| HS Code | 989893 |
| Product Name | Standard PVB Resin HX Series |
| Appearance | White granular powder |
| Viscosity | 45-200 mPa·s |
| Degree Of Butyralization | 68-82 mol% |
| Hydroxyl Content | 18-23 wt% |
| Acetate Content | ≤3 wt% |
| Moisture Content | ≤2 wt% |
| Glass Transition Temperature | 65-90 °C |
| Density | 1.07-1.11 g/cm³ |
| Softening Point | 60-100 °C |
| Refractive Index | 1.49-1.50 |
| Acid Value | ≤1 mg KOH/g |
| Molecular Weight | 180,000-250,000 |
| Tensile Strength | 30-50 MPa |
As an accredited Standard PVB Resin HX Series factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
| Packing | Standard PVB Resin HX Series supplied in sealed 20 kg multi-layer paper bags, protected against moisture, with clear labeling. |
| Container Loading (20′ FCL) | Standard PVB Resin HX Series loaded in 20′ FCL: palletized bags, secure bracing, moisture-proof packaging for safe transit. |
| Shipping | Standard PVB Resin HX Series ships in sealed multi-layer bags or fiber drums to prevent moisture absorption. Transport in dry, ventilated containers, avoiding exposure to heat or humidity. Handle gently to preserve particle integrity; no special hazardous classification applies, but keep away from ignition sources and store upright. |
| Storage | Store in a cool, dry, well-ventilated area, away from heat, ignition sources, and direct sunlight. Keep containers tightly sealed to prevent moisture absorption, as PVB can hydrolyze. Maintain stable temperatures to preserve resin quality. Under these conditions, typical shelf life is 12 months. Use within this period for optimal performance. |
| Shelf Life | Shelf life: 12 months from manufacture when stored sealed in a cool, dry place, avoiding moisture and heat. |
In architectural laminated safety glass conversion, Standard PVB Resin HX Series is introduced as the film-forming resin component at 72–78 wt% of the compounded interlayer mass, with plasticizer addition in the range of 22–28 phr on resin to set a post-laminate shear modulus appropriate for EN ISO 12543-2:2021 and ANSI Z97.1-2015 Class A safety glazing. The resin is typically supplied with a vinyl alcohol hydroxyl content of 18–22 mol% and a polyvinyl butyral content of 76–82 wt%; higher hydroxyl within this band increases glass adhesion and reduces plasticizer uptake, so HX series grade selection must be tied to the certificate of analysis. The formulation is pre-dried at 60–65 °C to residual moisture of 0.10–0.20 wt% before twin-screw compounding. Production-scale compounding lines use corotating screws with L/D 25:1–40:1, melt filtration at 30–50 µm, and a melt pump ahead of a slot die with lip gap 0.5–0.8 mm. Melt temperature is held at 180–215 °C; excursions above 220 °C increase degradation crosslinking and generate gel particles. The cast film is quenched on a chilled roll, embossed to surface roughness of Rz 20–60 µm for deairing, and conditioned to 0.35–0.45 wt% equilibrium moisture before lamination. Lamination itself uses vacuum deairing at 135–145 °C and autoclave pressure of 1.2–1.4 MPa for 30–90 min. Film tensile verification is conducted according to ASTM D638-14 at 23 ± 2 °C; production lots below 20 MPa tensile break strength are rejected for overhead glazing. The HX series grade with higher hydroxyl content produces stronger glass adhesion, requiring an adhesion-control dopant added at 0.001–0.01 phr to maintain pummel adhesion in the 3–7 range for safety glazing. Terminal product types arising from this process include curtain-wall laminated glass, overhead skylight glass, balustrade panels, hurricane-resistant laminated glazing, and sound-control double laminates where the PVB interlayer is paired with a second damping interlayer. On commercial cast-film lines with die widths above 2.5 m, die-lip deposit accumulation is observed after 6–8 h when melt temperature exceeds 215 °C; edge curl is corrected by controlling chill-roll temperature differential across the web to ±1 °C.
