Composite panel

• US 20010041256A1
• Filed: 05/08/2001
• Published: 11/15/2001
• Est. Priority Date: 11/09/1998
• Status: Abandoned Application

• Current Assignee: Peter F. Heilmayr
• Original Assignee: Peter F. Heilmayr
• Inventors: Heilmayr, Peter F.
• Application Number:
  US09/850,857
• Publication Number:
  US 20010041256A1
• Time in Patent Office: Days
• US Class Current: 428/318.6
• CPC Class Codes: B32B 27/30 comprising vinyl (co)polymers; comprising acrylic (co)polymers
• CPC Class Codes: Y10T 428/249988 Of about the same composition as, and adjacent to, the void-containing component
• CPC Class Codes: Y10T 428/249991 Synthetic resin or natural rubbers

Abstract

A three-layer extrusion of polymer material forming a decorative composite panel, with an outer and inner solid polymer layer of relatively high density, and a central polymer layer of lower density or a filled central polymer layer of higher density. The three layers are coextruded, and each face of the center layer is fused to a respective face of the outer and inner solid polymer layers, forming a solid panel that meets ASTM standards for Rigid Poly(vinyl chloride) Siding. The three layer panel can be coextruded with two extruders (ABA configuration) or three extruders (ABC configuration). The specific layer compositions result in cost savings and material reductions or in performance enhancement of the panel or in providing a higher heat distortion panel or for scrap reclamation.

Claims

1. A composite panel, comprising:

an inner impact modified solid polymer layer and an outer impact modified solid polymer layer, each of said layers having a uniform thickness between 0.004 inches and 0.020 inches, each of said solid polymer layers comprising a polyvinyl chloride polymer formulation with a specific gravity range from 1.35 to 1.50, and wherein each of said inner and outer solid polymer layers contains from 2.0 to 8.0 parts per hundred parts of an impact modifier;

a center layer selected from the group consisting of calcium carbonate filled polyvinyl chloride, foamed polyvinyl chloride, formed and calcium carbonate filled polyvinyl chloride, said center layer being coextruded so as to be fused to said inner and outer solid polymer layers, said center layer having a specific gravity ranging from 0.80 to 1.60 and having thickness ranging from 0.015 inches to 0.040 inches, and wherein said center layer is further characterized by the substantial absence of impact modifier;

said composite panel having a thickness between 0.035 inches and 0.060 inches; and

said composite panel having an impact resistance of 60 in. lbf. as measured in accordance with ASTM Standard D-3679-96.

3. The composite panel of

claim 1

, wherein the center layer is comprised of 2 to 6 parts per hundred parts of impact modifier and a low glass transition temperature formulation, wherein the inner and outer layers contain 2 to 8 parts per hundred parts impact modifier and wherein the panel shows a 50% impact strength improvement over ASTM-D3679-96 making it suitable for use in cold climates.

4. The composite panel of

claim 1

, wherein the center layer is a ground or pulverized regrind material which contains a material selected from the group consisting of PVC, filler, acrylics, ASA, CPVC, ABS, MBS, polystyrene, as well as materials made from these materials which have different colors where the center layer is combined with inner and outer high ductility impact modified layers so that the resultant product complies with ASTM Standard-D-3679-96.

2. A high heat distortion composite panel, comprising:

high ductility impact modified inner and outer layers formed of solid polyvinyl chloride;

a center layer selected from the group consisting of chlorinated polyvinyl chloride, ABS filled polyvinyl chloride and polystyrene, said center layer having opposed, exposed faces and having a specific gravity ranging from 0.80 to 1.70, and a uniform thickness ranging from 0.015 inches to 0.040 inches, said center layer being sandwiched between and coextruded to the inner and outer coextruded solid polymer layers, whereby said opposed faces of said center layer are fused during the coextrusion process to the inner and outer layers, respectively; and

wherein at least a selected one of the inner and outer layers contain coloring additives which give the panel darker colors than listed in ASTM D-3679, which can only be used without panel deformation problems when the above described materials are used to provide a panel with an increased heat distortion temperature.

