Coextruded multilayer vinyl chloride polymer laminates

• US 5,415,921 A
• Filed: 04/27/1993
• Issued: 05/16/1995
• Est. Priority Date: 04/27/1993
• Status: Expired due to Fees

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Grohman, Martin
• Primary Examiner(s): Buffalow, Edith
• Application Number:
  US08/053,929
• Time in Patent Office: 749 Days
• Field of Search: 425/518, 425/216, 425/519, 425/520-522, 525/67
• US Class Current: 428/216
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2309/105 Thickness
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/30 comprising vinyl (co)polymers; comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: C08L 2666/24 Graft or block copolymers according to groups C08L51/00, C08L53/00 or C08L55/02; Derivatives thereof
• CPC Class Codes: C08L 27/06 Homopolymers or copolymers of vinyl chloride
• CPC Class Codes: C08L 51/04 grafted on to rubbers
• CPC Class Codes: Y10S 428/911 Penetration resistant layer
• CPC Class Codes: Y10T 428/24975 No layer or component greater than 5 mils thick
• CPC Class Codes: Y10T 428/3192 Next to vinyl or vinylidene chloride polymer
• CPC Class Codes: Y10T 428/31924 Including polyene monomers
• CPC Class Codes: Y10T 428/31928 Ester, halide or nitrile of addition polymer
• CPC Class Codes: Y10T 428/31931 Polyene monomer-containing
• CPC Class Codes: Y10T 428/31935 Ester, halide or nitrile of addition polymer

Abstract

A laminate which is useful as a construction material is disclosed. The laminate has a substrate layer which contains vinyl chloride polymer, a butadiene rubber graft copolymer, and has a superstrate layer which contains vinyl chloride polymer, butylacrylate rubber graft copolymer, and titanium dioxide. The superstrate layer protects the substrate layer from excessive exposure to ultraviolet light, heat and moisture, and thereby protects the substrate layer from weathering during outdoor use of the laminate as a material for siding, gutter systems, downspouts, shutters, window casings, and other exterior outdoor weather exposed building material applications.

Claims

1. A coextruded multilayer laminate comprising:

(a) a substrate layer of a thermoplastic resin composition comprising

(i) from 50 to 99 percent by weight vinyl chloride polymer based on the entire weight of the resin composition,

(ii) from 1 to 10 percent by weight of a butadiene rubber graft copolymer based on the total weight of the resin composition, said graft copolymer being selected from the group consisting of graft polymer obtained by grafting from 15 to 50 percent by weight of a monomer selected from the group consisting of vinyl aromatics, vinyl cyanides, methacrylic alkyl esters, and mixtures thereof to 50 to 85 percent by weight of a butadiene rubber based on the total weight of the butadiene rubber graft polymer,

(b) a superstrate layer attached to said substrate layer to protect said substrate layer from heat, moisture and ultraviolet light, said superstrate layer comprising a polymeric composition comprising,

(i) from 50 to 98 percent vinyl chloride polymer based on the total weight of the polymeric composition,

(ii) from 1 to 10 percent by weight of a alkyl acrylate rubber graft copolymer based on the total weight of the polymeric composition, said alkyl acrylate rubber graft copolymers being selected from the group consisting of graft copolymers obtained by grafting from 10 to 50 percent by weight of a monomer selected from the group consisting of vinyl aromatics, vinyl cyanides, methylacrylic alkyl esters and mixtures thereof to 50 to 90 percent by weight of a alkyl acrylate rubber based on the total weight of the alkyl acrylate graft copolymer, and

(iii) from 1 to 20 percent by weight titanium dioxide based on the total weight of the polymeric composition.

2. The laminate of claim 1 wherein said laminate consists essentially of said substrate layer and said superstrate layer.

3. The laminate of claim 1 wherein said laminate consists of said superstrate layer and said substrate layer.

4. The laminate of claim 1 wherein said butadiene rubber graft polymer is selected from the group consisting of acrylonitrile-butadiene-styrene polymers and methyl methacrylate-butadiene-styrene polymers.

5. The laminate of claim 1 wherein said alkyl acrylate rubber graft polymer is selected from the group consisting of methyl methacrylate-butylacrylate-styrene graft polymers.

6. The laminate of claim 1 wherein said substrate layer has a thickness of from 0.01 to 0.3 inch;

said superstrate has a thickness of from 0.001 to 0.1 inch.

7. The laminate of claim 6 wherein said substrate layer has a thickness of from 0.03 to 0.06 inch.

8. The laminate of claim 1 wherein said polymeric composition comprises from 70 to 91 percent by weight vinyl chloride polymer, from 3 to 7 percent by weight butylacrylate rubber graft polymer, and from 5 to 15 percent by weight titanium dioxide.

9. The laminate of claim 1 wherein said substrate comprises from 79 to 96 percent by weight vinyl chloride polymer, from 1 to 10 percent by weight butadiene rubber graft polymer, from 1 to 5 percent by weight titanium dioxide.