Multilayered clear over color polyolefin sheets and layered backing structure
AssigneeA. Schulman, Inc.
InventorDennis Smith
Life of this patent
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Abstract
A multilayer structure includes a clear polyolefin layer, a colored polyolefin layer, and a random polyolefin backing layer. The colored and backing layers are coextruded and are permanently bonded at a layer interface, which is exclusive of an adhesive. The structure has a DOI of 70 or greater and passes a gravelometer impact test per the GM9508P standard, with a 10 pint load, at a −30° C. temperature, and at an impact angle of 30 degrees. Among other uses, the structures are appropriate for use as body panels in the motor vehicle industry. The structures display a “class A” finish and meet a variety of requirements for durability and weatherability. An ABA structured backing layer and a method of making it are also described herein.
Claims31
(canceled)
A multilayer polymeric sheet comprising:
- a top polymeric layer that includes 70 to 99.1% by weight of a first polypropylene/ethylene copolymer that is isotactic and has a 0.5% to 12% by mole ethylene content;
- and
- a backing layer on the opposite side of the sheet from the top polymeric layer, the backing layer comprising a thermoplastic polyolefin and a filler;
- wherein the multilayer polymeric sheet is sheet coextruded and is exclusive of an adhesive layer;
- the top polymeric layer further comprising at least one of:
- a slip agent, a nucleating agent, a clarifying agent, or combinations of these;
- wherein the multilayer polymeric sheet has a DOI of 70 or greater and passes a gravelometer impact test per the GM9508P standard, with a 10 pt load, at a −30° C. temperature, and at an angle of 30 degrees, with a rating of 7 or greater and no delamination or cracking.
A thermoformed product comprising:
- a coextruded sheet comprising a first polymeric layer that includes 60 to 99% by weight of a first polypropylene/ethylene copolymer that is isotactic and has a 0.5 to 12% by mole ethylene content and further comprising at least one of a nucleating agent, a clarifying agent and a slip agent;
- and a second polymeric layer comprising a thermoplastic polyolefin and a filler;
- the coextruded sheet being exclusive of an adhesive layer;
- the coextruded sheet thermoformed to produce a multilayer product that has a DOI of 70 or greater and passes a gravelometer impact test per the GM9508P standard, with a 10 pt load, at a −30° C. temperature, and at an angle of 30 degrees, with a rating of 7 or greater and no delamination or cracking.
A multilayer polymeric structure comprising:
- a clear, colored, or translucent top polymeric layer that includes 70 to 99.1% by weight of an isotactic polypropylene/ethylene copolymer that has a 0.5 to 12% by mole ethylene content;
- a backing layer on the opposite side of the structure from the top polymeric layer, the backing layer comprising a thermoplastic polyolefin and a filler;
- an optional colored or translucent layer between the top polymeric layer and the backing layer, the optional colored or translucent layer having 60 to 99% by weight of an isotactic polypropylene/ethylene copolymer and has a 0.5 to 12% by mole ethylene content;
- wherein the multilayer polymeric structure is sheet coextruded and is exclusive of an adhesive layer;
- the top polymeric layer further comprising at least one of:
- antioxidants, UV stabilizers, slip agents, or combinations of these;
- wherein at least one of the backing layer or the top polymeric layer is not treated to induce cross-linking;
- wherein the multilayer polymeric structure passes a gravelometer impact test per the GM9508P standard, with a 10 pt load, at a −30° C. temperature, and at an angle of 30 degrees, with a rating of 7 or greater and no delamination or cracking.
A method of making a multilayer polymeric structure comprising the steps of:
- coextruding a clear, colored, or translucent top polymeric layer that includes 70 to 99.1% by weight of an isotactic polypropylenelethylene copolymer that has a 0.5 to 12% by mole ethylene content with a backing layer on the opposite side of the structure from the top polymeric layer, the backing layer comprising a thermoplastic polyolefin and a filler;
- and optionally coextruding the top polymeric layer and backing layer with an optional colored or translucent layer between the top polymeric layer and the backing layer, the optional colored or translucent layer having 60 to 99% by weight of an isotactic polypropylene/ethylene copolymer and a 0.5 to 12% by mole ethylene content;
- wherein the multilayer polymeric structure is exclusive of an adhesive layer;
- the top polymeric layer further comprising at least one of antioxidants, UV stabilizers, slip agents, or combinations of these;
- wherein at least one of the backing layer or the top polymeric layer is not treated to induce cross-linking;
- wherein the multilayer polymeric structure passes a gravelometer impact test per the GM9508P standard, with a 10 pt load, at a −30° C. temperature, and at an angle of 30 degrees, with a rating of 7 or greater and no delamination or cracking.
Dependencies are inferred from the claim text.