Multilayer composite

Patent metadata

Field	Value
Publication number	US-2016009060-A1
Application number	US-201414770946-A
Country	US
Kind code	A1
Filing date	Mar 14, 2014
Priority date	Mar 15, 2013
Publication date	Jan 14, 2016
Grant date	—

Abstract

The invention relates to multilayer composites having improved weathering properties without reducing flame retardation properties. The composites have a fluoropolymer layer over a thermoplastic layer. The multilayer composite may be a fluoropolymer layer directly over a relatively flammable substrate or non-flammable substrate (like PVC), or it may be a fluoropolymer layer over a relatively flammable cap layer, over a substrate (that is flammable or non-flammable). The composite is formed using coating, coextrusion and/or lamination techniques. The multilayer composite is especially useful in articles having surfaces that are used in a relatively horizontal position, including decking, railings, roofing and window profiles. The composites provide improved weathering for the substrate without a reduction in flame-resistance, when compared to the substrate without the outer fluoropolymer layer. The multi-layer composite also provides enhanced chemical resistance, hardness, scratch and mar, and water resistance.

First claim

1 . A weatherable multilayer composite comprising:
a) an outer fluoropolymer layer b) a thermoplastic substrate layer.

2 . The weatherable multilayer composite of claim 1 , further comprising one or more intermediate thermoplastic polymer layers between the outer fluoropolymer layer and the thermoplastic substrate layer.

3 . The weatherable multilayer composite of claim 1 , wherein said intermediate layer comprises a thermoplastic selected from the group consisting of acrylics, styrenics, polycarbonates, polyolefins, and blends thereof.

4 . The weatherable multilayer composite of claim 3 , Wherein said intermediate layer comprises a acrylonitrile-styrene-acrylate (ASA) copolymer.

5 . The weatherable multilayer composite of claim 4 , wherein said intermediate layer comprises an alloy of ASA and a polyvinyl chloride polymer.

6 . The weatherable multilayer composite of claim 1 , wherein said fluoropolymer layer comprises two or more fluoropolymer layers, the layers having the same or different compositions.

7 . The weatherable multilayer composite of claim 1 , wherein said fluoropolymer comprises a polyvinylidene fluoride homopolymer, or a polyvinylidene fluoride copolymer comprising at least 70 weight percent of vinylidene fluoride monomer units.

8 . The weatherable multilayer composite of claim 7 , wherein said copolymer comprises from 1 to 30 weight percent of hexafluoropropylene.

9 . The weatherable multilayer composite of claim 1 , wherein said substrate is selected from the group consisting of acrylic polymers, styrenic polymers, polyolefins, polyvinyl chloride (PVC), polycarbonate (PC), polyurethane (PU), and mixtures thereof.

10 . The weatherable multilayer composite of claim 2 , wherein said thermoplastic polymer layer is selected form the group of flammable polymers consisting of acrylic polymers, styrenics, and polycarbonate, polyolefins, and blends of these polymers with other thermoplastics.

11 . The weatherable multilayer composite of claim 10 , wherein said acrylic polymer is a polymethyl methacrylate homopolymer or a copolymer comprising at least 70 weight percent of methyl methacrylate units.

12 . The weatherable multilayer composite of claim 2 , wherein said thermoplastic polymer layer is pigmented.

13 . The weatherable multilayer composite of claim 2 , wherein said fluoropolymer layer has a thickness of from 0.01 to 0.2 mm, said flammable thermoplastic polymer layer has a thickness of from 0.5 to 2.5 mm, and said substrate layer has a thickness of from 1.0 to 50 mm.

14 . An article comprising the weatherable multilayer composite of claim 1 .

15 . The article of claim 14 , wherein said article is a railing, decking, fencing, window profile or roofing articles.

16 . The article of claim 14 , wherein said article obtains a UL-94 rating of at least one Class higher than a multi-layer structure of the same composition but without said fluoropolymer layer

17 . The article of claim 14 , wherein said article obtains a UL-94 rating of V0.

18 . A process for forming the article of claim 11 , comprising the steps of
a) extruding a substrate layer, or coextruding a substrate layer and a thermoplastic polymer layer, b) separately forming a fluoropolymer film, and c) laminating the fluoropolymer film to the extruded substrate layer or to the thermoplastic polymer layer side of said thermoplastic polymer/substrate coextrusion, to form a multilayer composite.

Assignees

• Toft Adam N
• Arkema France

Inventors

• Toft Adam N
• Reed Jack
• Lefebvre Amy A
• Crabb Charles C
• Mehlmann Florence

Classifications

• B32B2307/712

  Weather resistant · CPC title

• B32B2419/00

  Buildings or parts thereof · CPC title

• B32B2307/536

  Hardness · CPC title

• B32B27/40

  comprising polyurethanes · CPC title

• B32B27/302

  comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers · CPC title