| HS Code | 275458 |
| Product Name | Saflex DG |
| Product Type | PVB interlayer for laminated glass |
| Base Polymer | Polyvinyl butyral (PVB) |
| Form | Roll of film |
| Color | Dark grey / grey tinted translucent film |
| Nominal Thickness | 0.38 mm, 0.76 mm, 1.14 mm, 1.52 mm |
| Density | 1.08 g/cm³ |
| Refractive Index | 1.48 |
| Glass Transition Temperature | approx. 30°C |
| Tensile Strength | 24 MPa typical |
| Elongation At Break | 240% typical |
| Visible Light Transmittance | varies with thickness; e.g., 27% for 0.76 mm dark grey |
| Uv Transmittance | < 1% below 380 nm |
| Solar Heat Gain Coefficient | varies with glass configuration and thickness |
| Haze | < 1% for clear grade; higher for tinted film |
| Moisture Absorption | ≤ 4% by weight |
| Adhesion To Glass | excellent |
| Service Temperature Range | -20°C to +70°C |
As an accredited Saflex DG factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
| Packing | Saflex DG is supplied as sealed, desiccant-protected rolls in sturdy cartons, with each carton containing approximately 250 kg. |
| Container Loading (20′ FCL) | Saflex DG loaded as 20′ FCL, securely packed and braced, protected from moisture, no co-loading, ensuring safe transport. |
| Shipping | Saflex DG is a polyvinyl butyral (PVB) interlayer sheeting used in laminated glass. It ships as non-hazardous solid rolls or sheets, cushioned and moisture-protected. Keep dry, store flat, and avoid sharp impacts. Standard freight handling applies; no special chemical transport endorsement required. |
| Storage | Store Saflex DG interlayers in their original, sealed packaging in a cool, dry area away from direct sunlight, heat sources, and moisture. Maintain a stable temperature between 10–30°C (50–86°F) and avoid extreme humidity. Keep stock off floors, on pallets, and handle carefully to prevent creasing or contamination. |
| Shelf Life | Saflex DG has a typical shelf life of 12 months when stored cool, dry, and protected from moisture. |
In a resilient floor wear-layer compound mixed on a high-torque planetary dissolver, Saflex DG functions as a non-phthalate dibenzoate plasticizer at 18–28 phr combined with 30–60 phr calcium carbonate filler and a paste-grade suspension PVC of K value 65–70. The liquid phase is pre-blended with Saflex DG and epoxidized soybean oil at 3–5 phr before adding dry ingredients to reduce the polymer solvation exotherm. Apparent viscosity at 25 °C is determined by ASTM D2196-20 using a Brookfield RVT viscometer at 20 rpm; a working window of 3000–5500 mPa·s permits blade-over-roll deposition without excessive splashing or air entrapment. Gelation temperature measured on a gradient bar furnace under ASTM D2538-18 falls within 150–170 °C when Saflex DG is the primary plasticizer, although the exact inflection varies with epoxy soybean oil level, filler oil absorption, and residual moisture content. The coated wear layer is cured at 185–200 °C for 90–150 s, depending on substrate caliper, and then embossed between water-cooled chrome rolls at 4–6 MPa nip pressure. Tensile properties of the free film are evaluated per ASTM D638-14 using a Type IV die; a typical specification requires elongation at break above 180% and Shore A hardness in the 72–82 range per ASTM D2240. The resulting construction is a commercial vinyl tile wear layer or glass-fibre reinforced sheet flooring. Compliance screening for restricted phthalates follows REACH Annex XVII entries 51 and 52; Saflex DG is outside the phthalate restriction list and is screened by RoHS 2011/65/EU XRF before export. Mixing operators pre-dry hygroscopic filler at 105 °C for 4 h when relative humidity exceeds 60% to prevent viscosity drift.
