aspect (1) through Aspect (27),
wherein the first substrate comprises soda lime glass.
[0205] Aspect (29) of this disclosure pertains to the laminate
according to any one or more of Aspect (1) through Aspect (26) and
Aspect (28), wherein the first substrate comprises a strengthened
glass.
[0206] Aspect (30) of this disclosure pertains to the laminate
according to any one or more of Aspect (1) through Aspect (29),
wherein the second substrate has a thickness less than the
thickness of the first substrate.
[0207] Aspect (31) of this disclosure pertains to the laminate
according to any one or more of Aspect (1) through Aspect (30),
wherein the second substrate comprises a strengthened glass.
[0208] Aspect (32) of this disclosure pertains to the laminate
according Aspect (30), wherein the second substrate exhibits a
compressive stress in the range from about 50 MPa to about 800 MPa
and a depth of compression in the range from about 35 micrometers
to about 200 micrometers.
[0209] Aspect (33) of this disclosure pertains to the laminate
according to any one or more of Aspect (1) through Aspect (32),
wherein the first substrate has a thickness and the ratio of the
thickness of the second substrate to the thickness of the first
substrate is greater than about 0.33.
[0210] Aspect (34) of this disclosure pertains to the laminate
according to any one or more of Aspect (1) through Aspect (33),
wherein the ratio of the thickness of the second substrate to the
thickness of the first substrate is about 0.39 or greater.
[0211] Aspect (35) of this disclosure pertains to the laminate
according to any one or more of Aspect (1) through Aspect (34),
wherein the ratio of the thickness of the second substrate to the
thickness of the first substrate is about 0.5 or greater.
[0212] Aspect (36) of this disclosure pertains to the laminate
according to any one or more of Aspect (1) through Aspect (35),
wherein the first polymer comprises an average transmittance of
greater than 80%, over a wavelength range from about 400 nm to
about 700 nm, at a first polymer thickness of 1 mm.
[0213] Aspect (37) of this disclosure pertains to the laminate
according to any one or more of Aspect (1) through Aspect (36),
wherein the laminate comprises an average transmittance of greater
than 80%, over a wavelength range from about 400 nm to about 700
nm, at any one or more of the thicknesses described herein.
[0214] Aspect (38) of this disclosure pertains to the laminate
according to any one or more of Aspect (1) through Aspect (37),
wherein the laminate has a sound transmission loss of transmission
loss of greater than about 38 dB over a frequency range from about
2500 Hz to about 6000 Hz.
[0215] Aspect (39) of this disclosure pertains to a vehicle
comprising a body, an opening and the laminate of any one or more
of Aspect (1) through Aspect (38) disposed in the opening.
[0216] Aspect (40) of this disclosure pertains to the vehicle of
Aspect (39) wherein the body comprises an automobile, a railcar,
aircraft or seacraft.
[0217] Aspect (41) of this disclosure pertains to an architectural
panel comprising the laminate of any one or more of Aspect (1)
through Aspect (40), wherein the panel comprises a window, an
interior wall panel, a modular furniture panel, a backsplash, a
cabinet panel, or an appliance panel.
[0218] Aspect (42) of this disclosure pertains to a polymer
comprising a polymerization product of a first constituent and a
second constituent, wherein the first constituent and second
constituent are selected from the group consisting of ethoxylated
nonylphenolacrylate, phenoxyethoxyethylacrylate,
phenoxyethylacrylate, Trimethylcyclohexylacrylate, isobornyl
acrylate, phenoxyethoxyethoxyethoxyethylacrylate,
ethoxyethoxyethylacrylate, isooctyl acrylate,
laurylethoxylated(4)acrylate, isodecyl acrylate,
ethoxyethoxyethylacrylate, N-Vinylcaprolactam, 2-propylheptyl
acrylate, heptadecyl acrylate, acrylic acid, isobornyl acrylate,
and adamatylmethacrylate, wherein the first constituent and the
second constituent are not the same.
