US 4,095,013 AGrant
Reusable Solar Control Film and Method of Making
Issue Date:1978-06-13
•6 Claims
•1 Drawing Sheets
Abstract
Solar control film incorporating a "cling" adhesive layer so that it can be repeatedly applied to and removed from a windowpane. The adhesive layer is obtained by coating on the film a solvent-soluble vinyl chloride or vinylidene chloride copolymer containing a vinyl stabilizer, a tack-inhibiting polymeric modifier and a plasticizer for vinyl resins.
Metadata
Assignee
- Minnesota Mining and Manufacturing Company
Inventor
- Thomas J. Burger
Application Information
Application Number:US 7968736
Filing Date:1977-05-16
Priority Date:1977-05-16
Art Unit:164
Classifications
IPC:
B32B 2730
Field of Search:
428427336;335;354;355;483;522;918372
Patent Drawings (1 sheets)
Description
BACKGROUND OF THE INVENTION
In one respect, this invention is related to solar control film adapted for bonding to windowpanes. In another aspect, the invention relates to a method of manufacturing solar control films.
It has long been recognized that a transparent or translucent film could be coated with a thin transparent-reflective metallic layer and used to control the solar radiation entering a room. For example, Lion U.S. Pat. No. 2,774,421 discloses roller-mounted window shades in which a transparent or translucent film is coated with a thin layer of vapor-deposited aluminum which may in turn be overcoated with a protective lacquer or varnish. While effective to a degree, Lion's window shade is spaced from the inner surface of a windowpane, thus permitting a considerable amount of heat to be admitted into the room.
Antonson et al U.S. Pat. No. 3,290,203 discloses a solar control film which, like Lion's, utilizes a transparent film which is metallized with a transparent-reflective aluminum layer on one face and provided with a protective overcoating. In the Antonson et al product, however, a water-activatible adhesive is employed to bond the solar control film directly to the inner surface of a windowpane, thereby greatly reducing the amount of solar energy which would otherwise enter the room, be absorbed by objects therein, and be re-emitted as heat. Another type of water-activated adhesive is shown in Theissen U.S. Pat. No. 3,681,179, where a normally tacky and pressure-sensitive adhesive is coated over the film and temporarily inacitivated by an overcoating of a water-soluble material. In both the Antonson et al and Theissen products, water is applied to the exposed coated surface, the windowpane (or both), the film placed in contact with the window and slid into position, and a squeegee thereafter being used to ensure intimate contact between the film and the windowpane. While both the Antonson et al and Theissen products have enjoyed widespread commercial success, there has been a desire for a solar control film product which could be utilized during the hot summer months and removed during the cold winter months. Although both the Antonson et al and Theissen solar control films can be removed, the process of removal is likely to destroy or distort them so that they cannot thereafter be easily reapplied.
For several years, various types of removable and replaceable solar control film have been available in the marketplace. In one embodiment, the solar control film has been simply a metallized biaxially oriented polyethylene terephthalate film in which the metallized layer is overcoated with a "cling" adhesive consisting essentially of a solvent-soluble polyester adhesive. In another embodiment, the "cling" adhesive is a plasticized vinyl film laminated to the structure by means of the soluble polyester adhesive. In the latter product, the structure adheres to a windowpane because of the plasticizer which exudes from the vinyl polymer and forms almost a monomolecular layer between the solar control film and the windowpane. While both types of product are easily applied and can be removed after being adhered to a windowpane for a comparatively short period of time, long-term exposure results in an adhesion buildup such that the solar control film is prone to distortion upon removal, effectively preventing it from being re-applied. Additionally, laminated products of the second type require both a coating and a laminating step, increasing the cost of manufacture.
SUMMARY OF THE INVENTION
The present invention provides a solar control film which is not tacky, which can be applied to a windowpane and allowed to remain in place for several months, removed at the end of the extended exposure to the rays of the sun without distortion, rolled on itself and stored until the next summer season, and again applied to the windowpane. Solar control films of the invention can be repeatedly applied, removed, and reapplied in this manner.
