Architectural panels

Abstract

A multilayer building panel article, comprising: (A) at least one layer of polyvinyl chloride material; (B) at least one tie layer, the at least one tie layer being of a composition comprising: (Bi) at least one ethylene-acrylate copolymer resin; (Bii) at least one tackifier; and (Biii) at least one inorganic filler material; and (C) at least one layer of metal substrate, and a process for making the multilayer building panel article.

Description

[Technical Field]

[0001] The present invention relates to multilayer building panel articles, and more particularly, to a multilayer building panel article having at least three layers, at least one of the layers being at least one tie layer that effectively bonds to at least one layer of polyvinyl chloride material and at least one layer of metal substrate, as well as a process for making the multilayer building panel article. [Background technology]

[0002] Polyvinyl chloride (PVC) is the third most widely produced synthetic plastic polymer in the world (after polyethylene and polypropylene) due to its excellent properties, such as flame retardancy, mechanical properties, corrosion resistance, heat resistance, and foamability. Due to its excellent properties, PVC is widely used in many different applications, such as building materials, flooring, artificial leather, pipes, wire and cable, non-food packaging, bottles, foam materials, sealants, and fibers. Furthermore, due to its excellent corrosion resistance, PVC is a potential candidate material for constructing corrosion-resistant panels by laminating PVC onto metal using a binder to bond the PVC to the metal and form a corrosion-resistant panel. Typically, corrosion-resistant panels are applied as roofing and walls in various buildings in different types of plants, such as steel plants, chemical plants, breeding plants, pesticide plants, electroplating plants, and waste-to-energy plants, where the corrosion resistance of the panels is highly desirable.

[0003] As mentioned above, PVC can be laminated onto metal substrates using a binder to bond the PVC to the metal and form anticorrosion panels. However, binders typically contain environmentally unfriendly solvents, and various governments have issued stricter environmental requirements regarding binders. Therefore, it would be advantageous to develop a solvent-free polymer adhesive tie layer film that has good bonding properties to PVC as well as metal substrates (or other polar surfaces) to avoid the need to use solvent-based binders.

[0004] Tie layers made from ethylene-based functional polymers have been widely used to bond various materials in applications such as food packaging, infrastructure, and transportation. However, using tie layers to bond PVC layers to metal is generally difficult because adhesion is typically achieved through polar or subvalent bonds instead of covalent bonds. Therefore, bonding PVC to metal materials using tie layers at high temperatures remains a challenge. Therefore, using tie layers to produce anti-corrosion panels with good anti-corrosion properties in high-temperature environments is also a challenge in the industry. For example, delamination and foaming in multi-layer panels are very common problems in roofing applications due to the panels' exposure to corrosion and sunlight. Therefore, known anti-corrosion building panels typically have a short service life. Existing adhesion promotion approaches are undesirable in many applications because the known adhesive approaches have very limited effectiveness. Various known adhesives rely on polar-polar interactions with PVC to provide bonding performance. However, the bonding performance of these known adhesives is not sufficient for high-temperature (e.g., above 50°C) applications.

[0005] It would be desirable to provide a solution to the problems of prior art adhesive approaches to bond a PVC substrate to a metal substrate using a tie layer to produce a corrosion-resistant panel that has good corrosion protection properties when used in high temperature environments. Summary of the Invention

[0006] One object of the present invention is to develop an environmentally friendly anti-corrosion panel for architectural applications, the panel structure comprising, for example, at least a three-layer structure consisting of at least one PVC layer, at least one tie layer, and at least one metal (such as steel) substrate layer.

[0007] In one embodiment, the novel environmentally friendly three-layer corrosion-resistant panel structure of the present invention includes at least one bonding layer disposed between the PVC layer and the metal substrate layer to bond the PVC layer to the metal substrate layer. The bonding layer provides good bonding to the PVC layer and the metal layer, and the panel including the bonding layer has a corrosion resistance of 90% or more. oor 120 o Resist delamination after being subjected to bending deformation testing. The tie layer used in making the above three-layer panel structure of the present invention also provides good bonding to the PVC layer at high temperatures (e.g., >50°C). Thus, a PVC layer that exhibits corrosion protection properties will continue to provide corrosion protection properties to the building panel as a whole at high temperatures, such as >50°C.

[0008] Thus, in one general embodiment, the present invention is directed to a multilayer building panel article comprising: (A) at least one layer of polyvinyl chloride material; (B) at least one tie layer of a composition comprising: (Bi) at least one ethylene-acrylate copolymer resin; (Bii) at least one tackifier; and (Biii) at least one inorganic filler material; and (C) at least one layer of a metal substrate.

[0009] In another embodiment, the present invention is directed to a process for making the above-described corrosion resistant multi-layer building panel article. [Brief explanation of the drawings]

[0010] [Figure 1] 1 is a schematic diagram showing a cross-sectional view of a three-layer corrosion-resistant multi-layer building panel structure of the present invention. [Figure 2] 1 is a schematic diagram showing a cross-sectional view of a four-layer corrosion-resistant multi-layer building panel structure of the present invention. [Figure 3] 1 is a schematic diagram showing a cross-sectional view of a five-layer corrosion-resistant multi-layer building panel structure of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0011] As used herein, the term "composition" refers to a mixture of materials that comprise the composition, as well as reaction products and decomposition products formed from the materials of the composition.

[0012] As used herein, the term "polymer" refers to a polymeric compound prepared by polymerizing (by copolymerization) monomers, whether of the same or different types. Thus, the generic term "polymer" encompasses (1) the term homopolymer (used to refer to a polymer prepared by polymerizing only one type of monomer, with the understanding that trace amounts of impurities may be incorporated into the polymer structure), and (2) the term copolymer or interpolymer (used to refer to a polymer prepared by polymerizing two or more different monomers, with the understanding that trace amounts of impurities may be incorporated into the polymer structure). Trace amounts of impurities (e.g., catalyst residues) may be incorporated into and / or present within the polymer. The polymer may be a single polymer or a polymer blend.

[0013] The term "interpolymer" refers to polymers prepared by the polymerization of at least two different types of monomers. Thus, the generic term interpolymer includes copolymers and other polymers prepared by the polymerization of more than two different monomers.

[0014] Copolymers prepared by polymerizing two monomer types are called "bipolymers."

[0015] The term "terpolymer" refers to a polymer prepared by polymerizing at least three different types of monomers.

[0016] The term "quaterpolymer" refers to a polymer prepared by polymerizing at least four different types of monomers.

[0017] An "acrylate polymer" (also known as an acrylic or polyacrylate) is any of a group of polymers prepared from acrylate monomers.

[0018] As used herein, the term "inorganic filler material" refers to inorganic fillers, metal oxide compounds, and mixtures thereof.

[0019] The term "corrosion protection" as used herein refers to the corrosion prevention provided by PVC. PVC has good corrosion protection performance, and if PVC can be firmly bonded to metals such as steel, the steel can be protected from corrosion while exposed to the elements. The bonding layer of the present invention provides an excellent bond between PVC and a steel substrate (e.g., no delamination during heating and aging) to protect the steel substrate from corrosion.