[0219] Aspect (43) of this disclosure pertains to the polymer of
Aspect (42), wherein the polymer comprises a polymerization product
comprises a third constituent, wherein the third constituent is
selected from the group consisting of ethoxylated
nonylphenolacrylate, phenoxyethoxyethylacrylate,
phenoxyethylacrylate, Trimethylcyclohexylacrylate, isobornyl
acrylate, phenoxyethoxyethoxyethoxyethylacrylate,
ethoxyethoxyethylacrylate, isooctyl acrylate,
laurylethoxylated(4)acrylate, isodecyl acrylate,
ethoxyethoxyethylacrylate, N-Vinylcaprolactam, 2-propylheptyl
acrylate, heptadecyl acrylate, acrylic acid, isobornyl acrylate,
and adamatylmethacrylate, wherein the third constituent is not the
same as the first and the second constituent.
[0220] Aspect (44) of this disclosure pertains to the polymer of
any one or more of Aspect (42) and Aspect (43), wherein the first
constituent comprises phenoxyethylacrylate and the second
constituent comprises phenoxyethoxyethylacrylate.
[0221] Aspect (45) of this disclosure pertains to the polymer of
any one or more of Aspect (42) and Aspect (43), wherein the first
constituent comprises isobornyl acrylate or phenoxyethylacrylate,
and the second constituent comprises
phenoxyethoxyethoxyethoxyethylacrylate.
[0222] Aspect (46) of this disclosure pertains to the polymer of
any one or more of Aspect (42) and Aspect (43), wherein the first
constituent comprises phenoxyethylacrylate and the second
constituent comprises phenoxyethoxyethylacrylate.
[0223] Aspect (47) of this disclosure pertains to the polymer of
any one or more of Aspect (42) and Aspect (43), wherein the first
constituent comprises isobornyl acrylate and the second constituent
comprises ethoxyethoxyethylacrylate,
phenoxyethoxyethoxyethoxyethylacrylate, phenoxyethoxyethylacrylate
isodecyl acrylate, isooctyl acrylate or
laurylethoxylated(4)acrylate.
[0224] Aspect (48) of this disclosure pertains to the polymer of
any one or more of Aspect (42) and Aspect (43), wherein the first
constituent comprises isobornyl acrylate, the second constituent
comprises phenoxyethylacrylate, and the third constituent comprises
ethoxyethoxyethylacrylate.
[0225] Aspect (49) of this disclosure pertains to the polymer of
any one or more of Aspect (42) and Aspect (43), wherein the first
constituent comprises trimethylcyclohexylacrylate and the second
constituent comprises phenoxyethoxyethylacrylate.
[0226] Aspect (50) of this disclosure pertains to the polymer of
any one or more of Aspect (42) and Aspect (43), wherein the first
constituent comprises N-Vinylcaprolactam and the second constituent
comprises phenoxyethoxyethylacrylate.
[0227] Aspect (51) of this disclosure pertains to the polymer of
any one or more of Aspect (42) and Aspect (43), wherein the first
constituent comprises 2-propylheptyl acrylate or heptadecyl
acrylate, and the second constituent comprises isobornyl
acrylate.
[0228] Aspect (52) of this disclosure pertains to the polymer of
any one or more of Aspect (42) and Aspect (43), wherein the first
constituent comprises acrylic acid and the second constituent
comprises laurylethoxylated(4)acrylate, or isodecyl acrylate.
[0229] Aspect (53) of this disclosure pertains to the polymer of
Aspect (43), wherein the first constituent comprises isobornyl
acrylate, the second constituent comprises isooctyl, and the third
constituent comprises acrylic acid.
[0230] Aspect (54) of this disclosure pertains to the polymer of
Aspect (43), wherein the first constituent comprises ethoxylated
nonylphenolacrylate, and the second constituent comprises
adamatylmethacrylate or isobornyl acrylate.
[0231] Aspect (55) of this disclosure pertains to the polymer of
any one or more of Aspect (42) through Aspect (54), wherein the
polymer is at least partially crosslinked with a crosslinking
agent.
[0232] Aspect (56) of this disclosure pertains to a laminate
comprising an interlayer structure comprising a first polymer
disposed between a first substrate and a second substrate, wherein
the first polymer is produced by the polymerization of one or more
ethylenically unsaturated compounds, wherein the laminate exhibits
a sound transmission loss of greater than about 38 dB over a
frequency range from about 2500 Hz to about 6000 Hz.
[0233] Aspect (57) of this disclosure pertains to the laminate of
Aspect (56), wherein the first polymer is produced by the
polymerization of one or more monomers comprising an allyl
compound, a vinyl compound, an acrylate, a methacrylate, an
acrylamide, or a methacrylamide, or any combination thereof.
