Coextruded multilayer sheets and a process for preparing the same

Abstract: Coextruded multilayer sheets comprising a first outer layer consisting of a blend containing polyvinylidene fluoride having an average molecular weight (Mw) not greater than 250,000 and an acrylic resin and at least one layer of a homo or copolymer of an alkylmethacrylate, preferably having a Vicat degree (49N, 50°C/h) of at least 90°C, in mixture with 5-40% by weight of an elastomer in grafted form.

Description: The present invention relates to coextruded multilayer sheets and to a process for preparing the same. More particularly the present invention relates to coextruded multilayer sheets based on methacrylic polymers, to a process for preparing the same and to the use of said coextruded multilayer sheets for the preparation of hydrosanitary articles and coachwork parts. Coextruded sheets based on methacrylic resins are known in the prior art. For instance, sheets consisting of a layer of polymethylmethacrylate coupled with at least one layer of a shock-resistant polymethylmethacrylate are described in British patent no. GB-A-2,080,199. These sheets, although they have excellent mechanical properties, have insufficient resistance against aggressive action of chemical agents contained both in products for personal hygiene, such as after-shaving products and perfumes, and in products for domestic cleaning. It is also known that protective layers based on fluorinated polymers have been used to improve the chemical resistance of some plastic materials. For instance, in European patent application no. EP-A-151,812 layers are disclosed consisting of a thermoplastic substrate coated with a protective thin plate based on a blend of polyvinylidene fluoride and polymethyl-methacrylate. The substrate must consist either of a polymer having an acrylic character or of a polymer compatible with acrylic resins, in order to achieve a good adhesion between the parts. ABS, polycarbonate, ABS/polycarbonates, polyvinylchloride and copolymer methyl-methacrylate-acrylonitrile-butadiene-styrene (MABS) have been cited in particular as suitable polymers for the substrate. The protective thin plate in the sheets of the prior art carries out exclusively a protection against aggressive agents, and in no exemplified case is there described the maintenance of the thermo-mechanical characteristics of the substrate. The present applicant has now found that, if use is made of a polyalkylmethacrylate (for instance polymethylmethacrylate) as thermoplastic material for the substrate and of a combination of a particular polyvinylidene fluoride and of the same polyalkylmethacrylate as material for the protective thin plate, even multilayer sheets could be obtained by coextrusion, in which sheets the protective layer, besides having an excellent resistance against aggressive agents, also has good thermo-mechanical characteristics, which could be compared with those of the substrate. Therefore the present invention in a first aspect provides coextruded multilayer sheets, comprising: a) a first outer layer consisting of a blend containing 40-70% by weight of polyvinylidene fluoride having an average molecular weight (Mw) not greater than 250,000 and a viscosity in the melted state, measured by a capillary rheometer at 230°C and at a shear rate of 100 sec⁻¹, not greater than 1500 Pas (15,000 poise), 30-60% by weight of a homo or copolymer of an alkylmethacrylate and 10-30% by weight, with respect to the sum of the preceding components, of an elastomer in grafted form; b) at least one layer of the same homo or copolymer of alkylmethacrylate as used in layer (a) in mixture with 5-40% by weight of an elastomer in grafted form; and c) optionally at least one intermediate layer between layers (a) and (b) of a homo or copolymer of an alkylmethacrylate. The present invention in a second aspect provides coextruded multilayer sheets, comprising: a') a first outer layer consisting of a blend containing 50-70% by weight of polyvinylidene fluoride having an average molecular weight (Mw) not greater than 250,000 and a viscosity in the melted state, measured by a capillary rheometer at 230°C and at a shear rate of 100 sec⁻¹, not greater than 1500 Pas (15,000 poise), and 30-50% by weight of a homo or copolymer of an alkylmethacrylate; b') at least