Polymeric sheets and laminas having high flexural durability

• US 5,478,629 A
• Filed: 01/21/1994
• Issued: 12/26/1995
• Est. Priority Date: 01/21/1994
• Status: Expired due to Fees

• Current Assignee: Empire Plastics Incorporated
• Original Assignee: Gencorp Incorporated
• Inventors: Norman, Donald E.
• Primary Examiner(s): Buffalow, Edith
• Application Number:
  US08/184,126
• Time in Patent Office: 704 Days
• Field of Search: 428/916, 428/200, 428/204, 428/13, 283/94, 283/904
• US Class Current: 428/200
• CPC Class Codes: B32B 2327/06 PVC, i.e. polyvinylchloride
• CPC Class Codes: B32B 2331/04 Polymers of vinyl acetate, e.g. PVA
• CPC Class Codes: B32B 2425/00 Cards, e.g. identity cards, credit cards
• 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 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/306 comprising vinyl acetate or vinyl alcohol (co)polymers
• CPC Class Codes: B32B 27/308 comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/322 comprising halogenated polyolefins, e.g. PTFE
• CPC Class Codes: B42D 25/00 Information-bearing cards or sheet-like structures characterised by identification or security features; Manufacture thereof printing processes to produce identification or security features B41M3/14
• CPC Class Codes: B42D 25/23 Identity cards
• CPC Class Codes: B42D 25/36 comprising special materials
• CPC Class Codes: B42D 25/45 Associating two or more layers
• CPC Class Codes: Y10S 283/904 Credit card
• CPC Class Codes: Y10S 428/916 Fraud or tamper detecting
• CPC Class Codes: Y10T 428/24843 with heat sealable or heat releasable adhesive layer
• CPC Class Codes: Y10T 428/24876 Intermediate layer contains particulate material [e.g., pigment, etc.]
• CPC Class Codes: Y10T 428/3154 Of fluorinated addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/3192 Next to vinyl or vinylidene chloride polymer

Abstract

Polymeric blends suitable for making plastic sheets and laminas which exhibit improved flexural durability while retaining stiffness and impact strength include a core made from a blend comprising polyvinyl chloride resin, a vinyl chloride-vinyl ester copolymer, one or more acrylic polymers or copolymers, a chlorinated polyolefin, a solid tin stabilizer, and one or more ester waxes. The lamina, which is suitable for use as an extended life credit card, is prepared by forming a polymeric blend of a core material into a base layer sheet material which is subsequently treated to reduce surface tension and improve ink adhesion thereto, then printed with desired indicia, and finally provided with a contact-transparent protective overlay which is laminated thereto. The protective layer is a sheet material made from either a polymer or copolymer such as polyvinyl fluoride, or a polymer blend comprising essentially the same components of the core material but utilizing a different tin stabilizer and including the use as an ultra-violet light stabilizer. The overlay polymer blend material is very compatible with the core material and has good flex life.

Claims

1. In a laminated article comprising a thermoplastic core having ink and/or dye on at least one surface thereof and at least one thermoplastic transparent overlay bound to said core, the improvement wherein said core comprises a blend of;

a resin which is a polyvinyl chloride polymer or copolymer containing at least 70 percent vinyl chloride repeat units therein;

from about 50 to about 200 parts by weight per 100 parts by weight of said resin of a copolymer of vinyl chloride and a vinyl ester wherein the ester group contains from 2 to 5 carbon atoms;

from about 25 to about 60 parts by weight per 100 parts by weight of said resin of one or more acrylic polymers, or copolymers, or blends thereof;

from about 10 to about 100 parts by weight per 100 parts by weight of said resin of a chlorinated polyolefin wherein the repeat unit of said polyolefin has from 2 to 4 carbon atoms;

from about 0.5 to about 10 parts by weight per 100 parts by weight of said resin of one or more solid alkyl tin stabilizers,

and from about 0.5 to about 10 parts by weight per 100 parts by weight of said resin of one or more ester waxes.

2. A laminated article according to claim 1, wherein said overlay is (a) a polymer blend of

a resin which is a polyvinyl chloride polymer or copolymer containing at least 70 percent vinyl chloride repeat units therein;

from about 10 to about 100 parts by weight per 100 parts by weight of said resin of a copolymer of vinyl chloride and a vinyl ester wherein the ester group contains from 2 to 5 carbon atoms;

from about 5 to about 30 parts by weight per 100 parts by weight of said resin of one or more acrylic polymers, or copolymers, or blends thereof;

from about 10 to about 30 parts by weight per 100 parts by weight of said resin of a chlorinated polyolefin wherein the repeat unit of said polyolefin has from 2 to 4 carbon atoms;

from about 0.5 to about 12 parts by weight per 100 parts by weight of said resin of one or more alkyl tin stabilizers,

from about 0.5 to about 5 parts by weight per 100 parts by weight of said polyvinyl chloride resin of one or more ester waxes,

and from about 0.1 to about 1.5 parts by weight per 100 parts by weight of said resin of one or more ultraviolet light stabilizers;

or

b) a polyvinyl chloride or a copolymer of a polyvinyl chloride polymer containing at least 70 percent vinyl chloride repeat units therein, or a copolymer of vinyl chloride and a vinyl ester wherein said ester portion contains from 2 to 5 carbon atoms, or a polyester, or a fluorine-containing polymer.