[0234] Aspect (58) of this disclosure pertains to the laminate of
any one or more Aspect (56) and Aspect (57), wherein the first
polymer is the polymerization product of two or more acrylate
monomers.
[0235] Aspect (59) of this disclosure pertains to the laminate of
any one or more of Aspect (56) through Aspect (58), wherein the
first polymer is at least partially crosslinked with a crosslinking
agent.
[0236] Aspect (60) of this disclosure pertains to the laminate of
any one or more of Aspect (56) through Aspect (59), wherein the
first substrate has a thickness of 2.1 mm or less.
[0237] Aspect (61) of this disclosure pertains to the laminate of
any one or more of Aspect (56) through Aspect (60), wherein the
first substrate has a thickness in the range from about 1.6 mm to
about 4 mm.
[0238] Aspect (62) of this disclosure pertains to the laminate of
any one or more of Aspect (56) through Aspect (61), wherein the
first substrate comprises an unstrengthened glass.
[0239] Aspect (63) of this disclosure pertains to the laminate of
any one or more of Aspect (56) through Aspect (62), wherein the
first substrate comprises soda lime glass.
[0240] Aspect (64) of this disclosure pertains to the laminate of
any one or more of Aspect (56 through Aspect (61) and Aspect (63),
wherein the first substrate comprises a strengthened glass.
[0241] Aspect (65) of this disclosure pertains to the laminate of
any one or more of Aspect (56) through Aspect (64), wherein the
second substrate has a thickness less than the thickness of the
first substrate.
[0242] Aspect (66) of this disclosure pertains to the laminate of
any one or more of Aspect (56) through Aspect (65), wherein the
second substrate comprises a strengthened glass.
[0243] Aspect (67) of this disclosure pertains to the laminate of
Aspect (66), wherein the second substrate exhibits a compressive
stress in the range from about 50 MPa to about 800 MPa and a depth
of compression in the range from about 35 micrometers to about 200
micrometers.
[0244] Aspect (68) of this disclosure pertains to the laminate of
any one or more of Aspect (56) through Aspect (67), wherein the
first substrate has a thickness and the ratio of the thickness of
the second substrate to the thickness of the first substrate is
greater than about 0.33.
[0245] Aspect (69) of this disclosure pertains to the laminate of
any one or more of Aspect (56) through Aspect (68), wherein the
ratio of the thickness of the second substrate to the thickness of
the first substrate is about 0.39 or greater.
[0246] Aspect (70) of this disclosure pertains to the laminate of
any one or more of Aspect (56) through Aspect (69), wherein the
ratio of the thickness of the second substrate to the thickness of
the first substrate is about 0.5 or greater.
[0247] Aspect (71) of this disclosure pertains to the laminate of
any one or more of Aspect (56) through Aspect (70), wherein the
first polymer exhibits an average transmittance of greater than
80%, over a wavelength range from about 400 nm to about 700 nm, at
a first polymer thickness of 1 mm.
[0248] Aspect (72) of this disclosure pertains to the laminate of
any one or more of Aspect (56) through Aspect (71), wherein the
laminate exhibits an average transmittance of greater than 80%,
over a wavelength range from about 400 nm to about 700 nm, at any
one or more of the thicknesses described herein.
[0249] Aspect (73) pertains to a vehicle comprising a body, an
opening and the laminate of any one or more of Aspect (56) through
Aspect (72), disposed in the opening.
[0250] Aspect (74) pertains to the vehicle of Aspect (73), wherein
the body comprises an automobile, a railcar, aircraft or
seacraft.
[0251] Aspect (75) pertains to an architectural panel comprising
the laminate of any one or more of Aspect (56) through Aspect (72),
wherein the panel comprises a window, an interior wall panel, a
modular furniture panel, a backsplash, a cabinet panel, or an
appliance panel.
[0252] Throughout this application, various publications are
referenced. The disclosures of these publications in their
entireties are hereby incorporated by reference into this
application in order to more fully describe the methods and
articles described herein.
[0253] Various modifications and variations can be made to the
materials, methods, and articles described herein. Other aspects of
the materials, methods, and articles described herein will be
apparent from consideration of the specification and practice of
the materials, methods, and articles disclosed herein. It is
intended that the specification and examples be considered as
exemplary.
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