one layer of the same homo or copolymer of an alkylmethacrylate as used in layer (a') in mixture with 5-40% by weight of an elastomer in grafted form; and c') optionally at least one intermediate layer between layers (a') and (b') of a homo or copolymer of an alkylmethacrylate. The polyvinylidene fluoride used in the sheets of the present invention is preferably a homopolymer having an average molecular weight (Mw) not greater than 250,000, preferably from 200,000 to 250,000 and a viscosity in the melted state, measured by means of a capillary rheometer at 230°C and at a shear rate of 100 sec⁻¹, not greater than 1500 Pas (15,000 poise), preferably from 800-1500 Pas (8,000 to 15,000 poise). Copolymers of polyvinylidene fluoride containing up to 30% by weight of other ethylenically unsaturated monomers such as tetrafluoroethylene, chlorotrifluoroethylene, hexafluoropropylene or ethylene, and having the above mentioned physical-chemical and rheological characteristics, can also be used. Homopolymers and copolymers of polyvinylidene fluoride are described in U.S. patent nos. US-A-2,435,537; 3,031,437 and 3,193,539. A product having the above-mentioned characteristics, particularly suitable for the sheets according to the present invention, is Kynar 720 (TM) produced by Pennwalt Company. The methacrylic polymers, and in particular those used in mixture with polyvinylidene fluoride, comprise both homo and copolymers of the alkyl esters of methacrylic acid, in which the alkyl group has from 1 to 8 carbon atoms and are characterized by a Vicat degree (49N, 50°C/h) of at least 90°C. Examples of such esters are methylmethacrylate, ethylmethacrylate, propylmethacrylate, isopropylmethacrylate and butylmethacrylate. These monomers can be used alone or in mixture with other products, for instance acrylates such as methylacrylate, ethylacrylate, propylacrylate, isopropylacrylate or butylacrylate, or ethylenically unsaturated monomers such as styrene, alpha-methylstyrene or acrylonitrile. The preferred methacrylic polymer is polymethylmethacrylate containing 0-20% by weight of methylacrylate and having a molecular weight not greater than 150,000, preferably from 100,000 to 150,000, and a viscosity in the melted state not greater than 3000 Pas (30,000 poise), preferably from 2000-3000 Pas (20,000 to 30,000 poise). The grafted elastomer is preferably an acrylic elastomer cross-linked and grafted with an alkylmethacrylate, preferably methylmethacrylate. Examples of acrylic elastomers are the polymers of the alkyl esters of acrylic acid, in which the alkyl group has from 1 to 8 carbon atoms. Examples of such esters are methylacrylate, ethylacrylate, propylacrylate, isopropylacrylate and butylacrylate, which are used alone or in mixture with amounts up to 20% by weight of other acrylic monomers such as methylmethacrylate or other ethylenically unsaturated monomers such as styrene or alpha-methylstyrene. Grafted, acrylic elastomers are described in Italian patent no. 1,199,836 of the applicant. The grafted elastomer can be available, for the attaining of coextruded sheets of the present invention, already premixed with the methacrylic polymer. Mixtures of grafted elastomers can be used as well. The thickness of the coextruded sheets of the present invention can range within wide limits; it is preferred, however, to operate with thicknesses ranging from 2 to 12 mm, generally from 4 to 8 mm. The thickness of every single layer preferably ranges from 0.1 to 10 mm, more preferably from 0.3 to 6 mm. The present invention in a further aspect provides a process for the preparation of coextruded multilayer sheets according to the first aspect of the present invention, which comprises coextruding a plurality of layers by means of independent extruders, connected at the outlet with a single extrusion head, said process being characterized in that: i) a blend containing 40-70% by weight of polyvinylidene fluoride having an average molecular weight not greater than 250,000, and a viscosity in the melted state, measured by a capillary rheometer at 230°C and at a shear rate of 100 sec⁻¹, not greater than 1500 Pas (15,000 poise), 30-60% by weight of a homo or copolymer of an alkylmethacrylate and 10-30% by weight, with respect to the sum of the preceding components, of an elastomer in grafted form, is fed to