Multilayer composition
View Patent ↗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.
1. An acrylic multi-layer article 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 acrylic polymer matrix and from 4 to 60 weight percent, based on the total inner layer composition, of core/shell impact modifier having an average particle size of greater than or equal to 225 nm,
c) a substrate
wherein layer a) is directly above and adjacent to layer b), and layer b is above and directly adjacent to said substrate.
2. The acrylic multi-layer article of claim 1 wherein said hard-core has a Tg of greater than 25° C.
3. The acrylic multi-layer article of claim 1 wherein said hard-core has a Tg of greater than 40° C.
4. The acrylic multi-layer article 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.
5. The acrylic multi-layer article of claim 1 wherein said thermoplastic polymer is an acrylic polymer matrix and comprises from 50 to 100 percent by weight of methyl methacrylate monomer units.
6. The acrylic multi-layer article 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.
7. The acrylic multi-layer article of claim 1 wherein said acrylic polymer matrix in the inner and outer layers is different.
8. The acrylic multi-layer article 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.
9. The acrylic multi-layer article of claim 1 wherein said outer layer has a thickness of from 2.5 microns to 2.5 mm.
10. The acrylic multi-layer article of claim 1 wherein said inner layer has a thickness of from 25 microns to 2.5 cm.
11. The acrylic multi-layer article 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.
12. The acrylic multi-layer article of claim 1 wherein said impact modifier in the outer layer has an average particle size of from 50-200 nm.
13. The multi-layer article of claim 1 further comprising a second outer layer on the opposite side of the inner layer for the first outer layer.
14. The multi-layer article of claim 1 , wherein said substrate is plastic, metal, wood, glass, or stone.
15. The multi-layer article of claim 14 , 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.
16. The multi-layer article of claim 1 , 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.
17. The article of claim 1 used as a flat sheet or formed by, in-mold decorating, blow molding, sheet forming, coextrusion, profile extrusion, or thermoforming.
18. The article of claim 1 comprising a spa; counter top; sink; bathtub liner and surround; automotive components; vehicle components; all-terrain and recreational vehicle components; 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.