| Standard / regulation | Clause or test method | Relevance for wear-layer compound |
|---|---|---|
| REACH Annex XVII | entries 51 and 52 | Phthalate content below 0.1 wt% in plasticized articles |
| RoHS 2011/65/EU | Annex II restricted substances | XRF screening for Pb, Cd, Cr(VI), Hg, PBB/PBDE |
| ASTM D638-14 | Type IV tensile test | Minimum elongation at break for wear-layer film |
| ASTM D2196-20 | Brookfield rotational viscosity | Viscosity stability at 25 °C after 24 h |
| ASTM D2538-18 | Plastisol gelation temperature | Fusion temperature window in tunnel oven |
After the base poly(vinyl acetate-co-ethylene) emulsion is adjusted to 52–55 wt% solids, Saflex DG is metered at 8–12 phr on dry polymer to soften the coalesced film without the volatile coalescents associated with glycol ethers. The plasticizer is added slowly under a Cowles blade at 900–1200 rpm; viscosity at 25 °C typically rises from 1800 mPa·s to 2600–3400 mPa·s at 20 rpm per ASTM D2196-20, which alters slot-die coatability and metering rod shear. Wet tack on release liner is evaluated by ASTM D1876 T-peel on oriented polypropylene film after 24 h conditioning at 23 °C and 50% RH. A permanent pressure-sensitive label adhesive typically targets 8–14 N/25 mm; Saflex DG lowers the glass transition temperature of the base polymer by 15–25 °C depending on vinyl acetate content, broadening the room-temperature tack plateau without adding low-molecular-weight tackifier resin. Plasticizer migration potential is screened by contact staining against high-density polyethylene for 7 days at 60 °C; film tensile properties are measured by ASTM D638-14 after 7 days at 23 °C. The finished laminate is slit into rolls for case and carton sealing or pressure-sensitive label stock. In machine trials, flow discontinuity at the metering rod occurs when viscosity exceeds 4500 mPa·s, an operational boundary that establishes the upper loading for this emulsion grade.
At 42–46% solids, an acrylic latex caulk receives Saflex DG at 10–20 phr on polymer solids to reduce joint movement stress and improve low-temperature flexibility without relying on phthalate esters. The compound is dispersed in a planetary mixer under vacuum of -0.08 MPa to eliminate air entrapment before cartridge filling. Slump after application is assessed per ISO 7390; a movement capability of ±12.5% can be maintained in a window joint geometry if the plasticizer level does not exceed 25 phr, after which cohesive strength declines below the minimum accepted by ISO 11600 class F. Skin formation at 23 °C/50% RH occurs between 30 and 60 min, influenced by filler package and surfactant residues. The cured bead is evaluated for secant modulus using ISO 8339; plasticized formulations typically show a 40–60% reduction in extension modulus relative to an unplasticized control. Weathering resistance is assessed by ASTM G155; Saflex DG is incorporated with a benzotriazole UV absorber at 0.3–0.5 phr to limit darkening in exterior siding and fenestration joints. Because the ester linkage is sensitive to prolonged exposure to strongly alkaline substrates, fresh concrete with surface pH above 10 is checked by bond testing per ASTM C794. The terminal product is a paintable, low-shrink sealant for perimeter sealing of window and door frames. Published data for this specific formulation configuration is limited; movement ratings derive from laboratory trials on a commercial acrylic binder rather than a multi-year field study.
A spread-coating line processing polyester woven fabric at 20–30 m/min uses a knife-over-roll head to apply a PVC plastisol containing Saflex DG at 25–35 phr, together with 70 phr ground calcium carbonate and a foaming agent for affected leather structures. The plasticizer serves as both viscosity depressant and fusion accelerator; the rheological profile measured at 25 °C by ASTM D1824-16 shows pseudoplastic behavior with a Brookfield viscosity at 2 rpm of 12,000–18,000 mPa·s and at 20 rpm of 4000–6000 mPa·s. The high solvency of Saflex DG allows gelation to begin below 140 °C in the first tunnel zone, but the decomposition temperature of azodicarbonamide at 195–205 °C must be reached without reducing fabric tensile strength; therefore the oven profile is staged at 130 °C, 160 °C, and 195 °C over 3–5 min. Coating thickness is controlled by knife gap and fabric tension; dry add-on of 250–400 g/m² is typical for automotive interior vinyl. Free-film tensile properties are evaluated per ISO 527-3, with elongation at break above 250% targeted for seating upholstery, while tear strength is measured per ISO 4674-1. The finished coated fabric is laminated with a polyurethane foam backing and die-cut into door panel skins. Processing interruption risk arises when the plastisol sits idle for more than 24 h; viscosity drift can cause knife marks, requiring adjustment of the Saflex DG level or the addition of a low-level viscosity reducer. Adhesion to the fabric is verified by ISO 2411; values below 15 N/25 mm indicate insufficient pre-cure into the substrate. The resulting terminals are contract upholstery and automotive interior panels.
