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Plastic sheet product offering matte appearance and method of preparation

a technology of plastic sheets and products, applied in the field of plastic sheets products, can solve the problems of loss of texture, limited predictability and consequent uniformity, frequent replacement of rolls, etc., and achieve the effects of less cleaning maintenance, less porous, and inexpensive preparation

Inactive Publication Date: 2006-01-26
EVONIK CYRO
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

"The patent describes a way to make a plastic sheet with a matte appearance that is durable and easy to clean. This sheet is made by adding a layer of a capstock composition to a core layer of thermoplastic polymer. The capstock composition contains particles that differ in refractive index from the thermoplastic polymer. The technique involves co-extrusion, which allows for precise control over the size and loading of the particles. The resulting sheet has improved properties and can be used in a variety of applications where a matte appearance is desired."

Problems solved by technology

However, such technology has several disadvantages such as frequent replacement of the rolls, limited predictability and consequent uniformity of the textural designs of the sheets produced, loss of the texture if the sheet is thermoformed, and the like.
Among the shortcomings of the prior art, the sheet materials presently available offer inconsistencies in appearance and difficulty in preparation, as there are often unacceptable variations in the thickness of the matte layer.
Also, in the instance where the finish is achieved by surface texturization, the products are more difficult to maintain and clean.

Method used

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  • Plastic sheet product offering matte appearance and method of preparation
  • Plastic sheet product offering matte appearance and method of preparation

Examples

Experimental program
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Effect test

example 1

[0023] In this example, a plastic sheet product containing one capstock layer bonded to the core layer was prepared. The first thermoplastic polymer used for the core layer and the second thermoplastic polymer used for the capstock layer were the same: a copolymer of about 94 wt. % methyl methacrylate and about 6 wt. % methyl acrylate having a melt index of 2.1, a weight average molecular weight of 150,000 and a refractive index of 1.490. The amount of the first thermoplastic composition for the core layer in relation to the second thermoplastic polymer for the capstock layer was such that, after feedblock coextrusion of the two layers, the core layer had a thickness of 5.75 mm and the capstock layer had a thickness of 250 microns. Particles comprising beads of a crosslinked polymethyl methacrylate with a refractive index of 1.52 and average particle diameters of about 40 microns were combined with the second thermoplastic polymer in an amount of 25 wt. % of the beads.

[0024] The eq...

example 2

[0026] Example 1 was repeated so as to prepare a plastic sheet product with capstock layers on both faces of the core layer and a total thickness of about 6 mm. Accordingly, the composition of the core layer and the capstock layer were the same as those of Example 1, and the general manufacturing procedure was also the same, with the exception that the flow channels on both sides of the feed block were opened so that the capstock layer composition could flow to both faces of the core layer. The amount of the first thermoplastic composition for the core layer in relation to the second thermoplastic polymers for each capstock layer was such that, after feedblock coextrusion of the three layers was complete, the core layer had a thickness of 5.5 mm and each capstock layer had a thickness of 250 microns.

example 3

[0027] In this example, as in Example 1, plastic sheet products containing one capstock layer bonded to the core layer were prepared. The first thermoplastic polymer used for the core layer and the second thermoplastic polymer used for the capstock layer were the same: a copolymer of about 94 wt. % methyl methacrylate and about 6 wt. % methyl acrylate having a melt index of 2.1, a weight average molecular weight of 150,000 and a refractive index of 1.490. The amount of the first thermoplastic composition for the core layer in relation to the second thermoplastic polymer for the capstock layer was such that, after feedblock coextrusion of the two layers, the core layer had a thickness of of between about 2 and about 9 mm as reflected in Table 1, and the capstock layer had a thickness of between about 125 and 195 microns as reflected in Table 1. Particles comprising beads of a crosslinked polymethyl methacrylate with a refractive index of about 1.52 and average particle diameters of a...

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Abstract

A plastic sheet product having a matte finish comprises a core layer of a thermoplastic polymer and at least one layer of a capstock composition which overlies, and is bonded to, at least one face of the core layer. The capstock composition comprises the same or different thermoplastic polymer and contains a plurality of discrete particles immiscible with and dispersed in the thermoplastic polymer of the capstock composition. The sheet product may be prepared by the co-extrusion of the thermoplastic polymer and the capstock composition, and in a particular embodiment, such co-extrusion may be conducted by means of a feedblock. In a particular embodiment, the thermoplastic polymer of the core layer and that of the capstock composition may be the same, such as in the instance of a methylmethacrylate-methylacrylate copolymer. Sheet products prepared in accordance with the invention exhibit improved post-processability and ease of surface maintenance, and may be fabricated into a variety of products including light diffusers, projection screens, and the like.

Description

CROSS REFERENCE TO RELATED APPLICATIONS [0001] The present application is a continuation-in-part of co-pending non-provisional application Ser. No. 09 / 817,788, filed Mar. 26, 2001, which, in turn, is based upon Provisional Application Ser. No. 60 / 192,057 filed on Mar. 24, 2000. Applicants claim the benefits of 35 U.S.C. § 120 as to the said non-provisional application, and 35 U.S.C. § 119(e) as to the said provisional application, and the disclosures of both of said applications are incorporated herein in their entireties.BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The invention relates to a plastic sheet product exhibiting a matte appearance which comprises a core layer and at least one layer of a capstock composition which overlies and is bonded to at least one face of the core layer, where the capstock composition contains particulate inclusions that yield the desired appearance and that emulates frosted glass. [0004] 2. Description of Related Art [0005] I...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): B32B27/00B32B27/08
CPCB32B21/08B32B27/08Y10T428/25Y10T428/24372Y10T428/26B32B27/20Y10T428/31855B32B2333/12B32B2250/02B32B2250/24B32B27/308B32B2307/418B32B2309/105B32B2307/554B32B2307/408
Inventor SPARKS, DARRELL L.LAFONTAINE, GRANT B.LITKE, JENNIFER A.SMITH, ROBERT E.
Owner EVONIK CYRO
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