a first extruder; ii) optionally a homo or copolymer of analkylmethacrylate is fed to at least one second extruder; and iii) a blend containing the same homo or copolymer of alkylmethacrylate as used in blend (i) and 5-40% of an elastomer in grafted form is fed to at least one third extruder; and wherein the layer coming from step (ii) is, if present, intermediate to the layers coming from steps (i) and (iii). The invention in a yet further aspect provides a process for the preparation of a coextruded multilayer sheet according to the second aspect of the present invention, which comprises coextruding a plurality of layers by means of independent extruders, connected at the outlet with a single extrusion head, said process being characterized in that: i') a blend containing 50-70% by weight of polyvinylidene fluoride having an average molecular weight not greater than 250,000 and a viscosity in the melted state, measured by a capillary rheometer at 230°C and at a shear rate of 100 sec⁻¹, not greater than 1500 Pas (15,000 poise), and 30-50% by weight of a homo or copolymer of an alkylmethacrylate is fed to a first extruder; ii') optionally a homo or copolymer of an alkylmethacrylat is fed to at least one second extruder; and iii') a blend containing the same homo or copolymer of alkylmethacrylate as used in layer (i') and 5-40% by weight of an elastomer in grafted form is fed to at least one third extruder; and wherein the layer coming from step (ii') is, if present, intermediate to the layers coming from steps (i') and (iii'). Besides the above-mentioned components, the extruders can be loaded with further additives, which are generally used in combination with plastic materials, such as dyes, pigments, anti-UV agents, antioxidizers, plasticizers and inert reinforcement fillers. The coextruded sheets of the present invention can be processed by thermomolding, by keeping the layer containing PVdF as surface at sight and can be used advantageously in the field of production of hydrosanitary articles such as bath-tubs, shower plates, wash-basins, bidets, walls equipped for saunas or baths, or coachwork parts such as roofs, headlight-covers, luggage car covers, doors and wheel-covers. The sheets obtained by the present invention, if compared with the conventional coextruded materials, present, on the layer containing PVdF, the advantages of a higher resistance against chemical agents, a higher impact strength and a lower water absorption. This characteristic proves to be particular advantageous when the sheets are used for the production of hydrosanitary articles. In fact, the main cause of yielding of these manufactured articles is connected with the inner tension produced by discontinuous contact with hot and cold water, which in time gives rise to the formation of crazes, which afterwards spread until they cause breaking of the article. From this point of view the sheets of the present invention are less subject to water absorption, if compared not only with extruded acrylic materials but even with cast ones. Therefore they combine in themselves the characteristics of excellent moldability, peculiar to extruded materials, with chemical resistance (moreover even improved) of pouring materials. The invention will be further described with reference to the following illustrative Examples. EXAMPLES 1 (unpigmented sheet) There was added into a two truncated cone mixer granules of polyvinylidene fluoride (PVdF) having a low molecular weight (Mw 220,000, viscosity 1000 Pas (10,000 Poise)), supplied by Pennwalt Company and designated KYNAR 720 (TM), and granules of polymethylmethacrylate for extrusion (PMMA) (copolymer of methylmethacrylate and methylacrylate, Mw 145,000, viscosity 3000 Pas (30,000 poise)) designated VEDRIL 9K (TM), in a ratio by weight of 60% and 40%. After having obtained a homogeneous mix, a BANDERA TR 30 (TM) (L/D = 25) one-screw extruder was fed with said mix, by operating under the following conditions: ZONE TEMPERATURES: FEEDING 190°C PLASTICIZATION 200°C DOSAGE 220°C HEAD 230°C SCREW RATE: 50 rmp DEGASSING PRESSURE: 740 mm HG Granules having high transparency were obtained, which after having been injection molded as DIN specimens, were found to have rather poor thermic and mechanical characteristics, as set forth in the following table: Vicat temperature (49N, 50°C/h) DIN 53460 50°C Rockwell hardness (Scale R) ASTM D 785 60 Modulus of elasticity to bending DIN 53457 1900 MPa The chemical resistance of the blend was also measured by stress-cracking tests, by subjecting the material to the simultaneous action of constant deformations exerted from the outside and to contact with aggressive chemical substances. The chemical resistance of the blend, expressed as Ec, deformation below which the crazes do not form, proved to be little higher than that of PMMA (in the presence of ethyl alcohol: Ec=0.3% as against 0.2%). The per cent water absorption, measured according to ASTM D570 on specimens, which had been extruded and afterwards conditioned over 24 hours in a stove at 50°C, proved to be equal to 0.05%, as against the value of 0.3% of the PMMA for extrusion. The granules, prepared as described hereinbefore, were fed to a BANDERA 80 (TM) (L/D ratio=30) extruder, connected with a BANDERA 160 (TM) (L/D ratio=32) extruder. The latter was fed with impact resistant PMMA (HIPMMA) consisting of a blend of PMMA for extrusion and of 33% by weight of a grafted acrylic elastomer, prepared according to example 1 of Italian patent no. 1,199,836. A coextruded sheet was obtained consisting of two overlapped layers A and C. Layer A consisted of the blend described hereinbefore and was 1 mm thick, whereas lower layer C was 4 mm thick. The operating conditions stated on the extruders were as follows: BANDERA 160 (TM) BANDERA 80 (TM) FEEDING ZONE TEMPERATURE 195°C 260°C PLASTICIZATION ZONE TEMPERATURE 250°C 265°C DOSAGE ZONE TEMPERATURE 235°C 245°C HEAD TEMPERATURE 240°C TEMPERATURE OF THE MELTED MATERIAL 230°C SCREW REVOLUTIONS 25 rpm CYLINDER TEMPERATURE 90°C -80°C - 120°C By testing the characteristics of the sheet, and in particular those of upper layer A, it was noted that they were different from the characteristics of the fed blend, and in particular it was observed that the thermic and mechanical properties were improved as follows: Vicat temperature (49N, 50°C/h) DIN 53460 85°C Rockwell hardness (Scale M) ASTM D 785 75 Modulus of elasticity to bending DIN 53457 2900 MPa The value of the modulus of elasticity had been obtained by measuring the modulus of elasticity to tensile stress, of the coextruded sheet, by means of the following formula: E coex = H blend *E blend +H substr. *E substr. H coex wherein E coex and H coex were the modulus of elasticity and the thickness of the coextruded sheet respectively, E blend and H blend the modulus of elasticity and the thickness of the layer of the PVdF-PMMA blend, whereas E substr. and H substr. represented the modulus of elasticity and the thickness of the support layer in impact resistant PMMA. The resistance to stress-cracking also exhibited a considerable increase (Ec=0.5% in the presence of ethyl alcohol). Moreover the coextruded sheet had a good resilience, equal to 4.2 kJ/m² for impact test to bending with sharp notch. An analysis by differential scanning calorimetry (DSC) carried out on a fragment of layer A, drawn from the coextruded sheet, showed the existence of a crystalline phase, attributable to PVdF, absent on the contrary in the blend obtained by injection molding. EXAMPLE 2 (pigmented sheet) There was followed the procedure as described in example 1; in this case, however, layers A and C were pigmented white. To this purpose, the same ingredients were mixed in the apparatuses already described in the example 1 with the difference that pigments based on titanium oxide were also added to mixes A and C. In order to obtain a homogeneous dispersion of the pigment in layer A, the addition of said pigment was carried out before the granulation process. The pigment of layer C was added to the granules, directly in the hopper, before extruding the sheet. The measured values of the thermic and mechanical properties did not significantly differ from those set forth in Example 1. EXAMPLE 3 (pigmented sheet) There was followed the procedure as described in example 2, by utilizing, however, impact-resistant polymethylmethacrylate (HIPMMA) in layer A, instead of PMMA, and moreover by modifying the blend composition. Layer A, being 1 mm thick, was a polymeric blend, which consisted of 40% by weight of PVdF (KYNAR 720) (TM) and of 60% of impact-resistant PMMA, which in its turn consisted of 70% PMMA