Automotive windshield production using Standard PVB Resin HX Series requires tighter plasticizer and moisture control than architectural sheet because UN ECE R43 headform impact and ANSI/SAE Z26.1-1996 optical requirements introduce an impact-energy boundary not present in most building glazing specifications. The interlayer formulation uses HX series resin at 70–80 wt% of the compounded sheet, with plasticizer loading of 18–30 phr selected to balance penetration resistance and glass adhesion. The production route begins with dry blending of resin, plasticizer, UV stabilizer, and adhesion-control salt; the premix is gravity-fed into a corotating twin-screw extruder with L/D 25:1–34:1, vacuum devolatilization at -0.08 MPa to remove water, and melt filtration at 25–40 µm. Sheet extrusion through an adjustable slot die at 170–200 °C is followed by embossing on water-cooled rolls; embossed surface roughness is controlled to Rz 30–50 µm because PVB interlayer must permit residual air evacuation during glass pre-pressing but must not produce visible roughness after autoclave. The HX series in standard molecular weight grades imposes a practical upper plasticizer limit of 30 phr; beyond this threshold, sheet blocking and roll-stock deformation are observed on double-rack storage, while below 18 phr, low-temperature impact toughness declines. Film is slit to nominal thicknesses of 0.76 mm, 1.14 mm, and 1.52 mm, then laminated between glass plies at 140–150 °C and 1.1–1.3 MPa autoclave pressure. Terminal products include laminated windshields, panoramic roof glass, side glazing, and head-up-display-compatible windshields where HX series may be combined with a wedge-shaped co-extruded layer; however, HX series alone is not formulated for acoustic interlayer damping applications unless explicitly modified for that configuration.
| Parameter | Architectural laminated glass | Automotive windshield | Reference method |
|---|---|---|---|
| Resin content of compounded interlayer | 72–78 wt% | 70–80 wt% | Certificate of analysis; gravimetric formulation control |
| Plasticizer loading on resin | 22–28 phr | 18–30 phr | Formulation balance; ISO 11357-2 glass transition shift |
| Melt temperature at slot die | 180–215 °C | 170–200 °C | In-die thermocouple array |
| Embossed surface roughness | Rz 20–60 µm | Rz 30–50 µm | ISO 21920-2 |
| Residual moisture before lamination | 0.35–0.45 wt% | 0.35–0.45 wt% | ISO 15512:2019 |
| Autoclave pressure | 1.2–1.4 MPa | 1.1–1.3 MPa | Autoclave process control; EN ISO 12543-2:2021 impact verification |
Ceramic green tape manufacture exploits the binder burnout profile of Standard PVB Resin HX Series when dissolved at 10–20 wt% solids in an azeotropic or pseudo-azeotropic solvent system such as ethanol/toluene 60:40 wt/wt; the addition ratio in the slurry is 3–8 phr on ceramic powder, with a plasticizer such as butyl benzyl phthalate at 0.5–2.0 phr and a phosphate ester dispersant at 0.3–1.0 phr. Compliance for the resulting fired ceramic bodies is assessed against IEC 60384-22 for multilayer ceramic capacitors, ASTM C1499-15 for biaxial flexural strength, and ASTM D792 for green density. Binder burnout residue limits are frequently specified by capacitor manufacturers at ≤0.2 wt% residual carbon after firing. Production-scale tape casting commonly uses a two-stage bead mill to disperse alumina or barium titanate with 1–3 mm zirconia media, followed by vacuum deaeration to a viscosity of 1,000–4,000 mPa·s at 10 s⁻¹. The slurry is cast through a doctor blade with a gap of 100–450 µm onto a polyester carrier moving at 0.3–1.5 m/min; drying is staged from 40 °C to 80 °C to avoid skinning and shrinkage cracks. Subsequent binder burnout requires a ramp rate no greater than 0.5 °C/min through 250–600 °C to prevent blistering and carbon entrapment. Terminal product types fabricated from HX-series-bound green tape include multilayer ceramic capacitor dielectric layers, alumina substrates, LTCC ceramic tapes, and solid oxide fuel cell electrolyte layers. The key operational boundary for HX series is its high solution viscosity relative to lower molecular weight PVB grades; slurries above 20 wt% binder solids may exceed practical doctor-blade viscosity ceilings, and water contamination above 0.1 wt% from solvent or powder must be avoided to prevent local gelation.
