Multilayer composition

• US 20070009752A1
• Filed: 05/10/2006
• Published: 01/11/2007
• Est. Priority Date: 07/08/2005
• Status: Active Grant

• Current Assignee: Trinseo Europe Gmbh
• Original Assignee: Arkema France (Arkema)
• Inventors: Horvath, Andrew, Lefebvre, Amy, Wanat, Robert, Hone, Donald
• Granted Patent: US 8,034,441 B2
• Time in Patent Office: Days
• US Class Current: 428/500
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2307/406 Bright, glossy, shiny surface
• CPC Class Codes: B32B 2307/558 Impact strength, toughness
• CPC Class Codes: B32B 2307/712 Weather resistant
• CPC Class Codes: B32B 2307/714 Inert, i.e. inert to chemical degradation, corrosion
• CPC Class Codes: B32B 2307/738 Thermoformability
• CPC Class Codes: B32B 2509/00 Household appliances
• CPC Class Codes: B32B 2605/00 Vehicles
• CPC Class Codes: B32B 27/06 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/18 characterised by the use of special additives
• CPC Class Codes: B32B 27/30 comprising vinyl (co)polymers; comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/308 comprising acrylic (co)polymers
• CPC Class Codes: Y10T 428/24983 Hardness
• CPC Class Codes: Y10T 428/249921 Web or sheet containing structurally defined element or component
• CPC Class Codes: Y10T 428/25 Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/254 Polymeric or resinous material
• CPC Class Codes: Y10T 428/269 including synthetic resin or polymer layer or component
• CPC Class Codes: Y10T 428/31855 Of addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31938 Polymer of monoethylenically unsaturated hydrocarbon

Abstract

The invention relates to a multi-layer acrylic composition having at least two impact modified layers. The outer layer is an acrylic layer containing impact modifiers having a particle size of less than 225 nm, and the impact modifiers in the inner thermoplastic layer have a particle size of greater than or equal to 225 nm. The invention also relates to multi-layer composites having the multi-layer acrylic composition on one or both sides. The multi-layer acrylic composition can also include blends of acrylic and fluoropolymers.

Claims

1. An acrylic multi-layer composition comprising from the outside in:

a) an outer layer comprising an acrylic polymer matrix and from 5 to 60 weight percent, based on the total outer layer composition, of a hard-core core/shell impact modifier having an average particle size of less than 225 nm, wherein said hard-core has a Tg of greater than 0°

C.; and

b) an inner layer comprising a thermoplastic polymer matrix and from 4 to 60 weight percent, based on the total inner layer composition, of impact modifier having an average particle size of greater than or equal to 225 nm.

2. The acrylic multi-layer composition of claim 1 wherein said hard-core has a Tg of greater than 25°

C.

3. The acrylic multi-layer composition of claim 1 wherein said hard-core has a Tg of greater than 40°

C.

4. The acrylic multi-layer composition of claim 1 wherein said acrylic polymer matrix in the outer layer comprises from 50 to 100 percent by weight of methyl methacrylate monomer units.

7. The acrylic multi-layer composition of claim 1 wherein said inner thermoplastic layer is an acrylic polymer matrix and wherein the acrylic polymer matrix in the inner and outer layers is the same.

8. The acrylic multi-layer composition of claim 1 wherein said acrylic polymer matrix in the inner and outer layers is different.

9. The acrylic multi-layer composition of claim 1 wherein said acrylic polymer matrix at least one of the inner or outer layers is a blend of a fluoropolymer and an impact modified acrylic polymer.

10. The acrylic multi-layer composition of claim 1 wherein said outer layer has a thickness of from 2.5 microns to 2.5 mm.

11. The acrylic multi-layer composition of claim 1 wherein said inner layer has a thickness of from 25 microns to 2.5 cm.

12. The acrylic multi-layer composition of claim 1 wherein said outer layer comprises from 8 to 40 weight percent, based on the total outer layer composition, of said hard-core core/shell impact modifier.

13. The acrylic multi-layer composition of claim 1 wherein said impact modifier in the outer layer has an average particle size of from 50-200 nm.

14. The multi-layer composition of claim 1 further comprising a second outer layer on the opposite side of the inner layer for the first outer layer.

19. An article comprising the multi-layer acrylic composition of claim 1.

20. The article of claim 19 used as a flat sheet or formed by, in-mold decorating, blow molding, sheet forming, coextrusion, profile extrusion, or thermoforming.

21. The article of claim 19 comprising a spa;

counter top;

sink;

bathtub liner and surround;

automotive and other vehicle components, including all-terrain and recreational vehicle components, such as body panels, tire cover, tonneau cover, cargo box, fender skirt, fifth wheel cover, lawn tractor components;

engine surround cover;

boat hull;

computer housing;

cell phone casing; and

as a replacement for metal cladding in appliances such as washing machines, refrigerators, and dishwashers.

5. The multi-layer composition of claim l,wherein said inner layer thermoplastic polymer matrix is selected from the group consisting of polycarbonate, polyester, polystyrene, styrene/acrylonitrile copolymer, polyolefins, poly(vinyl chloride), chlorinated poly(vinyl chloride), imidized acrylic polymer, and acrylic polymer.

6. The acrylic multi-layer composition of claim 5 wherein said thermoplastic polymer is an acrylic polymer matrix and comprises from 50 to 100 percent by weight of methyl methacrylate monomer units.

15. A multi-layer composite structure comprising, from outside to inside:

1) an acrylic multi-layer composition comprising from the outside in;

a) an outer layer comprising an acrylic resin and from 5 to 60 weight percent, based on the total outer layer composition, of a hard-core core/shell impact modifier having an average particle size of less than 225 nm;

b) an inner layer comprising a thermoplastic resin and from 4 to 60 weight percent, based on the total inner layer composition, of impact modifier having an average particle size of greater than or equal to 225 nm; and

2) a substrate.

16. The multi-layer composite of claim 15, wherein said substrate is plastic, metal, wood, glass, or stone.

17. The multi-layer composite of claim 15, wherein said plastic substrate is selected from the group consisting of polyacrylonitrile-butadiene-styrene, polyacrylonitrile-styrene-acrylic, polycarbonate/polyacrylonitrile-butadiene-styrene, high impact polystyrene, polyvinyl chloride, thermoplastic olefins, polyolefins, polystyrene, polystyrene-acrylonitrile, polycarbonate, polyethylene terephthalate, and glycolised polyester.

18. The multi-layer composite of claim 15, further comprising on the other side of the substrate from said inner and outer impact modified acrylic layers a second inner impact modified acrylic layer and then a second outer impact modified acrylic layer.