for extrusion and 30% of a grafted acrylic elastomer, the latter having been prepared as described in example 2 of Italian patent no. 1,199,836. Layer C consisted of impact-resistant PMMA as in example 1 and was 4 mm thick. The preparation of the blend and its subsequent granulation was carried out in the same manner as described in example 1. The blend obtained by granulation, subsequently injection molded, had the following thermic and mechanical properties: Vicat temperature (49N, 50°C/h) DIN 53460 55°C Rockwell hardness (Scale M) ASTM D 785 50 Modulus of elasticity to bending DIN 53457 1500 MPa The per cent water absorption, measured according to ASTM D570, which had been extruded and afterwards conditioned for 24 hours in an oven at 50°C, was found to be equal to 0.15%, as compared with the value of 0.36% of the impact-resistant PMMA for extrusion. The subsequent coextrusion of the sheet was carried out by using the same apparatuses and under the same conditions as described in example 1. In this case also, there was observed an increase of the thermic and mechanical properties of layer A with respect to the starting situation. Vicat temperature (49N, 50°C/h) DIN 53460 82°C Rockwell hardness (Scale M) ASTM D 785 70 Modulus of elasticity to bending DIN 53457 2200 MPa The resistance of the sheet to stress-cracking showed a good improvement as well (in the presence of ethyl alcohol from Ec = 0.4% to Ec = 0.6%). EXAMPLE 4 There was followed the procedure as described in example 1, by preparing a polymeric blend PVdF-PMMA (KYNAR 720 (TM))-VEDRIL 9K (TM)), having a ratio by weight of 60% and 40%, by utilizing the same apparatuses under the same conditions already described. The difference with respect to example 1 consisted in that a trilayer sheet A, B and C was produced instead of coextruded sheet A and C. Layer A consisted of blend PVdF-PMMA and was 1 mm thick. Intermediate layer B consisted of PMMA for extrusion VEDRIL 9K (TM) and was 3 mm thick. Support layer C consisted of shock-resistant PMMA as in example 1 and was 1 mm thick. The extrusion of the trilayer sheet was carried out by using three extruders BANDERA 80 (TM), BANDERA 160 (TM) and BANDERA 80 (TM) (L/D:30, 32 and 30 respectively). The following operating conditions were used in the three machines: BANDERA 80 (TM) BANDERA 160 (TM) BANDERA 80 (TM) TEMPERATURE OF THE FEEDING ZONE 260°C 195°C 255°C TEMPERATURE OF THE PLASTICIZATION ZONE 265°C 250°C 260°C TEMPERATURE OF THE DOSAGE ZONE 245°C 235°C 240°C HEAD TEMPERATURE 240°C TEMPERATURE OF THE MELTED MATERIAL 230°C SCREW REVOLUTIONS 25 rpm CYLINDER TEMPERATURE 90°C -80°C - 120°C The obtained sheet had a value of resilience equal to 1.5 kJ/m², measured by means of impact tests to bending with sharp notch. The advantages obtainable by the trilayer sheet were essentially economic, as the cost of conventional PMMA was lower, if compared with that of impact-resistant PMMA. EXAMPLE 5 (comparative example) Sheet coextruded according to example 2, but using PVdF, produced by Pennwalt Company and denominated KYNAR 740 (TM), had a higher molecular weight (Mw 282,000, viscosity 2000 Pas (20,000 Poise)). The PVdF-PMMA blend in a ratio by weight 60%-40%, obtained by granulation, had poor thermic and mechanical characteristics and a low resistence to stress-cracking. The subsequent phase of coextrusion of the sheet did not improve the thermic and mechanical properties, which remained therefore at a level that was clearly lower than that of the conventional PMMA, as the obtained data showed: Vicat temperature (49N, 50°C/h) DIN 53460 66°C Rockwell hardness (Scale M) ASTM D 785 57 Modulus of elasticity to bending DIN 53457 1900 MPa The degree of resistance to stress cracking remained at a level equal to that of the conventional PMMA. The example showed that too high molecular weights of PVdF did not allow the transformation of the blend properties during the coextrusion phase. EXAMPLE 6 (comparative example) Sheet was coextruded in the same manner as described in example 2, but the composition of the blend comprised by layer A was changed in that the ratio by weight between PVdF (KYNAR 720 (TM)) and PMMA (VEDRIL 9K (TM)) was 40%-60%. The thermic and mechanical properties of the blend, obtained by granulation, proved to be rather low: Vicat temperature (49N, 50°C/h) DIN 53460 