For glass-to-glass thin-film photovoltaic modules, Standard PVB Resin HX Series is extruded into encapsulant sheet at 100 phr resin with plasticizer 12–25 phr, methacryloxy silane coupling agent 0.2–0.5 phr, hindered amine light stabilizer 0.05–0.20 phr, and antioxidant 0.02–0.10 phr. The formulation must satisfy IEC 61215-1:2021 qualification and IEC 61730-1:2016 safety requirements, with optical yellowness index controlled below 1.5 after 1,000 h damp heat at 85 °C/85% RH per IEC 61215; no crosslinking is required, unlike EVA, but the moisture permeability of PVB demands edge-seal protection. Sheet production uses a single-screw or twin-screw extruder at 160–190 °C, a 25–40 µm melt-filter pack, and a chill-roll stack to produce 0.38–0.76 mm sheet. Module lamination occurs at 135–150 °C and 0.09–0.10 MPa vacuum for 20–40 min; controller setpoint temperature above 150 °C induces measurable plasticizer loss and sheet shrinkage. Terminal products include building-integrated photovoltaic glazing, semi-transparent solar windows, and thin-film glass-glass modules. Published long-term ultraviolet exposure data specific to HX series in building-integrated configurations is limited; validation must rely on IEC 61215 extended aging rather than accelerated assumptions. The operational boundary is severe at RH above 80%: PVB film will reabsorb atmospheric moisture during layup, resulting in edge clouding after lamination, and the use of a desiccant edge tape or climate-controlled layup room is mandatory for warranty-grade film.
Solvent-borne wash primers for structural steel incorporate Standard PVB Resin HX Series at 7–10 wt% of total liquid formula, combined with phosphoric acid 2–4 wt%, isopropanol 50–65 wt%, water 10–20 wt%, and zinc phosphate anti-corrosive pigment 5–10 wt%; compliance is assessed through ISO 12944-5:2019 for protective paint systems on steel, ASTM D3359 cross-cut adhesion, and ASTM B117 salt spray; production uses a high-speed dissolver at 10–15 m/s tip speed, filtration to 25 µm, and spray or roller application to 8–15 µm dry film; pot life after acid addition at 25 °C is limited to 8–24 h; terminal products include steel bridge girders, ship deck components, container corner castings, and coil-coated galvanized substrate pretreatments.
Gravure and flexographic inks formulated with Standard PVB Resin HX Series as a co-binder require a resin addition ratio of 4–12 wt% of press-ready liquid ink, prepared from a resin cut at 15–25 wt% solids in ethanol/ethyl acetate 70:30 wt/wt. The formulation may contain nitrocellulose 5–10 wt%, pigment 10–30 wt%, plasticizer 1–3 wt%, and retained solvent 55–70 wt%. Food-contact suitability for printed packaging is determined under EC 1935/2004 and the EuPIA Good Manufacturing Practice Note, while FDA 21 CFR 175.300 is used for United States resin migration compliance in non-direct-contact coatings. Ink manufacturing uses a bead mill with 0.4–0.8 mm zirconia media; two passes are run at 45 °C jacket temperature to maintain disperser seal life. Press viscosity is adjusted to 18–25 s on a Ford cup #4, and gravure cell duty is specified as 50–80 µm cell depth at 250–350 lpi screen ruling. Drying tunnel temperatures are maintained at 60–70 °C with LEL monitoring below 25% of the solvent lower explosive limit. Terminal product classes include snack-food packaging, heat-seal lidding films, confectionery wrappers, and aqueous-resistant paper labels. An operational limitation for HX series is its limited solubility in pure ester solvents above 20 wt% solids, which can lead to gelation during cold-cleaner solvent recovery loops at -10 °C.
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Standard PVB Resin HX Series is a polyvinyl butyral resin family manufactured by acid-catalysed acetalisation of polyvinyl alcohol with butyraldehyde. The series comprises HX-1, HX-2 and HX-3, differentiated by residual vinyl alcohol content, molecular weight and melt-flow behaviour. The specification window is set at vinyl butyral 80–88 wt%, vinyl alcohol 10–20 wt% and residual vinyl acetate ≤ 1.5 wt% by ASTM D1396-92. The grades are intended for plasticised safety-glass interlayers, glass adhesion primers, ceramic green-tape binders, ink binders and solvent-borne primers.
