US4469743A — Polyvinyl butyral laminates

Claim 1

Independent Claim 200 words

A process for preparing a polymeric laminate consisting essentially of: (a) coating at least one surface of a biaxially oriented, dimensionally stable, polyethylene terephthalate film having a thickness of about 2-7 mils and a haze level of less than about 1.0%, to provide a dry thickness of about 1-20 microns with an organic silanol coating composition consisting essentially of: (i) about 5-50 weight percent solids, the solids being partially polymerized and consisting essentially of 10-69 weight percent silica; 0.01-4 weight percent of azido functional silanol; and 30-89 weight percent of organic silanol of the general formula RSi(OH) 3 , wherein R is selected from methyl and up to about 40% of a radical selected from vinyl and phenyl; and (ii) about 95-50 weight percent solvent, the solvent comprising about 10-90 weight percent water and about 90-10 weight percent lower aliphatic alcohol and containing about 0.01-1.0% non-ionic surfactant; the coating composition having a pH of about 6.2-6.5; (b) bonding the coated polyethylene terephthalate film at elevated heat and pressure to a sheet of plasticized polyvinyl butyral to provide a laminate in which the surface of the polyethylene terephthalate not bonded to the polyvinyl butyral is coated with the organic silanol composition.

Claim 2

Dependent Claim 200 words

A process for preparing a polymeric laminate consisting essentially of: (a) coating at least one surface of a biaxially oriented, dimensionally stable, polyethylene terephthalate film having a thickness of about 2-7 mils and a haze level of less than about 1.0%, to provide a dry thickness of about 1-20 microns with an organic silanol coating composition consisting essentially of: (i) about 5-50 weight percent solids, the solids being partially polymerized and consisting essentially of 10-69 weight percent silica; 0.01-4 weight percent of azido functional silanol; and 30-89 weight percent of organic silanol of the general formula RSi(OH) 3 , wherein R is selected from methyl and up to about 40% of a radical selected from vinyl and phenyl; and (ii) about 95-50 weight percent solvent, the solvent comprising about 10-90 weight percent water and about 90-10 weight percent lower aliphatic alcohol and containing about 0.01-1.0% non-ionic surfactant; the coating composition having a pH of about 6.2-6.5; (b) bonding the coated polyethylene terephthalate film at elevated heat and pressure to a sheet of plasticized polyvinyl butyral to provide a laminate in which the surface of the polyethylene terephthalate not bonded to the polyvinyl butyral is coated with the organic silanol composition.

Claim 3

Dependent Claim 131 words

A process of claim 1 wherein the azido functional silanol in the coating solution is obtained by adding to the aqueous components of the coating composition an azido functional silane of the general formula: ##STR3## wherein R is an organic radical, X is selected from halo, hydroxy, alkoxy, aryloxy, organo oxycarbonyl, azido, amine, and amide radicals; T is selected from alkyl, cycloalkyl, aryl, alkaryl, and aralkyl radicals; a is an integer from 1 to 3; b is an integer from 0 to 2; c is an integer from 1 to 10; d is an integer from 1 to 3; and a+b+d equals 4; and Z is selected from ##STR4## where R' is selected from hydrogen, alkyl, cycloalkyl, aryl and --COOR" radicals; where R" is selected from alkyl, cycloalkyl, and aryl radicals.

Claim 4

Dependent Claim 16 words

A process of claim 2 wherein R is an aryl radical of from 6-28 carbon atoms.

Claim 5

Dependent Claim 21 words

A process of claim 2 wherein X is alkoxy of 1 to 3 carbon atoms, and a is 1 to 3.

Claim 6

Dependent Claim 19 words

A process of claim 2 wherein Z is a sulfonyl azide of the formula --SO 2 N 3 .

Claim 7

Dependent Claim 17 words

A process of claim 2 wherein Z is an azido formate of the formula --OCON 3 .

Claim 8

Dependent Claim 14 words

A process of claim 3 wherein the aryl radical is an alkylene diarylene radical.

Claim 9

Dependent Claim 13 words

A process of claim 1 wherein the non-ionic surfactant is a silicone surfactant.

Claim 10

Dependent Claim 23 words

A process of claim 1 wherein the polyvinyl butyral contains less than about 400 parts per million of potassium based adhesion control agent.

Claim 11

Dependent Claim 29 words

A process of claim 9 wherein the polyethylene terephthalate film is treated on at least one side to enhance the ability of the film to adhere to other materials.

Claim 12

Dependent Claim 29 words

A process of claim 10 wherein the polyethylene terephthalate film is treated with a reducing gas flame to enhance the ability of the film to adhere to other materials.

Claim 13

Dependent Claim 35 words

A process of claim 1 wherein one side of the polyethylene terephthalate film is coated with the coating composition and the polyvinyl butyral sheeting is bonded to the uncoated side of the polyethylene terephthalate film.

Claim 14

Dependent Claim 22 words

A process of claim 1 further comprising bonding at least one sheet of glass to the surface of the plasticized polyvinyl butyral.

