Poly(vinyl butyral) Composites with Different Silicate or Silica Dispersions

Poly(vinyl butyral) (PVB) displays exceptional adhesion to glass surfaces and high transparency, serving as the dominant interlayer material in laminated glass composites. This study systematically investigates PVB particulate composites, focusing on the interactions between a plasticized PVB matrix and silicate or silica dispersions as reinforcements. PVB composites reinforced with glass flakes, glass fibers, and fumed silica at loadings of 2, 5, and 8 vol% were produced and characterized. Optical microscopy and thermogravimetric analysis were employed to evaluate filler incorporation and dispersion under melt mixing conditions representative of industrial extrusion. Transparency measurements assessed the optical clarity of the composites, while ATR-FTIR was used to identify chemical interactions between PVB and the fillers. Regarding mechanical performance, fumed silica increased tensile strength up to 29 MPa and reduced displacement at fracture by 120%, while high-aspect-ratio flakes and silane-treated fibers only significantly increased composite stiffness. Impact resistance was additionally evaluated, revealing a significant enhancement upon the addition of fibrous reinforcements, especially when silane-treated fibers were used. Fumed silica increased the thermal stability of PVB by 7 °C and reduced water uptake to approximately 4.5%, in contrast to glass flakes, which increased water absorption reaching up to 8-11%. Lastly, the processability of composites was monitored, showing a progressive decrease with increasing filler content for all reinforcements. Overall, this work provides a comprehensive assessment of PVB-silicate/silica interfacial interactions and highlights the design of PVB composites suitable for advanced applications or the upcycling of secondary recycled PVB grades.