[0020] As used herein, the terms "comprising," "including," "having," and their derivatives are not intended to exclude the presence of any additional component, step, or procedure, whether specifically disclosed or not. For the avoidance of doubt, all compositions claimed through the use of the term "comprising" may include any additional additive, adjuvant, or compound, whether polymeric or otherwise, unless otherwise stated to the contrary. In contrast, the term "consisting essentially of" excludes any other component, step, or procedure from any subsequently recited scope, excepting those that are not essential to operability. The term "consisting of" excludes any component, step, or procedure not specifically delineated or listed.

[0021] As used throughout this specification, the following abbreviations have the following meanings, unless the context clearly dictates otherwise: "=" means "equal to," "~" means "approximately," "@" means "at," "<" means "less than," ">" means "greater than," "≦" means "less than or equal to," "≧" means "greater than or equal to," "I2" means "melt index," "°" means degrees, g = grams, mg = milligrams, pts = parts by weight, kg = kilogram, "kg / hr" = kilograms per hour, g / cc = grams per cubic centimeter, kg / m 3 = kilograms per cubic meter, g / mol = grams per mole, L = liter, mL = milliliter, g / L = grams per liter, Mw = mass molecular weight, Mn = number molecular weight, Mz = z-average molecular weight, m ​​= meter, μm = micrometer, nm = nanometer, mm = millimeter, cm = centimeter, min = minute, s = second, mm / s 2 = millimeters per second squared, mm / s = millimeters per second, ms = milliseconds, hr = hours, mm / min = millimeters per minute, m / min = meters per minute, m / s = meters per second, rad / s = radians per second, °C = degrees Celsius, °C / min = degrees Celsius per minute, o / s = degrees Celsius per second, mPa.s = millipascal-second, mPa = megapascal, MPa = megapascal, kPa = kilopascal, Pa.s / m 2 = Pascal-seconds per square meter, N = Newton, cN = centinewton, N / m = Newtons per meter (s); rpm = revolutions per minute, mm 2 = square millimeters, g / 10min = grams per 10 minutes, J = joules, J / g = joules per gram, % = percent, eq% = equivalent percent, vol% = volume percent, and wt% = weight percent.

[0022] Unless otherwise specified, all percentages, parts, ratios, and other amounts are defined by weight. For example, all percentages set forth herein are weight percentages (wt %) unless otherwise indicated.

[0023] Temperatures are given in degrees Celsius (°C), and "ambient temperature" means 20°C to 25°C unless otherwise specified.

[0024] Referring to FIG. 1, a multilayer panel structure or article, generally designated by reference numeral 10, is shown, including a bonding layer 11 having a first side 11a and a second side 11b, a PVC layer 12 having a first side 12a and a second side 12b, and a metal layer 13, such as a steel layer 13, having a first side 13a and a second side 13b. As shown in FIG. 1, the multiple layers are used to manufacture the building panel structure 10 by laminating individual film layer members together, and the bonding layer 11 used in the panel structure 10 is a single layer or monolayer 11 disposed in contact with and between the PVC layer 12 and the steel layer 13. One side (first side) 11a of the single-layer bonding layer 11 forms a continuous boundary between the innermost side (second side) 12b of the PVC layer 12 and the first side 11a of the bonding layer 11. The outer first side 12a of the PVC layer 12 is open to the environment. The other surface (second surface opposite the first surface) 11b of the bonding layer 11 forms a continuous boundary between the innermost surface (second surface) 13b of the steel layer 13 and the second surface 11b of the bonding layer 11. The outer first surface 13a of the steel layer 13 is open to the environment.

[0025] 2, there is shown a panel comprising a multilayer panel structure or article generally designated by reference numeral 20, including a first bonding layer 21 having a first surface 21 a and a second surface 21 b, a second bonding layer 22 having a first surface 22 a and a second surface 22 b, a PVC layer 23 having a first surface 23 a and a second surface 23 b, and a metal layer 24, such as a steel layer 24, having a first surface 24 a and a second surface 24 b. As shown in FIG. 2, the multiple layers are used to manufacture the building panel structure 20 by laminating together individual film layer members, with the bonding layer 21 in contact with and disposed between the second bonding layer 22 and the PVC layer 23, and one surface (first surface) 21 a of the bonding layer 21 forming a continuous boundary between the innermost surface (second surface) 23 b of the PVC layer 23 and the first surface 21 a of the bonding layer 21. The outer first surface 23a of the PVC layer 23 is open to the environment. The second tie layer 22 is in contact with and disposed between the first tie layer 21 and the steel layer 24, and the other surface (second surface opposite the first surface) 21b of the tie layer 21 forms a continuous boundary between the one surface (innermost first surface) 22a of the second tie layer 22 and the second surface 21b of the tie layer 21. The other surface (second surface opposite the first surface) 22b of the second tie layer 22 is in contact with and disposed between the second surface 21b of the first tie layer 21 and the innermost surface (second surface) 24b of the steel layer 24. The second surface 22b of the second tie layer 22 and the innermost surface 24b of the steel layer 24 form a continuous boundary between the second surface 22b of the second tie layer 22 and the innermost surface 24b of the steel layer 24. An outer first surface 24a of the steel layer 24 is open to the environment.

[0026] As shown in Figure 2, in some embodiments, one or more tie layer films can be used to manufacture a building panel product or article. For example, in another embodiment, the multi-layer panel structure of the panel can be a five-layer structure as shown in Figure 3. Referring to Figure 3, a panel is shown comprising a five-layer panel structure or article generally designated by reference numeral 30, including a first tie layer 31 having a first surface 31a and a second surface 31b, a second tie layer 32 having a first surface 32a and a second surface 32b, a first PVC layer 33 having a first outer surface 33a and a second inner surface 33b, a second PVC layer 34 having a first outer surface 34a and a second inner surface 34b, and a metal core layer 35, such as a steel layer 35, having a first surface 35a and a second surface 35b. As shown in FIG. 3, multiple layers are used to manufacture a building panel structure 30 by laminating individual film layer members together, and the core metal layer (or central layer) of the panel structure 30 is a metal substrate layer 35 positioned between and in contact with a first bonding layer 31 and a second bonding layer 32.

[0027] The first bonding layer 31 of the panel structure 30 is in contact with and disposed between the first PVC layer 33 and the core metal layer 35. One surface (first surface) 31a of the first bonding layer 31 forms a continuous boundary between the innermost surface (second surface) 33b of the PVC layer 33 and the first surface 31a of the first bonding layer 31. The other surface (second surface) 31b of the first bonding layer 31 forms a continuous boundary between one surface (first surface) 35a of the core metal layer 35 and the second surface 31b of the bonding layer 31. The outer surface 33a of the first PVC layer 33 is open to the environment.

[0028] 3, the second tie layer 32 is in contact with and disposed between the second PVC layer 34 and the steel core layer 35. One side (first side) 32a of the second tie layer 32 forms a continuous boundary between the other side (second side) 35b of the core metal layer 35 and the first side 32a of the second tie layer 32. The other side (second side opposite the first side) 32b of the second tie layer 32 is in contact with and disposed between the second side 35b of the core steel layer 35 and the innermost side (second side) 34b of the second PVC layer 34 and the second side 32b of the second tie layer 32. The outer side 34a of the second PVC layer 34 is open to the environment.