Claim 15

Dependent Claim 191 words

A polymeric laminate consisting essentially of, (a) a sheet of plasticized polyvinyl butyral; (b) a biaxially oriented, dimensionally stable, polyethylene terephthalate film bonded to the polyvinyl butyral and having a thickness of about 2-7 mils and a haze level of less than about 1.0%, and, (c) a coating on the polyethylene terephthalate film having a thickness of about 1-20 microns, the coating having been produced from an organic silanol composition consisting essentially of: (i) about 5-50 weight percent solids, the solids being partially polymerized and consisting essentially of 10-69 weight percent silica; 0.01-4 weight percent of azido functional silanol; and 30-89 weight percent of organic silanol of the general formula RSi(OH) 3 , wherein R is selected from methyl and up to about 40% of a radical selected from vinyl and phenyl; and (ii) about 95-50 weight percent solvent, the solvent comprising about 10-90 weight percent water and about 90-10 weight percent lower aliphatic alcohol and containing about 0.01-1.0% non-ionic surfactant; the coating composition having a pH of about 6.2-6.5; and in which at least the surface of the polyethylene terephthalate not bonded to the polyvinyl butyral bears a coating (c).

Claim 16

Dependent Claim 191 words

A polymeric laminate consisting essentially of, (a) a sheet of plasticized polyvinyl butyral; (b) a biaxially oriented, dimensionally stable, polyethylene terephthalate film bonded to the polyvinyl butyral and having a thickness of about 2-7 mils and a haze level of less than about 1.0%, and, (c) a coating on the polyethylene terephthalate film having a thickness of about 1-20 microns, the coating having been produced from an organic silanol composition consisting essentially of: (i) about 5-50 weight percent solids, the solids being partially polymerized and consisting essentially of 10-69 weight percent silica; 0.01-4 weight percent of azido functional silanol; and 30-89 weight percent of organic silanol of the general formula RSi(OH) 3 , wherein R is selected from methyl and up to about 40% of a radical selected from vinyl and phenyl; and (ii) about 95-50 weight percent solvent, the solvent comprising about 10-90 weight percent water and about 90-10 weight percent lower aliphatic alcohol and containing about 0.01-1.0% non-ionic surfactant; the coating composition having a pH of about 6.2-6.5; and in which at least the surface of the polyethylene terephthalate not bonded to the polyvinyl butyral bears a coating (c).

Claim 17

Dependent Claim 131 words

A laminate of claim 14 wherein the azido functional silanol in the coating solution is obtained by adding to the aqueous components of the coating composition an azido functional silane of the general formula: ##STR5## wherein R is an organic radical, X is selected from halo, hydroxy, alkoxy, aryloxy, organo oxycarbonyl, azido, amine, and amide radicals; T is selected from alkyl, cycloalkyl, aryl, alkaryl, and aralkyl radicals; a is an integer from 1 to 3; b is an integer from 0 to 2; c is an integer from 1 to 10; d is an integer from 1 to 3; and a+b+d equals 4; and Z is selected from ##STR6## where R' is selected from hydrogen, alkyl, cycloalkyl, aryl and --COOR" radicals; where R" is selected from alkyl, cycloalkyl, and aryl radicals.

Claim 18

Dependent Claim 16 words

A laminate of claim 15 wherein R is an aryl radical of from 6-28 carbon atoms.

Claim 19

Dependent Claim 21 words

A laminate of claim 15 wherein X is alkoxy of 1 to 3 carbon atoms, and a is 1 to 3.

Claim 20

Dependent Claim 19 words

A laminate of claim 15 wherein Z is a sulfonyl azide of the formula --SO 2 N 3 .

Claim 21

Dependent Claim 17 words

A laminate of claim 14 wherein Z is an azido formate of the formula --OCON 3 .

Claim 22

Dependent Claim 14 words

A laminate of claim 16 wherein the aryl radical is an alkylene diarylene radical.

Claim 23

Dependent Claim 13 words

A laminate of claim 14 wherein the non-ionic surfactant is a silicone surfactant.

Claim 24

Dependent Claim 23 words

A laminate of claim 14 wherein the polyvinyl butyral contains less than about 400 parts per million of potassium based adhesion control agent.

Claim 25

Dependent Claim 30 words

A laminate of claim 14 wherein the polyethylene terephthalate film has been treated on at least one side to enhance the ability of the film to adhere to other materials.

Claim 26

Dependent Claim 33 words

A laminate of claim 23 wherein the polyethylene terephthalate film has been treated on both sides with a reducing gas flame to enhance the ability of the film to adhere to other materials.

Claim 27

Dependent Claim 26 words

A laminate of claim 23 wherein the surface of the polyethylene terephthalate film bonded to the polyvinyl butyral has been treated with a water permeable colloid.

Claim 28

Dependent Claim 35 words

A laminate of claim 14 wherein one side of the polyethylene terephthalate film is coated with the coating composition and the polyvinyl butyral sheeting is bonded to the uncoated side of the polyethylene terephthalate film.

Claim 29

Dependent Claim 22 words

A laminate of claim 14 further comprising at least one sheet of glass bonded to the surface of the plasticized polyvinyl butyral.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1987-09-04	1988-03-05	1988-09-04	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1991-09-04	1992-03-05	1992-09-04	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1995-09-04	1996-03-05	1996-09-04	$7700.00	Window Closed / Lapsed

Polyvinyl butyral laminates

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