65°C Rockwell hardness (Scale M) ASTM D 785 60 Modulus of elasticity to bending DIN 53457 2100 MPa The degree of resistance of stress-cracking proved to be low as well (Ec 0.2% in ethyl alcohol with formation of macroscopic crazes). The subsequent coextrusion of the sheet, carried out in the same manner as described in example 1, did not bring about any change in the thermic and mechanical properties and in the resistance to stress-cracking of layer A, consisting of the above described blend. The example showed that the percentage of used PMMA was higher than the highest value that was necessary to obtain the crystallization of PVdF inside the blend, as, on the other hand, it was verified by DSC analysis, which did not show any melting peak attributable to the crystalline phase of PVdF. EXAMPLE 7 (comparative example) Sheet was coextruded according to Example 3, but the used PVdF, produced by Pennwalt Company and designated KYNAR 740 (TM), had a higher molecular weight (Mw 282,000, viscosity 2000 Pas (20,000 Poise)). The shock-resistant PVdF blend, in a ratio by weight of 40%-60%, obtained by granulation, showed poor thermic and mechanical characteristics and a low resistance to stress-cracking. The subsequent phase of coextrusion of the sheet did not improve the thermic and mechanical properties, which remained thus at a lower level with respect to shock-resistant PMMA, as shown by the obtained data: Vicat temperature (49N, 50°C/h) DIN 53460 64°C Rockwell hardness (Scale M) ASTM D 785 41 Modulus of elasticity to bending DIN 53457 1800 MPa This example showed that, in the blends containing shock-resistant PMMA, too high molecular weights in PVdF did not allow the transformation of the blend properties during the coextrusion phase. EXAMPLE 8 (comparative example) Sheet was coextruded in the same manner as described in example 3, but the composition of the blend comprised by layer A was changed in that the ratio by weight between PVdF (KYNAR 720 [TM]) and shock-resistant PMMA (VEDRIL 22E [TM]) was 20%-80%. The thermic and mechanical properties of the blend obtained by granulation were lower, if compared with those of the shock-resistant PMMA the blend consisted of, as shown by the following data: Vicat temperature (49N, 50°C/h) DIN 53460 75°C Rockwell hardness (Scale M) ASTM D 785 60 Modulus of elasticity to bending DIN 53457 1800 MPa The resistance to stress-cracking of the blend was lower, if compared with that of the shock-resistant PMMA (in ethyl alcohol Ec=0.2% as against Ec=0.4%). After the process of coextrusion, in layer A no change was noted in the thermic and mechanical properties or in the resistance to stress-cracking. In this case as well, as in example 6, the percentage of used PVdF was lower than the lowest value that was necessary to obtain a crystallization inside the blend, as, on the other hand, was shown by the absence of the melting peak of the crystalline phase by DSC analysis. EXAMPLE 9 A coextruded sheet, being 5.0 mm thick, produced as described in Example 2, was thermomolded in the form of a bath tub, by using the operating conditions typical of this technology. The sheet was thermomolded in such a way that layer A, consisting of blend PVdF-PMMA, formed the surface at sight of the manufacture, i.e. the surface in contact with the water. The process technology provided for: preheating of the sheet in a hot air furnace at a temperature of 170°C or by exposure for about 150 seconds at infrared radiant panels kept at a temperature of 600°C. the use of a thermomolder having a die equipped with a vacuum system; the subsequent application of a layer in polyester resin stiffened with fiber glass, on the lower side of the thus obtained tub (layer C). Afterwards the tub was subjeoted to the aging test as provided by European norm EN 198, which provided for the inlet, on alternate cycles, of amounts of cold water and hot water (75°C) and subsequent check of the possible damage. After 1000 cycles the tub was cut in two halves and no delamination was observed. EXAMPLE 10 A sheet, being 5.0 mm thick, produced as described in Example 3, was hot thermomolded in order to obtain a coachwork part (hood) for motor use. As in Example 9 the transformation technology comprised the use of a heating furnace in order to bring the sheet to a temperature higher than the