[0029] The first bonding layer 31 in the five-layer panel 30 is disposed in contact with one side of the core metal layer 35 and one side of the first PVC layer 33. The second bonding layer 32 in the five-layer panel 30 is disposed between the other side of the core metal layer 35 and one side of the second PVC layer 33. The first PVC layer 33 and the second PVC layer 34 may also be referred to as skin layers 33 and 34, respectively.

[0030] The film structure of a five-layer building panel article, such as panel 30 shown in FIG. 3, is sometimes referred to as an A / B / C / B' / A' multilayer film structure, where each A and A' is a first and second skin layer, respectively, of building panel article 30 of the present invention (e.g., PVC layers 33 and 34 shown in FIG. 3), each B and B' is a first and second adhesion-promoting tie layer, respectively, of building panel article 30 of the present invention (e.g., tie layers 31 and 32 shown in FIG. 3), and C is an inner core metal layer (e.g., metal core layer 35 shown in FIG. 3). Tie layer B is disposed in contact between outer layer A and core layer C, and another tie layer B' is disposed in contact between outer layer A' and core layer C. Outer layers A and A' can be the same material or different materials. Any combination of A, A', B, B', and C layers will be readily apparent to one skilled in the art of film manufacturing.

[0031] In other embodiments, the building panel article or product can be made from a combination of various film materials known in the art for use in manufacturing building panels. For example, referring again to FIG. 3 , skin layers 33 and 34 (A and / or A′ layers) can be formed from PVC resin, polyvinylidene fluoride (PVDF), polypropylene (PP), and mixtures thereof. At least one of layers 31 and / or 32 (B and / or B′ layers) can be formed from a tie layer composition described herein below as an adhesion-promoting tie layer. Additionally, the metal layer (C layer) can be made from a variety of substrates, including metals such as steel, aluminum, aluminum alloys, stainless steel, galvanized steel, and mixtures thereof, as the core metal layer of the building panel structure; other substrates such as aluminum composite panels, and mixtures thereof; and combinations of two or more of the above substrates.

[0032] The thickness of the bonding layers 31 and 32 used in manufacturing the multilayer building panel article 30 of the present invention is, for example, 10 μm to 120 μm in one embodiment, 10 μm to 100 μm in another embodiment, and 20 μm to 60 μm in yet another embodiment.

[0033] The thickness of the PVC layers 33 and 34 used in manufacturing the multilayer building panel article 30 of the present invention is, for example, 10 μm to 120 μm in one embodiment, 10 μm to 100 μm in another embodiment, and 20 μm to 60 μm in yet another embodiment.

[0034] The thickness of the metal core layer 35 used in manufacturing the multilayer building panel article 30 of the present invention is, for example, 10 μm to 120 μm in one embodiment, 10 μm to 100 μm in another embodiment, and 20 μm to 60 μm in yet another embodiment.

[0035] Generally, the overall thickness of the multilayer building panel article 30 of the present invention is, for example, from 30 μm to 360 μm in one embodiment, from 30 μm to 300 μm in another embodiment, and from 60 μm to 180 μm in yet another embodiment.

[0036] In one broad embodiment of the present invention, the process for making the panels of the present invention includes using any conventional lamination process and equipment known to those skilled in the art to form panels using typical lamination fabrication parameters that are readily determined by those skilled in the art of manufacturing architectural panel articles. For example, to construct the architectural panel member, the tie layer, PVC film layer, and steel substrate layer are laminated together at a temperature of ≥ 160°C in one typical embodiment, and 160°C to 200°C in another embodiment. Lamination may occur at the above temperature range for a time period of ≥ 2 seconds in one typical embodiment, ≥ 3 seconds in another embodiment, and 3 to 15 seconds in yet another embodiment. In other embodiments, other lamination process parameters / conditions may include, for example, preheating the metal layer and tie layer, followed by laminating the PVC layer with other layers on a lamination line at a lamination line speed of 1 m / min to 20 m / min in one typical embodiment, 4 m / min to 15 m / min in another embodiment, 6 m / min to 12 m / min in yet another embodiment, and 8 m / min to 10 m / min in yet another embodiment.

[0037] We now describe in detail an embodiment of a tie layer film member made from a tie layer composition, component (B) comprising (Bi) at least one ethylene-acrylate copolymer resin, (Bii) at least one tackifier, and (Biii) at least one inorganic filler material. The tie layer can be used in building panel member applications to bond a PVC film layer to a steel substrate layer. However, it should be noted that this is merely an exemplary, illustrative implementation of the embodiments disclosed herein. This embodiment can be applied to different types of building panel structures or articles and technologies that desire the incorporation of a tie layer that provides (1) good adhesion to PVC at high temperatures without detrimental delamination and without adversely affecting the mechanical and thermal properties of the panel, and (2) improved peel strength at temperatures above 50°C.

[0038] Tie layer formulations or compositions that can be used to manufacture tie layer film products or components that are incorporated as at least one layer in the building panel articles of the present invention include, for example, combinations, blends, or mixtures of (Bi) at least one ethylene-acrylate copolymer resin, (Bii) at least one tackifier, (Biii) at least one inorganic filler material, and (Biv) optionally one or more additives, agents, or components, if desired.

[0039] In a preferred embodiment of the present invention, the tie layer composition comprises a tie layer for bonding, for example, PVC or building panel structures (e.g., PVC layer-tie layer-steel layer). For example, the tie layer composition, component (B), comprises (Bi) 42% to 88% by weight of at least one ethylene-acrylate copolymer resin, (Bii) 10% to 50% by weight of at least one tackifier, (Biii) 2% to 8% by weight of at least one inorganic filler material, and (Biv) one or more effective concentrations of optional components, if desired. Optional component(s) (Biv) can be added to and mixed with any one or more of the above components (Bi) to (Biii), if desired.

[0040] In some embodiments, the compositions described above are advantageously used to make tie layer film products that are incorporated into the multilayer building panel articles of the present invention. In one embodiment, the tie layer film product is incorporated into a multilayer panel structure for building applications, and the tie layer film product is at least one layer of the multilayer building panel structure. In one embodiment, at least one layer of the multilayer building panel structure is a tie layer film that is in direct contact with the metal substrate of the panel structure.

[0041] Before a tie layer film product can be made from the tie layer composition, the tie layer composition is first processed into pellets. For example, the components (Bi) to (Biii) and optionally (Biv) that form the blend are melt blended (e.g., mixed by melting through an extruder) to form a melt blend. The melt blend is then conveyed from the extruder (e.g., a twin-screw extruder) through a strand die to a pelletizer to form pellets of the blend. Once produced, the pellets can be used immediately or stored for future use. To produce a tie layer film product with the desired corrosion protection properties, the pellets are first melted to form a melt feed blend, and the melt blend is then sent to a film manufacturing process well known to those skilled in the art of film manufacturing, such as a blown film process.