The primary differentiators are narrower hydroxyl-value control, lower gel-particle counts and reduced die-lip deposit formation. HX-1 carries a vinyl alcohol content of 20–22 mol%, HX-2 17–19 mol%, HX-3 11–14 mol%. Hydroxyl value controls equilibrium moisture pickup and adhesion to silane-treated float glass. In compressive shear testing on laminated coupons per ISO 12543-3:2021, HX-2 with 32 phr triethylene glycol bis(2-ethylhexanoate) (3GO) reaches 12–16 MPa after conditioning at 23 °C/50% RH, whereas a broad-distribution reference PVB of similar vinyl alcohol content gives 9–13 MPa. Gel-particle content in a 10 wt% methanol solution is ≤ 3 particles larger than 50 µm per 10 g resin by dark-field optical counting. This gel control has direct implications for optical defect density in thin interlayers.
| Property | HX-1 | HX-2 | HX-3 | Test method |
|---|---|---|---|---|
| Vinyl alcohol content (mol%) | 20–22 | 17–19 | 11–14 | ASTM D1396-92 |
| Weight-average molecular weight (g/mol) | 80,000–100,000 | 100,000–130,000 | 130,000–160,000 | ISO 16014-2:2019 |
| Melt volume-flow rate (cm³/10 min) at 190 °C/2.16 kg | 18–25 | 8–14 | 3–6 | ISO 1133-1:2022 |
| Apparent viscosity at 100 s⁻¹ (Pa·s) | 180–220 | 250–300 | 380–420 | ISO 11443:2021 |
| Glass transition temperature of neat resin (°C) | 68–72 | 70–74 | 75–78 | ISO 11357-2:2020 |
| Equilibrium moisture at 23 °C/50% RH (wt%) | 0.25–0.35 | 0.20–0.30 | 0.10–0.18 | ISO 15512:2019 |
On a counter-rotating twin-screw extruder with L/D 44:1 and a vacuum vented barrel at −0.08 MPa gauge, the HX Series is processed with a barrel temperature profile from 160 °C at the feed throat to 210 °C at the die. Pre-drying in a desiccant dryer at 60–70 °C for 4–6 h is required to reach a moisture content below 0.15 wt% before compounding or extrusion. At ambient relative humidity above 60%, equilibrium moisture content exceeds 0.4 wt%, and shear heating in the metering zone can generate bubble defects in the melt. Use of a devolatilising extruder is therefore recommended for thick sheet or high-speed cast film.
Melt viscosity measured by capillary rheometry at 190 °C follows shear-thinning behaviour. At 100 s⁻¹, apparent viscosity ranges from 180 Pa·s for HX-1 to 420 Pa·s for HX-3. The melt volume-flow rate under 2.16 kg at 190 °C is 18–25 cm³/10 min for HX-1, 8–14 cm³/10 min for HX-2, and 3–6 cm³/10 min for HX-3 by ISO 1133-1:2022. The processing window is limited: thermogravimetric analysis at 10 K/min in nitrogen shows 1 wt% mass loss at 240–250 °C. Holding above 230 °C for more than 8 min increases vinyl acetate hydrolysis side reactions and generates acetic acid odour. Published data for this specific configuration is limited at residence times longer than 10 min.
Plasticiser uptake and migration behaviour are central to safety-glass interlayer processing. HX-2 absorbs 100 g 3GO per 100 g resin within 35–45 min in a heated ribbon blender at 60 °C; HX-1 reaches the same uptake in 15–20 min, while HX-3 requires 50–65 min. After extrusion and lamination, a 0.76 mm HX-2 interlayer containing 32 phr 3GO shows a glass transition temperature of 28–32 °C by ISO 11357-2:2020. Heat ageing at 80 °C and 95% RH for 500 h yields surface plasticiser migration ≤ 2.0 wt% by gravimetric extraction. Conventional grades with similar glass transition temperature often show 3.0–4.5 wt% migration under the same conditions; the lower exudation in the HX Series is attributable to the narrowed molecular weight distribution and reduced low-molecular-weight fraction.
Conditioning at 50 °C/95% RH for 14 days increases the plasticised interlayer moisture content to 0.6–0.8 wt%. Water competes with vinyl alcohol groups at the glass interface, reducing adhesion. In laminated-glass coupons tested according to ISO 12543-3:2021, HX-2 retains compressive shear adhesion of 8–11 MPa after the conditioning period, whereas a conventional resin with equivalent nominal vinyl alcohol content falls to 5–7 MPa. The difference is traced to the controlled distribution of hydroxyl groups along the polymer backbone; this reduces the localised low-hydroxyl regions that form weak boundary layers under humid conditions. Edge clouding after 14 days at 50 °C/95% RH is ≤ 1.5 mm in a 0.76 mm interlayer, measured from the edge toward the laminate centre.
