PVB胶片的化学特性和物理特性
Chemistry and physics characteristic of PVB film
●基本特征 basic character：
化学名称chemistry name: 聚乙烯醇缩丁醛中间膜(俗称PVB胶片) Commonly known as PVB films
比重 proportion: 1．073
折射率 refractive index: 1．524
比热 specific heat: 0．4-0．5cal／g.℃
软化点 intenerate: 117℃-120℃
收缩率 shrink: <3．0％
含水量 containing water: 0．4，0．6％
拉伸强度 tensile strength: ≥200kg／cra
断裂伸长率 part elongate: ≥200％
延伸串 extend : ≥70％
厚度(mm) thickness: 0．38, 0．76，1．52
宽度(mm) width: 1220，1530，1830,2140, 2440
分子结构 molecule configuration:
-(CHCH2CHCH2)-+CH3CH2CH2CHO
I I
OH OH
聚乙烯醇(PVA) 丁醛(BA)
(CHCH2CHCH2)m -(CH2CH)n-
I I I
OH OH OH
＼ ／
CH
I
CH2CH2CH3 聚乙烯醇缩丁醛(PVB film胶片)
●乙烯醇基：23％重量比. vinyl alcohol group: Weight more than 23%,
加入增塑剂(4G7)，乙烯醇基达28％ Join plasticizer (4 G7), vinyl alcohol based of 28%
含有不等量的钾盐，添加剂 contain some kalium salt for additive
在普通氧化剂溶剂中会溶解(乙醇，酮，酯) it can melt in common oxidant solvent (ethanol ,ketone,ester )
●粘结机理： felt principle
玻璃中的SIOH和胶片小的COH基之间的氢键形成粘结力
Si-OH bond of glass combine with C-OH bond of PVB film in hydrogen bond state felting
胶片小的钾离子从玻璃中置换出氢，从而控制了粘结力
The kalium ion in film metathesis out hydrogen of glass,this step control the felt strength
水与COH基争夺和SIOH的结合
Water contest bond Si-OH of glass with C-OH of PVB film;
硬离子(钙，镁离子)妨碍了氢键的形成，降低了粘结力
Forcedly ion (calcium,magnesium ion) foreclose the forming of hydrogen bond,and debase felt force;
●物理特性 physical characteristic
无明显的熔点 it have not clear melting point
可承受250℃温度 can support 250℃
着火较慢，火焰传播较低 fire slow,blaze diffuse slow
不属于易燃物质 not belong to tinder
不属于危害性材料 not belong to harm material
易吸收水份 easy absorbe water
易受温度变化的影响 easy affect by temperature
折射率和玻璃接近 refractive index is near to glass
●粘结力受含水率的影响 felt strength is affacted with rate of containing water
PVB的含水率与相对湿度的关系 PVB rate of contain water relation with relative humidity
相对湿度为18％时，含水率为0．4％ relative humidity is 18% , rate of containing water is 0.4%
相对湿度为28％时，含水率为0．6％ relative humidity is 28% , rate of containing water is 0.6%
相对湿度为35％时，含水率为0．82％ relative humidity is 35% , rate of containing water is 0.82%
相对湿度为40％时，含水率为0．95％ relative humidity is 40% , rate of containing water is 0.95%
●本公司设备发明机理：intent principle of the one step PVB laminate machine
从PVB胶片粘结机理，可以看到，胶片与玻璃的粘结可靠性，并不是靠压力实现的，关键是： From PVB films bond mechanism，to see that film and glass the adhesive of the reliability, and not by pressure implementation, the key is:
1、胶片和玻璃的含水率要尽可能的小；Film and the moisture content of glass to the small as possible;
2、玻璃清洗最好用软水或去离子水，防止钙、镁等硬离子破坏氢键形成；
Glass cleaning, had better use soft water or deionized water, prevent calcium, magnesium and other hard ion damage hydrogen bond formation;
3、PVB胶片与玻璃的粘结化学反应，不需要压力条件，没有压力，粘结反应正常发生。
PVB films and glass the adhesive of the chemical reaction, do not need to pressure conditions, no pressure, binding reaction normal happen.
本公司设备原理：one step PVB laminate machine principle
1、我们的设备，在关键的除湿方面，设定了专门的除湿工序和除湿材料，保证粘结时，PVB胶片具有最小的含水率，与玻璃形成良好粘结，
The machine has special dehumidity process,insures that PVB film has the lowest humidity for felt,so we can obtain good laminating glass witch has no bubble and has more feltforcer than that of autoclave.