[0042] In one general embodiment of the present invention, a tie layer composition useful for preparing a tie layer, component (B), comprises, for example, (Bi) at least one ethylene-acrylate copolymer resin comprising ethylene copolymerized with one or more acrylate monomers. In some embodiments, ethylene-acrylate copolymer resins, ethylene-acrylate terpolymer resins, and mixtures thereof are prepared and used as component (Bi).

[0043] Examples of acrylate comonomers used in copolymerization with ethylene to form the ethylene-acrylate copolymer / terpolymer resin, component (Bi), include, for example, vinyl acetate (VA), methyl acrylate (MA), ethyl acrylate (EA), butyl acrylate (BA), and mixtures thereof. In a preferred embodiment, the resin comprises, for example, VA, MA, EA, and mixtures thereof.

[0044] In another embodiment, the at least one ethylene-acrylate copolymer / terpolymer resin, component (Bi), may optionally contain one or more functional groups selected from, but not limited to, the following: maleic anhydride, epoxy, hydroxy, carboxylic acid, carboxylate having the formula COOM (wherein M is Na, K, Li, Mg, Zn, Cs, Al, and mixtures thereof), and combinations of two or more of the foregoing functional groups.

[0045] Examples of some commercially available ethylene-acrylate copolymer / terpolymer resins useful in preparing tie layer compositions include, for example, the resin series available from The Dow Chemical Company under the trade names ELVALOY™ AC and FUSABOND™, and mixtures thereof.

[0046] The ethylene-acrylate copolymer / terpolymer resin, component (Bi), used in preparing the tie layer composition can be present in the composition in an amount, for example, generally from 42% to 88% by weight in one embodiment, from 55% to 85% by weight in another embodiment, and from 70% to 80% by weight in yet another embodiment, based on the total amount of components in the tie layer composition.

[0047] The at least one ethylene-acrylate copolymer / terpolymer, such as VA, MA, EA, BA, or mixtures thereof, which is component (Bi) of the tie layer composition, advantageously provides adhesive performance such as good bonding, high peel strength, etc.

[0048] In one general embodiment, a tie layer composition useful for preparing a tie layer includes, for example, at least one tackifier, component (Bii). The at least one tackifier, component (Bii) of the tie layer composition, such as hydrocarbon resins, C5, C9, or dicyclopentadiene, phenols, and mixtures thereof, is advantageously used to modify, for example, tack, adhesion, and cohesion.

[0049] Component (Bii), the tackifier, is available in pellet form, and multiple pellets are blended with component (Bi), the ethylene-acrylate copolymer / terpolymer resin.

[0050] Examples of tackifiers, component (Bii), useful in preparing the tie layer composition include, for example, at least one tackifier selected from the group consisting of aliphatic compounds having ≧C5 carbon atoms, hydrogenated compounds having ≧C5 carbon atoms, aromatic-modified aliphatic compounds having ≧C5 carbon atoms, aromatic compounds having ≧C9 carbon atoms, hydrogenated compounds having ≧C9 carbon atoms, rosin, terpene, and mixtures thereof. In a preferred embodiment, the tackifier comprises, for example, a ≧C5 aliphatic compound, a ≧C5 aromatic compound, and mixtures thereof.

[0051] Also, optionally, the resin contains functional groups selected from, but not limited to, at least one of maleic anhydride, epoxy, hydroxy, carboxylic acid, and carboxylate (COOM, where M may be selected from the group consisting of Na, K, Li, Mg, Zn, Cs, and Al). (Bii) 10% to 50% by weight of at least one tackifier, the tackifier being at least one hydrocarbon resin compound including aliphatic compounds (e.g., aliphatic compounds having ≧C5 carbon atoms), aromatic compounds (e.g., aromatic compounds having ≧C9 carbon atoms), alicyclic compounds (e.g., aromatic-modified aliphatic compounds having ≧C5 carbon atoms such as dicyclopentadiene (DCPD)), rosin, terpene, and mixtures thereof.

[0052] Examples of some commercially available tackifiers, component (Bii), useful in preparing the tie layer composition include Regalite™ resins (available from Eastman), such as Regalite™ 1125, and mixtures of the above resins with one or more other resins.

[0053] The tackifier, component (Bii), used in preparing the tie layer composition can be present in the composition in an amount generally from 10% to 50% by weight in one embodiment, from 12% to 30% by weight in another embodiment, and from 15% to 25% by weight in yet another embodiment, based on the total amount of components in the tie layer composition.

[0054] In some embodiments, the tackifier, component (Bii), can be selected from at least one of (a) aliphatic compounds having C5 to C9 carbon atoms, (b) hydrogenated compounds having C5 to C9 carbon atoms, (c) aromatic-modified aliphatic compounds having C5 to C9 carbon atoms, (d) aromatic compounds having C5 to C9 carbon atoms, (e) hydrogenated compounds having C5 to C9 carbon atoms, (f) rosin, (g) terpene, and (h) mixtures thereof.

[0055] In one typical embodiment, a tie layer composition useful for preparing a tie layer film product includes, for example, component (Biii), which is at least one inert inorganic filler material. Due to the unique properties of the inert inorganic filler material in the tie layer composition, the selection of the filler material is important in forming the tie layer composition. The type of filler material can improve the physical and mechanical properties of the composition, and thus the film member made from the tie layer composition, and ultimately the building panel article made using the film member. The various types and amounts of filler material, as well as the processing conditions for preparing the composition with the filler material, are important factors to consider in order to maximize the effect of the filler material on the polymer resin material. In some embodiments, the properties of the tie layer composition, particularly the corrosion protection properties, can depend, for example, on the type / composition, shape, size and size distribution, surface roughness, aspect ratio, and loading / concentration of the filler particles used in the tie layer composition.

[0056] The inert inorganic filler material, component (Biii) of the tie layer composition, can be selected from a wide range of material types. In general, inorganic filler materials can include, for example, inorganic fillers, metal oxides, ceramics, and mixtures thereof. Generally, filler materials are used in particulate form. In some embodiments, filler particles used in the tie layer composition can be made of, for example, fine glass, quartz, or silica. Glass fillers are typically made of crystalline silica, silicon dioxide, lithium / barium-aluminum glass, and zinc / strontium / lithium-containing borosilicate glass. Ceramic fillers are made of zirconia-silica or zirconium oxide. In preferred embodiments, inorganic filler materials can include, for example, quartz, fused silica, mica, clay, kaolin, wollastonite, feldspar, graphite, and mixtures thereof. Metal oxides can include, for example, silica (SiO), titanium dioxide (TiO), aluminum oxide (AlO), and mixtures thereof.

[0057] The filler particles used in the present invention can also be classified by shape. The shape of the filler material can include, for example, irregular, fibrous or acicular, spherical, and agglomerated. In a preferred embodiment, the inorganic filler material particles have a spherical or irregular shape depending on the manufacturing method of the filler. In another preferred embodiment, the filler material is spherical. Spherical particles are easier to incorporate into the resin composition. Examples of shape types of inorganic filler materials include spherical filler material shapes or layered clays, such as SiO2, Al2O3, and mixtures thereof. Spherical fillers advantageously increase the interfacial area, improving bonding strength and dissipating internal stress caused by bending.