3. A laminated article according to claim 2, wherein said core copolymer and said overlay copolymer of said vinyl chloride and said vinyl ester is polyvinyl chloride/vinyl acetate wherein the amount of said vinyl acetate units is from about 7 to about 15% by weight, wherein said core and said overlay chlorinated polyolefin is chlorinated polyolefin wherein the amount of said chlorination is from about 20 to about 50% by wt., wherein said alkyl group of said core alkyl tin stabilizer has from 1 to 10 carbon atoms and wherein the amount of said core tin stabilizer is from about 2.5 to about 7.5 parts by weight.

4. A laminate article according to claim 3, wherein said overlay is polyvinyl fluoride, wherein said laminated article is a monetary identification card, and wherein the laminated article has a flex life of at least 10,000 flexes.

10. A laminated article according to claim 1, wherein said overlay is polyvinyl fluoride.

5. A printable plastic substrate, comprising:

a sheet of a polymeric blend comprising;

resin which is a polyvinyl chloride polymer or copolymer containing at least 70 percent vinyl chloride repeat units therein;

from about 50 to about 200 parts by weight per 100 parts by weight of said resin of a copolymer of vinyl chloride and a vinyl ester wherein the ester group contains from 2 to 5 carbon atoms;

from about 25 to about 60 parts by weight per 100 parts by weight of said resin of one or more acrylic polymers, or copolymers, or blends thereof;

from about 10 to about 100 parts by weight per 100 parts by weight of said resin of a chlorinated polyolefin wherein the repeat unit of said polyolefin has from 2 to 4 carbon atoms;

from about 0.5 to about 10 parts by weight per 100 parts by weight of said resin of one or more solid alkyl tin stabilizers,

and from about 0.5 to about 10 parts by weight per 100 parts by weight of said resin of one or more ester waxes,

said polymeric sheet having an average machine direction--traverse direction flex life of at least 8,000 flexes.

6. A printable plastic substrate according to claim 5, wherein said copolymer of vinyl chloride and a vinyl ester is polyvinyl chloride/vinyl acetate wherein the amount of the vinyl ester units is from about 7 to about 15% by weight, wherein the amount of said polyvinyl chloride/vinyl acetate copolymer is from about 75 to about 125 parts by weight, wherein said alkyl group of said solid alkyl tin stabilizer has from 1 to 10 carbon atoms, wherein the amount of said solid tin stabilizer is from about 2.5 to about 7.5 parts by weight, wherein said chlorinated polyolefin is chlorinated polyethylene wherein the amount of said chlorine is from about 30 to about 40 percent by weight, and wherein the amount of said chlorinated polyethylene is from about 10 to about 25 parts by weight.

7. A printable plastic substrate according to claim 6, wherein said flex life is at least 10,000 flexes.

8. A transparent flexible polymeric overlay, comprising:

a thermoplastic sheet of a polymeric blend of;

a resin which is a polyvinyl chloride polymer or copolymer containing at least 70 percent vinyl chloride repeat units therein;

from about 10 to about 100 parts by weight per 100 parts by weight of said resin of a copolymer of vinyl chloride and a vinyl ester wherein the ester group contains from 2 to 5 carbon atoms;

from about 5 to about 30 parts by weight per 100 parts by weight of said resin of one or more acrylic polymers, or copolymers, or blends thereof;

from about 10 to about 30 parts by weight per 100 parts by weight of said resin of a chlorinated polyolefin wherein the repeat unit of said polyolefin has from 2 to 4 carbon atoms;

from about 0.5 to about 12 parts by weight per 100 parts by weight of said resin of one or more alkyl tin stabilizers,

from about 0.5 to about 5 parts by weight per 100 parts by weight of said resin of one or more ester waxes,

and from about 0.1 to about 1.5 parts by weight per 100 parts by weight of said resin of one or more ultraviolet light stabilizers,

said sheet having an average machine direction--transverse direction flex life of at least 6,000 flexes.

9. A transparent flexible polymeric overlay according to claim 8, wherein said copolymer of vinyl chloride and a vinyl ester is polyvinyl chloride/vinyl acetate wherein the amount of vinyl ester units is from about 7 to 15% by weight and wherein the amount of said polyvinyl chloride/vinyl acetate copolymer is from about 25 to about 60 parts by weight, wherein said chlorinated polyolefin is chlorinated polyethylene wherein the amount of chlorination is from about 30 to about 40 percent by weight and wherein the amount of said chlorinated polyethylene is from about 10 to about 20 parts by weight, wherein the amount by weight of said one or more alkyl tin stabilizers is from about 4 to about 10 parts by weight, wherein the amount by weight of said one or more waxes is from about 0.5 to about 3 parts by weight, and wherein said sheet flex life is at least 7,000 flexes.