The solar control film of the invention is comparatively simple and inexpensive and is superior to the prior art solar control films incorporating plasticized vinyl films in that it does not increase in adhesion, even when exposed to temperatures on the order of 65.degree. C for extended periods of time.
In accordance with the invention, a solar control film is provided with a thin, transparent "cling" adhesive stratum, or layer, of plasticized resin composition. This composition consists essentially of 100 parts by weight of plasticized solvent-soluble copolymer of vinyl monomers, consisting essentially of either (a) 80-97 parts by weight vinyl chloride and 3-20 parts by weight of monomers selected from the group consisting of vinyl acetate, vinyl alcohol and dibasic acid or (b) vinylidene chloride:acrylonitrile copolymer. The vinyl chloride copolymers are characterized by solubility of 20 parts by weight in 100 parts by weight of a 50:50 toluene:methylethyl ketone blend at room temperature, while the vinylidene chloride copolymers are similarly characterized by solubility of 20 parts by weight in 100 parts by weight of a 30:70 toluene:methylethyl ketone blend at room temperature. The vinyl copolymer may also contain small amounts of dibasic acid monomer.
In addition to the vinyl or vinylidene chloride copolymer, the coating contains 1-5 parts by weight of at least 1 lubricating, chlorine-scavenging light stabilizer for vinyl resins. This stabilizer is a liquid soap selected from the class consisting of (a) soaps having one or more metallic cations selected from the group consisting essentially of barium, cadmium and zinc and (b) tin soaps.
The "cling" adhesive layer also contains 5-100 parts by weight of at least one plasticizer for vinyl resin.
An especially important component of the "cling" adhesive layer is 5-200 parts by weight of at least one tack-controlling, adhesion buildup-inhibiting polymeric modifier selected from the class consisting of polymethylmethacrylate, polyethylmethacrylate, polyisobutylmethacrylate, poly-n-butylmethacrylate, poly-n-butylmethylmethacrylate, and n-butylmethacrylate:isobutylmethacrylate copolymer.
In accordance with the method of the invention, a reusable solar control sheet material is made by a process comprising the steps of (a) providing a self-supporting transparent film having a transparent-reflective layer of metal bonded to one face thereof, a layer of polymeric material protectively overlying the metal coat, (b) providing an organic solvent solution of the "cling" adhesive components mentioned in the preceding paragraphs, (c) applying a thin coating of the solution over the layer of protective polymeric material and (d) evaporating the solvent.
BRIEF DESCRIPTION OF THE DRAWING
The single FIGURE of the drawing depicts a crosssectional view of a solar control product made in accordance with the invention.
DESCRIPTION OF PRESENTLY PREFERRED EMBODIMENTS
As an aid to understanding the invention, a series of tabulated examples will be shown below. In each of these examples, a 2-mil (50-micron) biaxially oriented polyethylene terephthalate film was vapor-coated with aluminum to achieve a visible light transmission of approximately 20%. Over the aluminum vapor coating was then knife-coated through a 2-mil (50-micron) opening, a solution of the following components:
The coating was dried by exposing it for 10 minutes to the radiation from a 230-watt infrared lamp at a distance of 8 inches (20 centimeters), leaving a dried coating which weighed approximately 5.5 grams/m.sup.2 and had a thickness of approximately 0.15 mil (4microns). The purpose of this coating is to provide a protective layer over the aluminum coating and inhibit its oxidation, all as is disclosed more fully in the aforementioned Antonson et al U.S. Pat. No. 3,290,203.
In each of the examples (unless otherwise noted), the following "cling" adhesive solution was then coated over the polyester protective coating:
The adhesive solution was applied with a knife coater having a 2-mil (50-micron) opening and the solvent evaporated to leave a dry coating which weighed approximately 5.5 grams/m.sup.2 and had a thickness of about 0.15 mil (4 microns).