[0058] Examples of inorganic filler materials, component (Biii), useful for preparing the tie layer composition include, for example, spherical SiO, AlO, bond angles AlO having various angle distributions for the O-Al-O bond units (e.g., T-shaped AlO units and trigonal AlO units), and mixtures thereof. Generally, the O-Al-O bond angles in the T-shaped AlO units include, for example, 168.81°, 93.05°, and 99.55°, and the O-Al-O bond angles in the trigonal AlO units include, for example, 121.66°, 121.46°, and 116.40°. In a preferred embodiment, the inorganic filler material includes, for example, SiO, AlO, and mixtures thereof.

[0059] In other embodiments, the inorganic filler material can also be made available in pellet form and blended with other components, such as component (Bi), an ethylene-acrylate copolymer / terpolymer resin in the form of multiple pellets.

[0060] Examples of some commercially available inorganic filler materials, component (Biii), useful for preparing the tie layer composition include silicon dioxide, such as SHA0030 (available from Lianyungang Ruichuang New Material Technology Co., LTD), and mixtures of the above fillers with one or more other fillers.

[0061] The filler particles used in the present invention can also be classified by size. The particle size of the filler material used in preparing the tie layer composition can be selected from a variety of sizes, including macrofils, which have filler sizes ranging from 1 μm to 100 μm, microfils, which have filler sizes ranging from 0.03 μm to 0.05 μm, hybrid fillers, which have a mixture of particles from 1 μm to 20 μm and sometimes smaller particles as small as 40 nm, and nanocomposites, which have filler sizes of 100 nm or less.

[0062] In some embodiments, the size of the filler material is, for example, 1 μm to 20 μm in one typical embodiment, 1 μm to 15 μm in another embodiment, and 2 μm to 10 μm in yet another embodiment.

[0063] The inorganic filler material, component (Biii), used in preparing the tie layer film composition can be present in the composition in an amount sufficient to provide corrosion protection to the tie layer composition, and thus to the film member made from the composition. The loading of the filler material in the tie layer film composition is generally from 2 to 8 weight percent in one embodiment, from 2.5 to 7 weight percent in another embodiment, and from 3 to 6 weight percent in yet another embodiment, based on the total amount of components in the tie layer composition.

[0064] In one embodiment, the inorganic filler material can be compounded into the base resin along with the tackifier. In another embodiment, the inorganic filler material can be compounded in the form of a masterbatch. For example, the inorganic filler material can be incorporated into the masterbatch at a high concentration, and the carrier resin for the masterbatch can be ethylene acrylate.

[0065] In another embodiment, the tie layer composition can include one or more optional components, component (Biv), selected from a wide variety of optional additives. The additives, in combination with the other components of the tie layer composition, can be formulated to enable performance of a specified function while maintaining the excellent benefits / properties of the composition. For example, the following additives, such as antioxidants, UV stabilizers (e.g., HALS, UV absorbers, etc.), flame retardants; PVC powder; plasticizers, calcium stearate, and mixtures thereof, pigments, colorants, UV absorbers, processing aids, other fillers, compatibilizers, other resins different from component (Bi), other tackifiers different from component (Bii), other inorganic fillers or metal oxides different from component (Biii), and the like, as well as mixtures thereof, can be blended into the formulated tie layer resin composition to form the tie layer composition.

[0066] When used in a tie layer composition, optional additives can be present in an amount generally ranging from 0% to 10% by weight in one embodiment, from 0.1% to 5% by weight in another embodiment, and from 1% to 3% by weight in yet another embodiment, based on the total amount of components in the tie layer composition. In other embodiments, optional additives can be added to the film composition in an amount generally less than 5% by weight in one embodiment, less than 3% by weight in another embodiment, and less than 1% by weight in yet another embodiment.

[0067] In one broad embodiment of the present invention, the process for making the tie layer composition includes, for example, mixing or blending components (Bi), (Bii), and (Biii) described above, and any desired optional component (Biv) described above. Both dry blending and compounding processes, well known to those skilled in the art for mixing polymer resins, can be used. In a preferred embodiment, a compounding process is used.

[0068] Generally, the dry blending process involves the following steps: Step (1): Weighing out the correct proportions of each of the above tie layer composition components (Bi), (Bii), and (Biii), and optionally (Biv), provided in pellet or powder form; Step (2): Using a mixer such as a tumble blender or ribbon blender or any equivalent dry blender, mix all of the tie layer composition ingredients together.

[0069] Generally, the compounding (or melt blending) process involves the following steps: Step (1): Supplying the tie layer composition components (Bi), (Bii), and (Biii), and optionally (Biv), at supply rates proportional to their respective ratios; Step (2): Melt-mixing the ingredients in a mixer, such as a twin-screw extruder or a single-screw extruder, or a continuous mixer or a batch mixer, to form a homogeneous melt; Step (3): Filtering the molten composition using a melt screen changer; Step (4): The filtered polymer melt is pelletized into final blend pellets using, for example, an underwater pelletizer, a strand pelletizer, or a hot melt cutter.

[0070] Generally, components (Bi), (Bii), and (Biii), and optionally (Biv), are processed in a mixing device known to those skilled in the art of mixing devices, such as an extruder, batch mixer, or continuous mixer, at a temperature of 120°C to 180°C and a torque of 10 N / m to 15 N / m, at 10 rpm to 100 rpm, with a hold time of 4 to 7 minutes.

[0071] Some of the advantageous / beneficial properties of the tie layer compositions produced according to the aforementioned mixing or blending processes may include, for example, the ease of producing the tie layer compositions, i.e., the ease and more even (uniform or homogeneous) dispersion of the different components (Bi), (Bii), and (Biii), and optionally (Biv) of the tie layer composition, and the improved processability of the compositions, i.e., the ease of processing the compositions, which allows for easier production of tie layer film products or components. When films are produced using the tie layer compositions, the tie layer films exhibit significantly improved properties such as homogeneity, improved adhesion, and improved delamination after flex and heat aging, while maintaining other mechanical and thermal properties that meet the requirements of the intended application.

[0072] In some embodiments, tie layer film articles are produced from the tie layer compositions described above. The tie layer films are useful for incorporation into multilayer building panel structures or articles for architectural applications. The tie layer films have a combination of excellent properties, including high levels of bond strength and good bonding that does not delaminate after deformation, even when exposed to sunlight, when applied to panel structures for architectural construction. In the manufacture of multilayer building panel structures or articles, the tie layer advantageously bonds very strongly to the metal substrate layer and the PVC layer of the panel, providing sufficient bonding to prevent or minimize delamination of any one or more layers that make up the multilayer building panel article.

[0073] In a preferred embodiment, a blown film process, well known to those skilled in the art of film manufacturing, is used to produce the tie layer film. The blown film process for making a blown film tie layer generally includes the steps of: (a) providing a tie layer composition, for example, in the form of pellets; (b) melting the pellets to form a molten mass, for example, in a heated extruder; (c) extruding the resulting molten mass using an extrusion process; and (d) processing the extruded material to form a film by a blown film process. For example, in the blown film process, heated bubbles are formed from the resulting molten mass, and the bubbles are then collapsed to form a blown film. Furthermore, the heated bubble formation step may include a stretching step to orient the film.