5. A cost efficient triwall panel with adequate strength for siding applications, comprising:

inner and outer layers solid PVC polymer layers having 2 to 8.0 parts per hundred parts impact modifier incorporated therein, wherein the impact modifiers in the layer exposed to the elements are selected from the group consisting of methyhnethacrylate grafted onto butylacrylate, EVA (ethylenevinylacetate), ASA (acrylonitrile-styrene-acrylate) and chlorinated polyethylene, and wherein the inner or outer layer not exposed to the elements contain the impact modifiers used in the exposed layer or MBS (methylmethacrylate-butadiene-styrene) or ABS (acrylonitrile-butadiene-styrene);

a center layer coextruded with said inner and outer layers, the center layer having little or no impact modifier, the center layer being foamed PVC, filled PVC or foamed and filled PVC; and

wherein the triwall panel so constructed provides adequate impact strength for siding, sheet and fence panels by employing impact modifier in the inner and outer layers but is also produced at reduced cost by leaving out any impact modifier in the center layer and using a foamed, filled or foamed and filled center layer rather than employing impact modifier throughout the wall thickness of the panel.

6. A high heat distortion triwall panel which allows the use of darker colors than those called out in ASTM Standard D3679-96 while exhibiting a heat distortion temperature exceeding 169 degrees F., comprising:

inner and outer high-ductility impact modified solid PVC polymer layers having 2 to 7.5 parts per hundred parts impact modifier incorporated therein;

a center layer a center layer selected from the group consisting of chlorinated polyvinyl chloride, ABS filled polyvinyl chloride and polystyrene, said center layer having opposed, exposed faces and having a specific gravity ranging from 0.80 to 1.70, and a uniform thickness ranging from 0.015 inches to 0.040 inches, said center layer being sandwiched between and coextruded to the inner and outer coextruded solid polymer layers, whereby said opposed faces of said center layer are fused during the coextrusion process to the inner and outer layers, respectively;

wherein at least a selected one of the inner and outer layers contain coloring additives which give the panel darker colors than listed in ASTM D-3679, the resulting triwall panel also passing overall impact strength requirements in spite of reduced ductility and increased glass transition temperature of the center layer, which can only be used without panel deformation problems when the above described materials are used.

7. An increased impact strength triwall panel, comprising:

inner and outer layers solid PVC polymer layers having 2 to 8.0 parts per hundred parts impact modifier incorporated therein, wherein the impact modifiers in the layer exposed to the elements are selected from the group consisting of methylmethacrylate grafted onto butylacrylate, EVA (ethylenevinylacetate), ASA (acrylonitrile-styrene-acrylate) and chlorinated polyethylene, and wherein the inner or outer layer not exposed to the elements contain the impact modifiers used in the exposed layer or MBS (methylnethacrylate-butadiene-styrene) or ABS (acrylonitrile-butadiene-styrene);

a center layer coextruded with said inner and outer layers, the center layer having 2 to 6 parts impact modifier and a low glass transition temperature formulation, the impact modifier used in the center layer and unexposed outer layer being of the non-weatherable MBS or ABS type for cost efficiency; and

wherein the triwall panel so constructed exhibits a 50% impact strength improvement over ASTM-D3679-96, making it suitable for use in cold climates.

8. A composite triwall panel having a regrind center layer, comprising:

inner and outer high-ductility impact modified layers of solid PVC polymer having 2 to 8.0 parts per hundred parts impact modifier incorporated therein, wherein the impact modifiers in the layer exposed to the elements are selected from the group consisting of methylmethacrylate grafted onto butylacrylate, EVA (ethylenevinylacetate), ASA (acrylonitrile-styrene-acrylate) and chlorinated polyethylene, and wherein the inner or outer layer not exposed to the elements contain the impact modifiers used in the exposed layer or MBS (methylmethacrylate-butadiene-styrene) or ABS (acrylonitrile-butadiene-styrene);

a coextruded center layer, wherein the center layer is a ground or pulverized regrind material which contains a material selected from the group consisting of PVC, filler, acrylics, ASA, CPVC, ABS, MBS, polystyrene, as well as materials made from these materials which have different colors where the center layer is combined with inner and outer high ductility impact modified layers so that the resultant product complies with ASTM Standard-D-3679-96.