Test Procedure
Each of the tabulated examples was tested as follows:
Adhesion Buildup.
A sheet of solar control film approximately 6 cm .times. 18 cm was applied to cleaned, moistened plate glass and a squeegee used to remove excess water. The glass-solar control film laminate was then dried, film-side up, for at least 4 days at approximately 20.degree. C, 20% relative humidity. Adhesion of the solar control film to the glass was measured by slitting a portion of the film between razor blades spaced 1 inch (about 2.5 cm) apart, doubling the 1-inch (2.5 cm) strip of film back of itself at 180.degree., and measuring the force required to remove it at a rate of 4 cm/second.
A second glass-solar control film laminate was prepared and dried in the same manner as the first and thereafter heated for 16 hours at 65.degree. C and 20% relative humidity. Adhesion of the film to glass was then measured in the same way as for the first sample. (It has been found empirically that this heating process subjects the solar control film to conditions similar to those encountered inside a recreational vehicle parked in summer sunshine.)
Peel Resistance.
To measure the ability of the solar control film of the invention to cling to the surface of glass to which it is applied and resist being inadvertently peeled therefrom -- or even falling off the windowpane shortly after being applied thereto -- an additional test was run on the film of some examples. In this test, a 2-inch .times. 7-inch (51 mm .times. 178 mm) sample of the product was applied to 3/8-inch (9.5 mm) plate glass and allowed to dry, all as described above. A 1-inch (2.5 cm) strip of strongly adherent normally tacky and pressure-sensitive adhesive tape was then adhered to the exposed surface of the solar control film, the strip extending across the 2-inch (51-mm) dimension of the solar control film parallel to and 1 inch (2.5 cm) from one end. A paper clip was inserted over the top of the adhesive tape so that it extended between the tape and the solar control film. To the opposite end of the paper clip was then attached a 500-gram weight. The glass-solar control film laminate was then positioned so that it was mounted at 30.degree. to the vertical, with the solar control film being on the upper surface and the adhesive tape at the upper end. The time required for the solar control film to pull away from the glass was then determined.
Components of Cling Adhesive Composition
To simplify the presentation of examples in tabular form, individual components of the "cling" adhesive are designated by abbreviations; the component indicated by each abbreviation is shown below:
In the following examples, all parts are by weight.
EXAMPLES 1-10
Vinyl Copolymer
These examples all incorporate 100 parts of vinyl polymer, 40 parts G-40 plasticizer, 5 parts G-62 plasticizer, 2 parts 462 stabilizer and 25 parts A-101 modifier. Only the type of vinyl copolymer is varied.
EXAMPLES 11 and 12
Vinylidene Chloride Copolymer
These examples incorporate 100 parts F220, 40 parts G-40 plasticizer, 5 parts G-62 plasticizer, 2 parts 462 stabilizer and the indicated amounts of A-101 modifier.
EXAMPLES 13 - 37
Variations in plasticizer for vinyl resins
Each composition listed below is identical to that of Example 1 except for (a) the use of a different plasticizer system and (b) variations in the amount of detackifier.
EXAMPLES 38 - 43
Stabilizer for Vinyl Resins
The following examples are all identical to Example 1 except for the use of a different stabilizer for the vinyl resins: In each example, however, the total amount of stabilizer employed was 2 parts, as in Example 1.
EXAMPLES 44 - 52
Variations in tack-controlling, adhesion buildup-inhibiting polymeric modifier
Each of the following examples is identical to Example 1 except for varying the type and amount of modifier.
The examples set forth above, while numerous, do not purport to be exhaustive. It is believed, however, that they illustrate the types of variation which can be made in the "cling" adhesive coatings employed in the practice of the invention. Numerous other compositions can also be made to function effectively by making suitable adjustments in the ratios of individual components.