[0074] In another embodiment, the tie layer composition may optionally be first dried by heating in a dryer to remove surface moisture. The melting step (b) of the blown film process may be carried out at a temperature range of from 120° C. to 200° C. in one embodiment, from 130° C. to 180° C. in another embodiment, and from 150° C. to 180° C. in yet another embodiment. The extrusion of the tie layer composition may be carried out through an extruder die.

[0075] In one broad embodiment, the film composition described above is used to make a film member, such as a tie layer film. The tie layer film may be a single layer (i.e., the resulting film member is produced as a single layer without any other coextruded film layers), or the tie layer film may be a multilayer structure in which at least one layer is the tie layer film of the present invention (i.e., the resulting film member is produced using two or more of the same or different layers coextruded together). The film compositions used to make the tie layer film are described above.

[0076] In one embodiment, a single layer tie layer used to bond to a metal substrate layer, such as steel, is also bonded to PVC, For example, a multi-layer building panel article incorporating a single layer tie layer can have a structure such as PVC layer-tie layer-steel layer.

[0077] Generally, one-layer (i.e., monolayer) films used as tie layers in the multilayer building panel articles of the present invention can include, for example, tie layer films made from tie layer composition resins. Monolayer films advantageously provide good bonding to steel. For monolayer bonded structures that bond to both steel and PVC, in some embodiments, it is advantageous to use tie layer films made from tie layer composition resins that contain at least one component of a maleic anhydride-grafted material. For example, the maleic anhydride-grafted material can be selected from the group consisting of maleic anhydride (MAH)-grafted polyolefins, MAH-grafted polyolefin elastomers (POEs), maleic anhydride-grafted ethylene acrylate copolymers, and mixtures thereof.

[0078] Single-layer tie layer film structures and at least the first tie layer of multi-layer tie layer film structures may comprise, for example, a film sheet of any desired length and width, for example, having a thickness of 20 μm to 100 μm in one typical embodiment, 25 μm to 90 μm in another embodiment, and 30 μm to 80 μm in yet another embodiment.

[0079] In one broad embodiment, the process for making the monolayer film member includes using any conventional film-forming process, such as, for example, a blown film process, and any conventional film-forming equipment known to those skilled in the art of forming films.

[0080] Some of the advantages of the tie layer include, for example, (1) good adhesion to PVC without delamination after (a) oven aging (2 hours at 85° C.) and (b) water boiling (2 hours at 70° C.), and (2) improved peel strength at 50° C. More specifically, advantageous / beneficial properties exhibited by tie layers manufactured according to the above process and incorporated into multilayer building panel articles include, for example, (1) the ability of the multilayer building panel article of the present invention to withstand a 0.05° C. peel strength test specimen of the present invention. o / s~1.0 o / s at a speed of 90 o(1) the multilayer building panel article of the present invention exhibits no delamination after being flexed to a 90°C (20°F) angle and heat-aged for 2 hours at 85°C, and (2) the multilayer building panel article of the present invention exhibits no delamination after immersion of a multilayer building panel article specimen in hot water (e.g., 70°C) for 2 hours, and (3) the multilayer building panel article of the present invention includes a multilayer building panel article specimen that exhibits a peel strength greater than a comparative article specimen that does not include a tie layer useful in the present invention, as described above. For example, an article specimen made from a comparative tie layer resin may include a pure ELVALOY™ AC resin, such as pure ELVALOY™ AC1218, and the comparative article specimen has a peel strength of, for example, 1.5 N / mm, as measured by the test method set forth in ASTM D1876.

[0081] To provide delamination protection to the multilayer building panel articles of the present invention, the tie layers should exhibit suitable storage modulus characteristics, G', and suitable loss modulus characteristics, G"'. For example, in some embodiments, the multilayer building panel articles of the present invention comprise at least one tie layer having a storage modulus characteristic, G', of less than 4.70E+05 in one typical embodiment, from 2.00E+05 to less than 4.70E+05 in another embodiment, and from 2.30E+05 to less than 4.70E+05 in yet another embodiment. For example, in some embodiments, the multilayer building panel articles of the present invention comprise at least one tie layer having a loss modulus characteristic, G"', of greater than 1.22E+05 in one typical embodiment, from greater than 1.22E+05 to 2.0E+05 in another embodiment, and from 1.22E+05 to 1.60E+05 in yet another embodiment.

[0082] An oscillatory frequency sweep test is performed using a parallel plate rotational rheometer to measure the G' and G'' values ​​of the bonding layer. Characterization of the bonding layer to test the G' and G'' values ​​can be performed using a stress-controlled rheometer, such as the AR2000ex (available from TA Instruments). Stainless steel parallel plates (e.g., 8 mm diameter) are used against a thin disk of polymer (e.g., 8 mm diameter, 600 μm or less thick). In one embodiment of the test, the temperature is set to 85°C and the frequency is set to 0.1 rad / s to 100 rad / s at 2% strain. If G' measured using the test is <4.70E+05 and G'' is >1.22E+05, delamination of the layers of the panel can be prevented or significantly reduced.

[0083] In addition to the single-layer tie layer films described above, in some embodiments, tie layer films can include two or more film substrates combined to form a tie layer film member. For example, a tie layer film can be made from two, three, five, seven, nine, or more layers, provided that at least one of the layers is a tie layer film made from the tie layer composition described above. Multi-layer tie layer film substrates can also be used in the manufacture of the multilayer building panel articles of the present invention.

[0084] In some embodiments, a multilayer tie layer film used to bond to a metal substrate layer of a multilayer building panel article may be composed of two or more different tie layers. In a preferred embodiment, the multilayer tie layer film comprises a two-layer film structure including two film layers, i.e., a first tie layer film and a second tie layer film. For example, a first tie layer of the multilayer tie layer film is used in conjunction with a second tie layer, and the first and second tie layers contact each other to form a continuous boundary between the two tie layers. The first tie layer may be the same as the second tie layer, or the first tie layer may be different from the second tie layer. For example, in one embodiment, a first tie layer of a multilayer tie layer film may be made from a tie layer composition described above (e.g., an ethylene-acrylate copolymer or terpolymer resin), and a second tie layer may be made from the same composition as the first tie layer, or the second tie layer may be made from a different composition than the first tie layer film (e.g., a maleic anhydride grafted polyethylene-acrylate resin), provided that the second, different tie layer is compatible with the first tie layer. The layers of the multilayer tie layer film are made using known film manufacturing processes, such as blown film processes or cast film processes.

[0085] A two-layer tie layer film member can be disposed between a PVC layer and a metal substrate (e.g., steel) layer to form the multilayer building panel article structure of the present invention. In the above two-layer tie layer film member embodiment, the first tie layer can be adjacent to and in contact with the PVC layer, and the second tie layer can be adjacent to and in contact with the metal substrate layer. In another embodiment, the first tie layer can be adjacent to and in contact with the metal substrate layer, and the second tie layer can be adjacent to and in contact with the PVC layer.

[0086] The first tie layer film can be made from the tie layer composition described above.