softening temperature, a thermomolder equipped with a pumping system for vacuum and the application of a layer of polyester resin stiffened with fiber glass. The thermomolding process was carried out in such a way that layer A formed the surface at sight of the manufacture; the polyester resin stiffened with fiber glass was applied successively on layer C. The surface of the thus obtained thermomolded manufacture was put into oontact with pure isopropylic alcohol, in order to verify the properties of chemical resistance of shock-resistant blend PVdF-PMMA; the subsequent check did not show phenomena of stress-cracking. EXAMPLE 11 By using two coextruded sheets prepared according to examples 2 and 3, two bath tubs were produced as described in Example 9. There was carried out on both tubs the tests according to norm EN 198 and in particular the following tests: resistance to thermic cycles, according to the method of test A.3 of said norm; resistance to chemical products for domestic use, according to method of test A.4 of said norm; test of impact resistance of the tub, according to the method of test A.5 of said norm. Result of the tests: resistance to thermic cycles: the norm provides that the tub has to resist 100 cycles; both test tubs resisted 1000 thermic cycles without damage; resistance to chemical products for domestic use: both tubs did not exhibit any damage or stains after having been subjected to the reactants listed in the norm; resistance to impact tests: after having carried out the tests, the tubs did not exhibit any damage. EXAMPLE 12 By using a coextruded sheet produced according to example 2 and subsequently processed as in example 9, there was obtained a bath tub, which was subjected to the following test: 1000 thermic cycles according to European norm EN 198 A.3; at the end of the test no defect or damage was observed. After the cycles there was carried out a test of resistance to the following chemical products, according to method A.4 of norm EN 198: denatured ethyl alcohol spirit of turpentine eau-de-Cologne red nail-varnish after-shaving lotion. At the end of the test the tub did not exhibit any damage or stain; it must be noted that the test of chemical resistance was carried out on the tub, after it had already undergone the test of resistance to the thermic cycles, whereas the norm provided that the tests had to be carried out on tubs as such (of course a less critical condition).

Claims: A multilayer coextruded sheet, comprising: a) a first outer layer comprising a blend containing 40-70% by weight of polyvinylidene fluoride having an average molecular weight (Mw) not greater than 250,000 and a viscosity in the melted state, measured by a capillary rheometer at 230°C and at a shear rate of 100 sec⁻¹, not greater than 1500 Pas (15,000 poise), 30-60% by weight of a homo or copolymer of an alkylmethacrylate and 10-30% by weight, with respect to the sum of the preceding components, of an elastomer in grafted form; b) at least one layer of the same homo or copolymer of alkylmethacrylate as used in layer (a) in mixture with 5-40% by weight of an elastomer in grafted form; and c) optionally at least one intermediate layer between layers (a) and (b) of a homo or copolymer of an alkylmethacrylate. A multilayer coextruded sheet, comprising: a') a first outer layer comprising a blend containing 50-70% by weight of polyvinylidene fluoride having an average molecular weight (Mw) not greater than 250,000 and a viscosity in the melted state, measured by a capillary rheometer at 230°C and at a shear rate of 100 sec⁻¹, not greater than 1500 Pas (15,000 poise), and 30-50% by weight of a homo or copolymer of an alkylmethacrylate; b') at least one layer of the same homo or copolymer of alkylmethacrylate as used in layer (a') in mixture with 5-40% by weight of an elastomer in grafted form; and c') optionally at least one intermediate layer between layers (a') and (b') of a homo or copolymer of an alkylmethacrylate. A sheet as claimed in claim 1 or 2, characterized in that the polyvinylidene fluoride has an average molecular weight ranging from 200,000 to 250,000. A sheet as claimed in Claim 3, wherein the polyvinylidene fluoride has a viscosity in the melted state, measured by means of a capillary rheometer at 230°C and at a shear rate of 100 sec⁻¹ from 800-1500 Pas (8,000 to 15,000 poise). A sheet as claimed in any of claims 1 to 4, characterized in that the methacrylic polymers comprise both homo and copolymers of the alkyl esters of methacrylic acid, wherein the alkyl group has from 1 to 8 carbon atoms, and have a Vicat degree (49N, 50°C/h) of at least 90°C. A sheet as claimed in claim 5, characterized in that the methacrylic polymer is polymethylmethacrylate containing 0-20% by weight of methylacrylate and having an average molecular weight not greater than 150,000 and a viscosity in the melted state not greater than 3000 Pas (30,000 poise). A sheet as claimed in Claim 6, characterised in that the methacrylic polymer has a viscosity in the melted state from 2000-3000 Pas (20,000 to 30,000 poise). A sheet as claimed in any of claims 1 to 7, characterized in that the grafted elastomer is an acrylic elastomer grafted with an alkylmethacrylate. A sheet as claimed in Claim 8, in which the grafted acrylic elastomer is a polymer of a C₁-C₈ alkyl ester of acrylic acid. A sheet as claimed in claim 8 or 9, in which the acrylic elastomer is grafted with methylmeth-acrylate. A sheet as claimed in any of claims 1 to 10, characterized in that the grafted elastomer is premixed with the methacrylic polymer. A sheet as claimed in any of claims 1 to 11, characterized by being from 2 to 12 mm thick. A sheet as claimed in Claim 12, characterised by being from 4 to 8 mm thick. A sheet as claimed in any of claims 1 to 13, characterized in that the thickness of each single layer ranges from 0.1 to 10 mm. A sheet as claimed in Claim 14, characterised in that the thickness of each single layer ranges from 0.3 to 6 mm. A process for the preparation of a coextruded multilayer sheet according to claim 1, comprising coextruding a plurality of layers by means of independent extruders connected at the outlet with a single extrusion head, said process being characterized in that: i) a blend containing 40-70% by weight of polyvinylidene fluoride having an average molecular weight not greater than 250,000 and a viscosity in the melted state, measured by a capillary rheometer at 230°C and at a shear rate of 100 sec⁻¹, not greater than 1500 Pas (15,000 poise), 30-60% by weight of a homo or copolymer of an alkylmethacrylate and 10-30% by weight, with respect to the sum of the preceding components, of an elastomer in grafted form, is fed to a first extruder; ii) optionally a homo or copolymer of an alkylmethacrylate is fed to at least one second extruder; and iii)a blend containing the same homo or copolymer of alkylmethacrylate as used in blend (i) and 5-40% by weight of an elastomer in grafted form is fed to at least one third extruder; and wherein the layer coming from step (ii) is, if present, intermediate to the layers coming from steps (i) and (iii). A process for the preparation of a coextruded multilayer sheet according to claim 2, comprising coextruding a plurality of layers by means of independent extruders, connected at the outlet with a single extrusion head, said process being characterized in that: i') a blend containing 50-70% by weight of polyvinylidene fluoride having an average molecular weight not greater than 250,000 and a viscosity in the melted state, measured by a capillary rheometer at 230°C and at a shear rate of 100 sec⁻¹, not greater than 1500 Pas (15,000 poise), and 30-50% by weight of a homo or copolymer of an alkylmethacrylate is fed to a first extruder; ii')optionally a homo or copolymer of an alkylmethylacrylate is fed to at least one second extruder; and iii')a blend containing the same homo or copolymer of alkylmethacrylate as used in blend (i') and 5-40% by weight of an elastomer in grafted form is fed to at least one third extruder; and wherein the layer coming from step (ii') is, if present, intermediate to the layers coming from steps (i') and (iii'). Use of the coextruded sheets, according to any one of the preceding claims, for the production by thermomolding, of hydrosanitary articles for saunas and baths or coachwork parts for cars.

Inventors: ANGHILERI ANDREA, BINAGHI MARCO, RONCHETTI TULLO, SEMPIO CARLO, VAILATI ITALO, ANGHILERI, ANDREA, BINAGHI, MARCO, RONCHETTI, TULLO, SEMPIO, CARLO, VAILATI, ITALO
Applicants: ATOCHEM ELF ITALIA, ELF ATOCHEM ITALIA S.R.L.
Application year: 1990
Main classification: B32B27
IPC codes: B32B27