Multiple layer polymer interlayers having an embossed surface

Abstract

The present invention provides multiple layer interlayers having a relatively soft inner layer and relatively stiff outer layers that can be laminated without unacceptable optical distortion and used in various multiple layer glass panel type applications. Multiple layer interlayers of the present invention have surface topography that is formed by embossing the exposed surface of the interlayer, or individual layers of the multiple layer interlayer, after formation of the interlayer or layers. The embossing process is carried out under temperature conditions that prevent the transfer of the embossing to inner layers of the interlayer. By precisely controlling the embossing of the interlayer, lamination of the interlayer with a rigid substrate does not lead to unacceptable optical distortion caused by the transfer of the surface topography through outer, stiffer layers into softer, internal layers of the interlayer.

1 . A polymer interlayer comprising:
 a first polymer layer comprising a plasticized thermoplastic polymer;   a second polymer layer comprising a plasticized thermoplastic polymer; and,   a third polymer layer comprising a plasticized thermoplastic polymer;   wherein said second polymer layer is disposed between said first polymer layer and said third polymer layer;   wherein said first polymer layer has a tensile break stress that is at least 15 kilograms per square centimeter greater than the tensile break stress of said second polymer layer;   wherein said third polymer layer has a tensile break stress that is at least 15 kilograms per square centimeter greater than the tensile break stress of said second polymer layer;   wherein the surface of said first polymer layer opposite said second polymer layer has an embossed R Z  value of 50 to 90 microns; and,   wherein said first polymer layer has a thickness 0.05 to 0.71 millimeters.   
     
     
         2 . The interlayer of  claim 1 , wherein said surface of said first polymer layer opposite said second polymer layer has an embossed R SM  value of less than 700 microns. 
     
     
         3 . The interlayer of  claim 1 , wherein said surface of said first polymer layer opposite said second polymer layer has a permanence value of less than 95%. 
     
     
         4 . The interlayer of  claim 1 , wherein the surface of said third polymer layer opposite said second polymer layer has an embossed R Z  value of 50 to 90 microns, an embossed R SM  value of less than 700 microns, and a permanence of less than 95%. 
     
     
         5 . The interlayer of  claim 1 , wherein said first polymer layer, said second polymer layer, and said third polymer layer each comprise poly(vinyl butyral). 
     
     
         6 . The interlayer of  claim 1 , wherein the surface of said first polymer layer opposite said second polymer layer has an embossed R Z  value of 50 to 70 microns. 
     
     
         7 . A polymer interlayer comprising:
 a first polymer layer comprising a plasticized thermoplastic polymer;   a second polymer layer comprising a plasticized thermoplastic polymer; and,   a third polymer layer comprising a plasticized thermoplastic polymer;   wherein said second polymer layer is disposed between said first polymer layer and said third polymer layer;   wherein said first polymer layer has a tensile break stress that is at least 15 kilograms per square centimeter greater than the tensile break stress of said second polymer layer;   wherein said third polymer layer has a tensile break stress that is at least 15 kilograms per square centimeter greater than the tensile break stress of said second polymer layer; and,   wherein the surface of said first polymer layer opposite said second polymer layer has a permanence value of less than 95%.   
     
     
         8 . The interlayer of  claim 7 , wherein said surface of said first polymer layer opposite said second polymer layer has an embossed R SM  value of less than 700 microns. 
     
     
         9 . The interlayer of  claim 7 , wherein said surface of said first polymer layer opposite said second polymer layer has an R Z  value of 50 to 90 microns and a thickness of 0.05 to 0.71 millimeters. 
     
     
         10 . The interlayer of  claim 7 , wherein the surface of said third polymer layer opposite said second polymer layer has an embossed R Z  value of 50 to 90 microns, an embossed R SM  value of less than 700 microns, and a permanence of less than 95%. 
     
     
         11 . The interlayer of  claim 7 , wherein said first polymer layer, said second polymer layer, and said third polymer layer each comprise poly(vinyl butyral). 
     
     
         12 . The interlayer of  claim 7 , wherein the surface of said first polymer layer opposite said second polymer layer has a permanence value of less than 90%. 
     
     
         13 . A polymer interlayer comprising:
 a first polymer layer comprising a plasticized thermoplastic polymer;   a second polymer layer comprising a plasticized thermoplastic polymer; and,   a third polymer layer comprising a plasticized thermoplastic polymer;   wherein said second polymer layer is disposed between said first polymer layer and said third polymer layer;   wherein said first polymer layer has a tensile break stress that is at least 15 kilograms per square centimeter greater than the tensile break stress of said second polymer layer;   wherein said third polymer layer has a tensile break stress that is at least 15 kilograms per square centimeter greater than the tensile break stress of said second polymer layer;   wherein the surface of said first polymer layer opposite said second polymer layer has an embossed R SM  value of less than 700 microns.   
     
     
         14 . The interlayer of  claim 13 , said surface of said first polymer layer opposite said second polymer layer has a permanence value of less than 95%. 
     
     
         15 . The interlayer of  claim 13 , wherein said surface of said first polymer layer opposite said second polymer layer has an R Z  value of 50 to 90 microns and a thickness of 0.05 to 0.71 millimeters. 
     
     
         16 . The interlayer of  claim 13 , wherein the surface of said third polymer layer opposite said second polymer layer has an embossed R Z  value of 50 to 90 microns, an embossed R SM  value of less than 700 microns, and a permanence of less than 95%. 
     
     
         17 . The interlayer of  claim 13 , wherein said first polymer layer, said second polymer layer, and said third polymer layer each comprise poly(vinyl butyral). 
     
     
         18 . The interlayer of  claim 13 , wherein the surface of said first polymer layer opposite said second polymer layer has an embossed R SM  value of less than 600 microns. 
     
     
         19 . A method of producing a polymer interlayer, comprising the steps:
 forming a first polymer melt, a second polymer melt, and a third polymer melt;   coextruding said first polymer melt, said second polymer melt, and said third polymer melt to form said interlayer;   cooling said interlayer to below 90° C.;   heating a surface of said interlayer to 138° C. to 204° C.; and,   embossing said surface of said interlayer to an R Z  of 20 to 90 microns with said embossing;   wherein said first polymer layer has a tensile break stress that is at least 15 kilograms per square centimeter greater than the tensile break stress of said second polymer layer; and,   wherein said third polymer layer has a tensile break stress that is at least 15 kilograms per square centimeter greater than the tensile break stress of said second polymer layer.   
     
     
         20 . The method of  claim 19 , wherein said cooling is done to below 60° C. 
     
     
         21 . A multiple layer glazing panel produced by the method comprising the steps:
 forming a first polymer melt, a second polymer melt, and a third polymer melt;   coextruding said first polymer melt, said second polymer melt, and said third polymer melt to form said interlayer;   cooling said interlayer to below 90° C.;   heating a surface of said interlayer to 138° C. to 204° C.; and,   embossing said surface of said interlayer to an R Z  of 20 to 90 microns with said embossing;   wherein said first polymer layer has a tensile break stress that is at least 15 kilograms per square centimeter greater than the tensile break stress of said second polymer layer;   wherein said third polymer layer has a tensile break stress that is at least 15 kilograms per square centimeter greater than the tensile break stress of said second polymer layer; and,   laminating said interlayer between two rigid substrates to form said multiple layer glazing panel.