[0087] In one typical embodiment, the second layer film useful in combination with the tie layer film can be made from a conventional polymer resin. For example, a two-layer tie layer film member includes a first film layer made from the tie layer composition described above and a second layer having a component selected from maleic anhydride grafted polyethylene (MAH-g-PE), maleic anhydride grafted POE (MAH-g-POE), maleic anhydride grafted ethylene acrylate copolymer, or a mixture thereof.

[0088] In other embodiments, the second layer film can be made from one or more of exemplary resin materials such as maleic anhydride grafted polyethylene (MAH-g-PE), maleic anhydride grafted POE (MAH-g-POE), maleic anhydride grafted ethylene acrylate copolymer, maleic anhydride grafted ethylene vinyl acetate copolymer, and mixtures thereof. In preferred embodiments, resin materials for the second layer film include, for example, MAH-g-PE / EMA and mixtures of any one or more of the above resins with one or more other resins.

[0089] Examples of some commercially available resins useful for preparing the second layer film include, for example, one or more resins in the resin series available from The Dow Chemical Company under the trade names FUSABOND™, BYNEL™, and ELVALOY™ AC, one or more resins in the resin series available from ARKEMA under the trade name EVASIN™, one or more resins in the resin series available from REPSOL under the trade names ALCUDIA and EBANTIX, and mixtures thereof.

[0090] The second layer film structure may comprise, for example, a film sheet of any desired length and width, e.g., having a thickness of 20 μm to 100 μm in one typical embodiment, 25 μm to 90 μm in another, and 30 μm to 80 μm in yet another embodiment. The ratio of the first layer to the second layer is generally 0:100 to 100:0 in one embodiment, 30:70 to 70:30 in another embodiment, 40:60 to 60:40 in yet another embodiment, and 50:50 to 50:50 in yet another embodiment.

[0091] Some of the advantageous properties of multilayer building panel articles or products manufactured using the above-described tie layer include, for example, (1) the panel advantageously exhibits a high level of peel strength, and (2) the panel advantageously does not exhibit delamination after bending at an angle and aging at high temperatures, such as in boiling hot water. In addition, the panel as a whole advantageously exhibits a high level of corrosion protection, which can be attributed to the corrosion protection properties of the PVC outer layer, which in turn provides corrosion protection to the metal substrate layer of the panel, which is strongly bonded to the PVC layer via the above-described tie layer. Because the tie layer provides a strong bond (e.g., high peel strength) between the PVC layer and the metal layer, delamination of the panel layers does not occur, thereby extending the useful life of the panel when exposed to the elements or potentially corrosive environments.

[0092] The multi-layer anticorrosion building panel article of the present invention prepared as described above can be used in various applications where it is advantageous for the panel to exhibit anticorrosion properties.For example, the anticorrosion panel can be applied as roofing and walls of various buildings in different types of plants where anticorrosion properties are highly required, such as steel plants, chemical plants, breeding plants, pesticide plants, electroplating plants, and waste power plants. [Example]

[0093] The following Inventive Example (Inv. Ex.) and Comparative Example (Comp. Ex.) (collectively "Examples") are presented herein to further illustrate the features of the present invention, but are not intended to be construed, either explicitly or implicitly, as limiting the scope of the claims. Inventive Examples are identified by Arabic numerals, and Comparative Examples are designated by alphabetic letters. The following experiments analyzed the performance of embodiments of the compositions described herein. Unless otherwise specified, all parts and percentages are by weight based on total weight.

[0094] Various terms, notations, and raw materials used in the examples (Inv. Ex.) and comparative examples (Comp. Ex.) of the present invention are explained as follows. "MI" stands for melt index. "RT" means room temperature (between 20°C and 25°C). "G'" represents the storage modulus. "G''" represents the loss modulus.

[0095] raw materials The ingredients / raw materials used to prepare the tie layer compositions of the building panel samples tested in the examples are listed in Table I.

[0096] [Table 1]

[0097] Sample preparation Mixing procedure Tie layer composition samples for forming test panels were prepared as follows.

[0098] The resins and tackifiers used in the examples were fed into a Brabender mixer at 150°C. The mixer rotor speed was set to 10 rpm, and the ingredients in the mixer were mixed until the resin melted. Next, the inorganic filler was added to the mixer chamber, and the resulting mixture was continued to mix at 80 rpm for 5 minutes. The resulting compound was then removed from the mixer, allowed to solidify, and then cut into small pieces for further use.

[0099] Film hot pressing procedure Some small pieces of the compound prepared in the mixer as described above were placed in a hot press and preheated at 150°C for 10 minutes. The hot press was vented intermittently (e.g., every 2 minutes) for eight separate periods. The compound pieces were then held at 150°C and 10 MPa (pressure between the upper and lower plates of the hot press) for an additional 5 minutes. The film obtained from the hot press was cooled to room temperature at 10 MPa within 5 minutes. After cooling, the resulting film had a thickness of ∼100 μm.

[0100] Preparation of multilayer sample panel structure The sample panel structure prepared for the examples can be a multi-layer structure including a steel layer, a tie layer, and a PVC layer as shown in the schematic diagram of Figure 2. The sample panel can be prepared using lamination at 180°C for 5 seconds. In the single tie layer embodiment shown in Figure 1, MAH-g-POE / PE / EMA is required to allow good bonding with the steel.

[0101] The sample panel structures prepared for the examples and tests were rectangular multilayer structures including a steel layer having a thickness of 40 μm to 70 μm, a first tie layer having a thickness of 15 μm to 60 μm and containing an MAH-g-POE / PE / EMA composition, a second tie layer having a thickness of 15 μm to 60 μm and containing an MAH-g-PE / EMA composition, and a PVC layer having a thickness of 90 μm to 110 μm. The sample panel structures prepared for the examples and tests are shown in the schematic diagram in Figure 2. The dimensions of the rectangular sample panel structures were 2 cm wide x 10 cm high. The overall thickness of the rectangular sample panel structures was generally 145 μm to 300 μm.

[0102] The data generated in the examples are based on two tie layers (i.e., first and second tie layers) described above and shown in Figure 2. The first tie layer of the present invention was prepared from the tie layer composition described above and in Tables III and IV, and the second tie layer used in the examples was a blown film made from BYNEL™ 30E868. In other embodiments, the second tie layer may include products such as resins from the resin series available from The Dow Chemical Company under the trade names FUSABOND™, ELVALOY™, and BYNEL™.