Film made from HX-2 on a chill-roll casting line at 0.76 mm thickness achieves luminous transmittance of 90.5–91.5% and haze ≤ 1.0% by ASTM D1003-21. Gel counts after mixing are low enough to avoid visible optical defects: the specification of ≤ 3 particles per 10 g resin above 50 µm corresponds to fewer than 0.5 specks/m² in a 0.76 mm interlayer. For automotive glass where localised light scattering is a rejection criterion, a 50 µm particle is detectable under side illumination. The HX Series reduces rework rates on an automotive interlayer extrusion line because die-lip deposit formation over a 72 h continuous run is ≤0.2 g/m² compared with 0.6–1.0 g/m² for standard resin.
Solvent-borne coating and ceramic binder applications require low ash and controlled solution rheology. A 10 wt% solution of HX-1 in ethanol/toluene at 60:40 w/w and 25 °C has a Brookfield viscosity of 800–1,200 mPa·s; HX-2 gives 1,500–2,200 mPa·s, and HX-3 2,800–3,600 mPa·s. The ash content after incineration is ≤ 0.05 wt% by ISO 3451-1:2019. In ceramic tape casting with an alumina slurry at 55 wt% solids, HX-1 binder dosage of 4–6 wt% of powder mass yields green tape tensile strength of 2.0–3.5 MPa when measured on a universal testing machine at 10 mm/min. This property is relevant for multilayer ceramic capacitors, where binder burnout must complete before 400 °C to avoid carbon residue.
Primer formulations containing 5–8 wt% HX-2 in isopropanol-toluene at 80:20 w/w yield a dry film thickness of 2–5 µm. Cross-hatch adhesion to float glass is 100% by ISO 2409:2020 after 24 h cure at 23 °C; conventional PVB primers often require an additional silane pretreatment to reach the same rating. The HX Series imparts a surface energy of 38–42 mN/m to the primer, measured by contact angle goniometry using distilled water and diiodomethane.
Batch-to-batch variance on an automotive interlayer extrusion line is controlled through melt viscosity and moisture release kinetics. Across 10 production lots, the melt volume-flow rate at 190 °C/2.16 kg varied by ±1.2 cm³/10 min for HX-2, while the plasticised film thickness variation at 0.76 mm was ±0.025 mm. The gel-particle count remained below the specification limit in 9 of 10 lots, with a single lot at 4 particles per 10 g, triggering line-side sorting under an internal optical quality-control protocol. Such variance is below the threshold that causes visible defects in automotive windshields.
Regulatory compliance for the HX Series is documented under REACH EC 1907/2006 as a registered polymer intermediate, under RoHS 2011/65/EU with concentrations of Pb, Hg, Cd, Cr(VI) below 1000 mg/kg and Cd below 100 mg/kg, and under FDA 21 CFR 175.105 as an indirect food-contact adhesive component subject to end-use formulation testing. Migration testing for specific food simulants under EU Regulation 10/2011 requires formulation-specific evaluation; published data for this specific configuration is limited to non-food-contact industrial uses.
Standard packaging is 25 kg polyethylene-lined multiwall bags, stacked 10 bags per pallet. The resin is supplied as free-flowing granules with bulk density 0.55–0.65 g/cm³ by ISO 60:2023. The particle size distribution is 90% between 0.2 mm and 0.8 mm by sieving. These parameters are set to minimise bridging in hoppers and to allow consistent gravimetric feeding at 200 kg/h on an interlayer coextrusion line.
Operational boundaries are specific: the HX Series is not recommended with amine-based adhesion promoters or high-acid-number acrylic resins in solvent systems because residual acetate groups can hydrolyse and shift formulation pH below 4.5 at 60 °C, causing viscosity drift and yellowish chromophore formation. Processing with zinc stearate above 1 phr should be avoided because zinc ions accelerate deacetylation at temperatures above 200 °C. Storage stability in unopened bags is 24 months at 25 °C and 50% RH; resins held above 35 °C may block and require re-grinding before blending.