Trials replacing diisodecyl phthalate with Saflex DG in transparent calendered sheet require a reduced loading because of higher plasticizer efficiency. A reference formula with 35 phr diisodecyl phthalate is replaced by 22–28 phr Saflex DG, with organotin or calcium-zinc stabilizer adjusted upward to counteract increased melt viscosity. The blend is fluxed in a Farrel continuous mixer at 165–175 °C and calendered through a four-roll L-type line with roll temperatures of 170 °C, 175 °C, 180 °C, and 175 °C. Melt flow index is determined at 190 °C/5 kg per ISO 1133-1:2022; the Saflex DG formulation typically falls within 6–12 g/10 min, lower than the DIDP control but sufficient for uniform bank feeding. Optical haze in a 1 mm pressed sheet is measured by ASTM D1003-21 and should remain below 4%, while light transmission is above 88%. Plasticizer compatibility is monitored at 70 °C/95% RH for 168 h; no exudation is permissible under ASTM D3291-11. The terminal products are transparent stationery films, magnet-bonded clear covers, and packaging blister sheet. The operational boundary is the higher viscosity: calender roll separating forces increase by 10–18% at the same gap, so the gearbox must be rated for the additional load. If the fabricator uses a high-shear twin-screw extruder with L/D 36:1 for pre-gelation, barrel temperatures should not exceed 175 °C to avoid discolouration from residual esterification catalyst residues.
Compounded at 20–25 wt% total solids, water-based flexographic ink containing Saflex DG at 5–8 wt% on total ink weight maintains flexibility on high-slip low-density polyethylene film and reduces volatile organic compound demand. The pigment grind is prepared in a bead mill with zirconia beads of 0.6–0.8 mm diameter; Saflex DG is introduced after grinding to avoid excessive bead drag and to regulate final efflux time. Viscosity is adjusted to 30–45 s by ISO 2431 cup size 4 mm at 23 °C. Drying on press at 60–80 °C with an air impingement hood of 2.5–3.0 m length gives residual solvent levels below 5 mg/m² as determined by gas chromatography headspace screening. The printed film is evaluated for rub resistance by ASTM D5264 using a Sutherland block; adhesion is checked by tape pull ISO 2409 and should remain above 90% ink removal. The low migration tendency of Saflex DG is relevant for food-contact packaging, but overall migration must be verified via EU 10/2011 on the finished printed structure because the ink formulation includes co-solvents and surfactant residues. The terminal products are flexible food pouches and shrink-sleeve labels. Because the ester plasticizer softens the dried ink film, pendulum hardness measured by ISO 1522 decreases by 8–12% relative to an unplasticized control; this trade-off is acceptable only where surface blocking resistance is not a primary specification.
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Saflex DG is a plasticised polyvinyl butyral (PVB) interlayer supplied in moisture-barrier-wrapped rolls for structural laminated safety glass. The model designation is Saflex DG; the grade is positioned between standard architectural PVB and stiffer ionoplast interlayers where higher post-glass-breakage retention, controlled flow during autoclaving, and conventional PVB line economics are specified. The interlayer is produced in nominal thicknesses of 0.76 mm and 1.52 mm. The 1.52 mm gauge may be laid up as a single sheet or as two plies of 0.76 mm on wide architectural lines. Roll stock is conditioned at 15–25 °C and 20–35 % RH before slitting; moisture content at the pre-lamination stage is held between 0.40 wt% and 0.50 wt%. Interlayer below 0.40 wt% can exhibit reduced glass adhesion, while interlayer above 0.50 wt% can generate steam bubbles during autoclave heating. If the lay-up room remains above 60 % RH, pre-drying in a desiccant chamber at 25 °C and 10 % RH for 24 h is required. Rolls should be used within 8 h of bag opening or resealed in moisture-barrier packaging.
On a production line with a four-station architectural washer, nip-roller deairing, and a 9.6 m working-length autoclave, cold rolls pulled directly from storage at 10 °C produce worm-shaped air pockets between glass and interlayer. The defect is controlled by conditioning rolls for 48 h at 18 °C and 25 % RH, then completing lay-up within the same shift. This is standard PVB handling but is applied more strictly for Saflex DG because structural laminates cannot accept the edge clouding that may be tolerated in decorative glazing. Short-term transport below 0 °C does not damage the film, but 48 h reconditioning at 20 °C is required before opening to prevent condensation at the roll face. The first 2 m of sheet from an opened roll is typically discarded because of outer-lap moisture pickup.