[0103] Test Method The general procedure for testing the multi-layer test panel specimens was as follows. Step (I): Multilayer test panel specimens are 0.05 o / s~1.0 o / s at a speed of 90 o and heat aged at 85°C for 2 hours. Step (II): The panel specimen was immersed in hot water (70°C) for 2 hours. Step (III): The panel specimen was subjected to the 180-degree peel strength test method. o T-peel tests were performed on an Instron machine equipped with an environmental cabinet according to the procedure described in ASTM D1876. The test speed used was 100 mm / min. Panel specimens were heated to 50°C and then pulled at 100 mm / min until fracture. Sample test methods and evaluation criteria

[0104] [Table 2]

[0105] Test results Discussion of results All multilayer sample panels tested were prepared as shown in Figure 2. The panel samples were o The specimen was bent to a 90°C peel strength test at room temperature and 50°C. oThe bent specimens were heated at 85°C to observe whether delamination of the specimens occurred. The test results of the panel specimens are listed in Tables III and IV. Table III shows that panel specimens having a tackifier content of ≥15 wt% and an SiO2 content of ≥2.0 wt% exhibited no delamination upon heating at 85°C and aging in boiling hot water. The peel strength of the panel specimens was also improved at both room temperature and 50°C. Table IV shows the results obtained based on the use of ELVALOY AC1224 matrix resin. Table IV shows that panel specimens having a tackifier content of ≥15 wt% and an SiO2 content of ≥2.0 wt% exhibited no delamination upon heating at 85°C and aging in boiling hot water. The peel strength of the panel specimens listed in Table IV was also improved at both room temperature and 50°C.

[0106] The G' values ​​listed in Tables III and IV represent the ability of the bonding layer to store energy in the building panel when the building panel is subjected to a 90° bending test. A higher G' value indicates a panel with greater internal energy storage. For example, if G' is greater than 4.70E+05, the internal energy storage obtained from the 90° bending test is too high, and the building panel tends to delaminate in the bending region of the panel during a heating test or a water boiling test. The G" values ​​listed in Tables III and IV represent the internal energy dissipation and adhesive capabilities of the building panel. If G" is high, i.e., greater than 1.22E+05, better internal energy relaxation and better adhesion of the panel layers can be achieved, and delamination of the panel can be avoided.

[0107] The multi-layer building panel member of the present invention employs at least one tie layer made from a composition comprising an ethylene-acrylate copolymer resin, a tackifier, and an inorganic filler material, whereby the synergistic effect of the copolymer resin and tackifier with the inorganic filler material is provided to the building panel member by the tie layer. o The adhesive exhibits improved bond performance at elevated temperatures when subjected to bending tests of 1000 psi and exhibits excellent peel strength performance.

[0108] [Table 3] * If delamination occurs, delamination is designated as "0" and if delamination does not occur, no delamination is designated as "1".

[0109] [Table 4] * If delamination occurs, delamination is designated as "0" and if delamination does not occur, no delamination is designated as "1".

Claims

1. 1. A multi-layer building panel article comprising: (A) at least one layer of polyvinyl chloride material; (B) at least one tie layer of the following composition: (Bi) at least one ethylene-acrylate copolymer resin; (Bii) at least one tackifier; and (Biii) at least one inorganic filler material, at least one bonding layer bonding to at least one metal substrate layer and to the at least one polyvinyl chloride material layer, the at least one bonding layer providing a bond sufficient to minimize delamination of any one or more layers comprising the multilayer building panel article; (C) at least one layer of a metal substrate.

2. 10. The multilayer building panel article of claim 1, wherein the at least one bonding layer is characterized by having a storage modulus property of less than 4.70E+05 and a loss modulus property of greater than 1.22E+05, and the at least one bonding layer provides sufficient bonding to minimize delamination at temperatures of 50°C or greater.

3. 10. The multilayer building panel article of claim 1, wherein the acrylate comonomer used to prepare the at least one ethylene-acrylate copolymer resin is selected from the group consisting of vinyl acrylate, methyl acrylate, ethyl acrylate, butyl acrylate, methyl 3-methoxyacrylate, and mixtures thereof.

4. 10. The multilayer building panel article of claim 1, wherein the at least one ethylene-acrylate copolymer resin comprises a functional group selected from the group consisting of maleic anhydride, epoxy, hydroxy, carboxylic acid, and carboxylate having a structure of COOM, where M is Na, K, Li, Mg, Zn, Cs, Al, and mixtures thereof, and mixtures of two or more of the foregoing functional groups.

5. 10. The multilayer building panel article of claim 1, wherein the at least one tackifier is selected from the group consisting of at least one of aliphatic C5, hydrogenated C5, aromatic modified aliphatic C5, aromatic C9, hydrogenated C9, rosin, terpene, and mixtures thereof.

6. 10. The multilayer building panel article of claim 1, wherein the at least one inorganic filler material is selected from the group consisting of silica, calcium carbonate, quartz, fused silica, talc, mica, clay, kaolin, wollastonite, feldspar, aluminum hydroxide, graphite, aluminum oxide, and mixtures thereof.

7. 10. The multilayer building panel article of claim 1, wherein the at least one ethylene-acrylate copolymer resin, component (Bi), is an ethylene-acrylate bipolymer resin, an ethylene methyl acrylate terpolymer resin, or a mixture thereof; the at least one tackifier, component (Bii), is a hydrogenated C9 compound; and the at least one inorganic filler material, component (Biii), is spherical silica powder or spherical aluminum oxide.

8. 8. The multi-layer building panel article of claim 7, wherein said spherical silica powder or spherical aluminum oxide particles are between 2 micrometers and 5 micrometers in diameter.

9. 10. The multilayer building panel article of claim 1, wherein the at least one ethylene-acrylate copolymer resin, component (Bi), has a concentration of 42 to 88 weight percent, the at least one tackifier, component (Bii), has a concentration of 10 to 50 weight percent, and the at least one inorganic filler material, component (Biii), has a concentration of 2 to 8 weight percent.

10. 10. The multilayer building panel article of claim 1, wherein the at least one layer of polyvinyl chloride material, component (A), has a thickness of from 90 micrometers to 110 micrometers, the at least one tie layer, component (B), has a thickness of from 15 micrometers to 120 micrometers, and the at least one layer of metal substrate, component (C), has a thickness of from 40 micrometers to 70 micrometers.

11. 10. The multilayer building panel article of claim 1, wherein the at least one bonding layer bonds to the metal and the polyvinyl chloride, the at least one bonding layer providing (a) bond strength properties to the panel at room temperature, and (b) delamination resistance properties to the panel at room temperature according to a 90 degree bend test, the at least one bonding layer being characterized by having a storage modulus property of less than 4.70E+05 and a loss modulus property of greater than 1.22E+05.

12. 10. The multi-layer building panel article of claim 1, wherein said article is a corrosion-resistant steel panel member.

13. 1. A process for manufacturing a multi-layer structure for a building panel article, comprising: (A) at least one layer of PVC material; (B) at least one tie layer of the following composition: (Bi) at least one ethylene-acrylate copolymer resin; (Bii) at least one tackifier; and (Biii) at least one inorganic filler material, at least one bonding layer bonding to at least one metal substrate layer and to the at least one polyvinyl chloride material layer, the at least one bonding layer providing a bond sufficient to minimize delamination of any one or more layers comprising the multilayer building panel article; (C) at least one layer of a metal substrate.

14. 14. The process of claim 13, wherein the at least one tie layer is characterized by having a storage modulus characteristic of less than 4.70E+05 and a loss modulus characteristic of greater than 1.22E+05, and wherein the at least one tie layer provides sufficient bonding to minimize delamination at temperatures of 50°C or greater.

15. The process of claim 13, wherein the lamination is carried out at a temperature of from 160°C to 200°C.

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