Claims
Accordingly, what is claimed is as follows:
1. In a solar control sheet material comprising a self-supporting transparent film, a transparent-reflective coat of metal bonded to one face of said film, and a layer of polymeric material protectively overlying said metal coat, said sheet material having particular utility for application to the room side of windowpanes to reduce light transmission and heat transmission from outside, the improvement comprising, bonded to said product over said layer of polymeric material, a thin, transparent stratum of plasticized resin composition, said composition consisting essentially of a blend of 1. 100 parts by weight of solvent-soluble copolymer of vinyl monomers, consisting essentially of either a. 80-97 parts by weight of vinyl chloride and 3-20 parts by weight of monomers selected from the group consisting of vinyl acetate, vinyl alcohol and dibasic acid, or b. vinylidene chloride:acrylonitrile copolymer, 2. 5 to 100 parts by weight of at least one plasticizer for vinyl resins, 3. 1 to 5 parts by weight of at least one lubricating, chlorine-scavenging light stabilizer for vinyl resins, said stabilizer being a liquid soap selected from the class consisting essentially of a. soaps of at least two divalent metals selected from the group consisting essentially of barium, cadmium and zinc, and b. tin soaps, 4. 5 to 200 parts of at least one tack-controlling, adhesion buildup-inhibiting polymeric modifier selected from the class consisting of polymethylmethacrylate, polyethylmethacrylate, polyisobutylmethacrylate, poly-n-butylmethacrylate, poly-n-butylmethylmethacrylate, and n-butylmethacrylate: isobutylmethacrylate copolymer, said stratum being further characterized by adhesion to glass in the range of 2-40 grams per centimeter of width throughout a temperature range of 20.degree. - 65.degree. C., even after exposure to a temperature of 65.degree. C. for 2 weeks, whereby said product can be repeatedly utilized in the cycle of being applied to and firmly bonded to a windowpane, thereafter subjected to a wide range of sun exposure and temperatures for a period of months without either degradation or excessive adhesive buildup, and removed without distortion.
2. The invention of claim 1 wherein at least 2 parts of the plasticizer are epoxidized soybean oil.
3. The invention of claim 1 wherein the vinyl stabilizer is a soap of barium, cadmium and zinc.
4. The invention of claim 1 wherein the plasticized resin contains an effective amount of UV absorber.
5. The invention of claim 1 wherein the vinyl stabilizer is a tin soap.
6. The method of making a reusable solar control sheet material comprising the steps of A. providing a self-supporting transparent film having a transparent-reflective layer of metal bonded to one face of said film, a layer of polymeric material protectively overlying said metal coat, B. providing an organic solvent solution of 1. 100 parts by weight of copolymer of vinyl monomers consisting essentially of a. 80-97 parts by weight of vinyl chloride and 3-20 parts by weight of monomers selected from the group consisting of vinyl acetate, vinyl alcohol and dibasic acid, 20 parts by weight of said copolymer being soluble at room temperature in 100 parts by weight of a 50:50 toluene:methyl ethyl ketone blend, or b. vinylidene chloride:acrylonitrile copolymer, 20 parts by weight of said copolymer being soluble of room temperature in 100 parts by weight of a 30:70 toluene:methylethyl ketone blend. 2. 5 to 100 parts by weight of at least one plasticizer for vinyl resins, 3. 1 to 5 parts by weight of at least one lubricating, chlorine-scavenging light stabilizer for vinyl resins, said stabilizer being a liquid soap selected from the class consisting essentially of a. soaps of at least two divalent metals selected from the group consisting essentially of barium, cadmium and zinc, and b. tin soaps, 4. 5 to 200 parts of at least one tack-controlling, adhesion buildup-inhibiting polymeric modifier selected from the class consisting of polymethylmethacrylate, polyethylmethacrylate, polyisobutylmethacrylate, poly-n-butylmethacrylate, poly-n-butyl methylmethacrylate, and n-butylmethacrylate: isobutylmethacrylate copolymer, C. applying a thin coating of said solution over said layer of protective polymeric material, and D. evaporating said solvent.