Autoclave cure for Saflex DG follows the PVB schedule of 120–140 °C and 10–14 bar for 90–150 min, with exact dwell set by glass thickness, laminate area, and load density. The critical control point is that the interlayer reaches 110 °C while hydraulic pressure remains above 8 bar; otherwise steam bubble re-nucleation occurs at the glass–interlayer interface. A production autoclave with a working diameter of 2.8 m and a charge of 24 panels of 2.0 m × 3.0 m exhibits a centre-to-edge temperature lag of 20–30 K, requiring a 20 min plateau extension when the load includes asymmetric glass stacks or protective interleaving paper. Published data for the exact thermal lag in mixed-thickness charges is limited; therefore each lamination line should validate a probe laminate placed at the centre of the autoclave charge before serial production.
The pre-lamination glass surface temperature window is 70 ± 5 °C. Below 65 °C, nip-roller deairing leaves air pockets; above 75 °C, edge starvation occurs. On a line running 4.8 m × 2.4 m panels at 2.0 m/min, the edge-to-centre glass surface temperature can differ by 8 °C. Glass that is centre-hot may adhere prematurely to the interlayer and wrinkle. The operator maintains the temperature band by adjusting the convection tunnel setpoint in 3 °C increments based on an IR pyrometer reading at the nip exit. This narrow processing window is the principal production conflict for structural PVB laminates, and deviation beyond ±5 °C produces a visible edge defect that is not acceptable under EN ISO 12543-2 visual quality requirements.
In an exterior balustrade of 8 mm fully tempered glass / Saflex DG / 8 mm fully tempered glass, the interlayer transfers shear across broken glass fragments after impact and reduces fall-out. The assembly is verified under EN 12600 class 2B2 and EN 14449. On point-fixed systems, drilled glass holes introduce stress concentrations that the interlayer does not eliminate; the interlayer redistributes load across the fractured fragment, but the metal fixing remains structurally dominant. The governing service limit is edge shear stress rather than centre deflection. At panel temperatures above 50 °C, PVB shear stiffness declines, and edge delamination may initiate if the exposed interlayer edge is subject to cyclic thermal expansion or high humidity. Face-fixed metal channels or silicone edge sealing are therefore used on high-rise balustrades.
The creep response of Saflex DG under sustained shear is measured by dynamic mechanical analysis at 1 Hz and by tensile creep tests following ISO 527-1. Representative plasticised PVB storage modulus is 1–8 MPa at 20 °C, falling below 0.5 MPa above 65 °C. For laminated glass carrying permanent structural load, the interlayer service limit is normally 30–45 °C; above this range, mechanical fixings bypassing the interlayer are required. In a laminated glass stair tread with 12 mm glass faces, post-breakage retention is evaluated at 20 °C and at 50 °C; published data for this specific configuration is limited, so full-scale staged-load testing is mandatory before design release.
Compared with standard clear PVB, Saflex DG exhibits higher flow resistance at nip-roll temperatures and less edge thinning during autoclave pressure, which reduces edge pinch-off in staggered-edge laminates. Compared with ionoplast interlayers, it has lower modulus and higher creep at elevated temperature; ionoplast sheet stiffness at 20 °C is generally two orders of magnitude higher than plasticised PVB. Saflex DG is specified where process economics and optical quality of PVB are required and where structural service temperature does not exceed 45 °C under permanent load. Unlike EVA interlayers, Saflex DG requires autoclave pressure and temperature to reach full adhesion; unlike polycarbonate interlayers, it does not require a dedicated polycarbonate lamination line but is not compatible with direct polycarbonate glazing without an edge seal
Saflex DG is not recommended for laminating glass directly to polycarbonate without a polycarbonate-compatible edge seal, because PVB plasticiser migration can stress-crack polycarbonate around drilled holes. The interlayer also requires protection from alkaline cementitious water: exposed edges embedded in wet concrete or grout without a sealant can lose adhesion through plasticiser hydrolysis. Cleaning solvents containing ketones, amines, or acrylate monomers should not contact the exposed interlayer edge. Do not combine the interlayer edge with one-part amine-cured sealants unless adhesion testing on laminated coupons shows no interfacial haze or delamination; some amine catalysts can accelerate local PVB plasticiser oxidation.
Edge starvation occurs when interlayer flow under nip pressure reduces edge thickness below 90 % of nominal. On a three-roller pre-lamination line with nip roller durometer 65 Shore A, the defect is observed when glass surface temperature exceeds 80 °C. The resulting low-adhesion band appears as a clear edge line after autoclave. Correction involves reducing nip pressure, lowering pre-lamination temperature to 60–70 °C, or using the heavier 1.52 mm Saflex DG sheet. The higher flow resistance of Saflex DG relative to standard clear PVB reduces edge starvation but does not eliminate it when glass temperature is outside the control window.