2、粘结工艺的保证，在PVB胶片溶解过程中，给夹层玻璃施加1个大气压的等静压，使得PVB胶片流动，填平因玻璃不平整带来的PVB熔融胶体再分布，经过实际生产，我们得出结论，1个大气压完全可以满足PVB夹层钢化玻璃生产的要求；
Bonding technology guarantee, in PVB films dissolved in the process, to sandwich glass on the 1 atmosphere and static pressure, make PVB films flow, fill and level of glass not brings the PVB molten colloid and distribution, through actual production, we draw the conclusion, 1 atmosphere can meet the PVB sandwich toughened glass production requirements;
3、用我们公司设备的生产的产品已通过国家权威部门的检测，获得CCC认证，并申请了发明专利
The laminate product by this principle machine has obtained CCC attestation of china
●目前工艺分析：analyse of autoclave process
目前的高压釜工艺，必须在合片室含水率20%以下的环境中合片,PVB胶片含水率：0.4%,我们理解
Autoclave process : PVB film should be added in glass at the condition of the room relative humidity is below than 20%,that is the PVB film contains 0.4% water
1、 预滚压排气，只能排除合片时的气体，经过预滚压封边后，胶片里的所含的水便无法排出了，胶片高温溶解时，该水汽形成气泡。另外一个形成气泡原因是，较低温度下分解的挥发物形成气泡，
Pre-press exhaust only can exhaust of air of PVB film,it can not discharge the 0.4% water in the PVB film ,the 0.4% water is closed in the laminating glass after eshaust process,it became bubble when PVB film is melt at high temperature,
2、 高压釜粘结的目的是，通过高压把水汽和较低温挥发气体形成的气泡加压溶解在胶片中，PVB与玻璃粘结过程中出现的微小气泡，靠高压保持使气泡不现形，国家标准中，耐热 试验，100℃水煮2小时，不产生气泡的要求，便是针对高压釜产品冷却后，气泡在压力下不现形，但是100℃水煮，释放了原粘结压力，含水率高粘结不好时，便会出现气泡，
Purpose of apply autoclave is that the 0.4% water and low temperature volatilization material of PVB is melted in PVB film by high pressure,bubble is not appear.the standand of heat test is that laminating glass should be poached for two hours and has no bubble appear,reason to do this test is that PVB film is intenerated at 100℃ and high presure by autoclave is weaken,so laminating glass bubble may be appear when laminating glass is not good.
3、 高压工艺与粘结强度没有关系；
Autoclave process has no connection with felt intensity of PVB film and glass.
4、 高压釜工艺的另一目的，我们理解是，钢化玻璃不平整，PVB胶片热熔状态下流动性差，靠高压将熔融PVB胶体，压向玻璃各个不平位置；
Another purpose of Autoclave process, we understand is, toughened glass is uneven, PVB films hot melt state poor liquidity, by high-pressure will melt PVB colloid, and pressure to glass each uneven position;
●一步法PVB夹胶玻璃工艺的实现 The one-step PVB the laminated glass technology realization：
1、 除去PVB胶片中所含的4%-6%水分，则不需要高压釜，实现PVB层压玻璃的非压力一步层压工艺；
Remove PVB films contain 4%-6% water, do not need to GaoYaFu, realize PVB laminated glass of the pressure step laminated process
2、 应用等静压方法施加一个大气压的压力，使PVB胶片在熔融条件下填平玻璃和的不平整性；
application and static pressure method exerts a atmospheres of pressure, make PVB films in molten glass and fill and conditions of uneven sex;
3、 西安美尔斯电子有限公司(http//www.merdq.com)经过反复试验； xi`an mers electric equipment Co.,ltd(http//www.merdq.com) after repeated experiments;
4、 发明了非压力PVB一步法PVB夹胶玻璃专利技术和设备，产品质量优于高压釜传统工艺。
Invented the pressure PVB one-step PVB the laminated glass patent technology and equipment, the product quality is better than GaoYaFu traditional craft.
● 质量分析比较 Quality analysis：
1、经国家安全玻璃与石英玻璃检测中心检测全部合格，达到CCC标准；
Approved by the national safety glass and quartz glass test center testing all qualified to CCC standards；
2、非压力PVB夹胶玻璃的粘结强度大于高压釜的夹胶玻璃。
原因是：高压釜工艺过程中，PVB胶片始终含有4%-6%的水分，水分子与COH基争夺和SIOH的结合，因此粘结力受含水率的 |
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