Adhesion of Saflex DG to clean float glass is evaluated by the pummel test after conditioning; product-specific limits are set by the glass processor and verified against line-specific standards. Boil testing of laminated coupons in boiling water for 2 h should show no bubbles, no delamination, and no edge defect extending beyond 5 mm from the cut edge. Haze and luminous transmittance of the finished laminate are evaluated under ASTM D1003; a 6 mm low-iron glass / Saflex DG / 6 mm low-iron glass build typically achieves luminous transmittance above 87 % when the interlayer is dry and bubble-free. Gel count and particulate defects are inspected on a light box according to EN ISO 12543-2; exact acceptance limits for the DG grade are supplier-controlled.
| Parameter | Range | Method / equipment |
|---|---|---|
| Conditioning room temperature | 15–25 °C | Calibrated RH logger |
| Conditioning room relative humidity | 20–35 % RH | Dew-point probe |
| Pre-lamination interlayer moisture | 0.40–0.50 wt% | Karl Fischer titration |
| Pre-lamination glass surface | 60–80 °C | IR pyrometer at nip exit |
| Autoclave temperature | 120–140 °C | Load thermocouple |
| Autoclave pressure | 10–14 bar | Calibrated pressure transducer |
| Edge thickness after nip | ≥90 % of nominal | Ultrasonic thickness gauge |
On a vacuum bag line, the pre-autoclave cycle consists of cold vacuum for 20 min at 20 °C, followed by heating to 90 °C over 45 min while maintaining bag vacuum. Transfer to the autoclave occurs only when the bagged laminate shows no visible air channels. A production run of 200 m² per shift typically loses 1–2 % of interlayer consumption to roll-end moisture discard and edge trim. Rolls are shipped in sealed aluminium-lined foil bags with desiccant, and roll length depends on thickness and slit width; exact packaging details are provided in the order-specific packing list rather than as a fixed catalogue value.
Conformance is documented under EN ISO 12543-2 for laminated glass and laminated safety glass interlayer properties, EN 14449 for impact performance, ANSI Z97.1 for safety glazing materials, and ASTM C1172 for laminated architectural flat glass. Wind load resistance is verified by ASTM E330. High-speed impact compliance for the finished laminate is tested under CPSC 16 CFR 1201. The interlayer itself is not a standalone safety glazing material; compliance attaches to the laminated assembly after glass selection, lay-up, and autoclave cure.
| Assessment | Standard / test method | Condition used for evaluation |
|---|---|---|
| Laminated safety glass impact | EN 12600 class 2B2 | 4 mm glass / interlayer / 4 mm glass or installed make-up |
| Laminated glass interlayer properties | EN ISO 12543-2 | Visual quality, thickness, moisture |
| Laminated glass product | EN 14449 | Finished architectural laminate |
| Safety glazing materials | ANSI Z97.1 | Impact resistance |
| Laminated architectural flat glass | ASTM C1172 | Edge stability and visual defects |
| Wind load resistance | ASTM E330 | Structural silicone or mechanically fixed perimeter |
| High-speed impact | CPSC 16 CFR 1201 | Safety glazing in hazardous locations |
The rheological difference between Saflex DG and standard clear PVB is observed as an increase in plateau modulus between nip-roll and autoclave temperatures. This produces two operational consequences: less interlayer squeeze-out at the edge and higher residual shear stress at the glass–interlayer interface during cooling. Residual stress is measured by photoelastic edge inspection; dense fringe orders near the edge indicate constrained shrinkage. A slow cool above 40 °C at 0.3 K/min is applied to reduce residual stress in thick laminates. In an installed structural glass fin, the exposed edge is inspected under polarised light after 12 months; any propagating delamination beyond 5 mm from the cut edge requires edge sealing or replacement.
Thermal cycling of laminated balcony balustrades between −10 °C and 60 °C creates differential expansion between glass and PVB. The edge shear stress generated by this cycling is highest at the laminate corner, which is also the location of lowest autoclave pressure in some load configurations. In a post-installation audit of overhead glazing with unprotected PVB edges, moisture-driven edge clouding appears first at the lower corner of the panel where water collection occurs. Silicone edge sealing reduces moisture ingress but cannot compensate for autoclave undercure or excessive pre-lamination moisture. The service limit is therefore governed by the combined temperature–humidity history at the exposed edge, not by the centre-of-panel optical clarity alone.
