Thin multi-layer paneling structure

Abstract

The invention relates to a multi-layer paneling structure having a high gloss cap and second layer of high impact resistance thermoplastic polymer or composites for exterior and interior paneling applications where chemical resistance and/or scratch resistance is desired. The invention also relates to a high gloss, multi-layer panel that can easily be repaired, once marred, to return the surface gloss to at least 90% of the original surface gloss. The invention further relates to articles made with the multi-layer paneling structure of the invention. The multi-layer structure can be used alone, or can be very thin and used as a replacement for an undercoating and coating on an article, such as a metal car part.

What is claimed is: 
     
         1 . A multi-layer polymer structure comprising:
 a. a thin, high gloss outer polymeric cap layer, having a 60° gloss of greater than 80, preferably greater than 85, and more preferably greater than 90, as measured by a BYK Gardner Micro-Tri-Gloss 20/60/85 degree Gloss Meter, wherein said cap layer has a thickness of from 0.01 mm to 0.8 mm, preferably 0.0127 mm to 0.65 mm, and more preferably from 0.04 mm to 0.38 mm; and   b. an internal high impact resistant layer, wherein said high impact layer has an ASTM D256 notched Izod result at 23° C. of greater than 0.8 ft-lb/in, preferably greater than 1.0 ft-lb/in, and more preferably greater than 1.3 ft-lb/in.   
     
     
         2 . The multi-layer polymer structure of  claim 1 , wherein said thin, high gloss outer polymeric cap layer has a heat deflection temperature (HDT), as measured by ASTM D648 (1.8 MPa) of at least 175° F., when prior to measurement, the samples are annealed at 80° C. for 96 hours then slow-cooled over 4 hours to 23° C. 
     
     
         3 . The multi-layer polymer structure of  claim 1 , wherein said thin, high gloss outer polymeric cap layer comprises as the matrix polymer at least one acrylic and/or styrenic polymer. 
     
     
         4 . The multi-layer polymer structure of  claim 1 , wherein said thin, high gloss outer cap layer contains less than 5 weight percent, preferably less than 3 weight percent, preferably less than 1 weight percent, and most preferably no impact modifiers. 
     
     
         5 . The multi-layer polymer structure of  claim 1 , wherein said thin, high-gloss outer polymeric layer further comprises 0-20 weight percent, preferably 10-15 weight percent nanoparticles. 
     
     
         6 . The multi-layer polymer structure of  claim 5 , wherein said nanoparticles are selected from the group consisting of silica, alumina, zinc oxide, barium oxide, molybdenum disulfide, boron nitride, tungsten disulfide, titanium oxide, Nanographene, nanographite, graphite nanoplatelets, and graphite oxide nanoparticles. 
     
     
         7 . The multi-layer polymer structure of  claim 1 , wherein said thin, high gloss outer polymeric cap layer is chemical resistant and scratch resistant, having a gloss retention of over 85%, preferably over 90% and a delta E of less than 5, preferably less than 3 for each test material according to following procedure: for 6×6 inch samples conditioned at 85° C. for one hour and rubbed with ten back-and-forth strokes with each test material then wiped, washed, and reconditioned for at least one hour, and 60° gloss re-measured, the test materials for the rub being done with chemicals such as butylene glycol and glyceryl stearate typically found in sunscreens; soaked into a cloth that is a 3″×14″ PIG Hazmat Pad (MAT302). 
     
     
         8 . The multi-layer polymer structure of  claim 1 , wherein the polymer of said thin, high gloss outer polymeric cap layer has a weight average molecular weight of at least 70,000 g/mol. 
     
     
         9 . The multi-layer polymer structure of  claim 1 , wherein said internal high impact resistant layer, is a thermoset, thermoplastic, and/or a polymer composite. 
     
     
         10 . The multi-layer polymer structure of  claim 1 , wherein said internal high impact resistant layer, comprises a thermoplastic selected from the group consisting of acrylonitrile butyl styrene (ABS) polyvinyl chloride (PVC), and high impact polystyrene (HIPS), polycarbonate (PC), a blend of acrylic polymer and polylactic acid, impact modified acrylics, impact modified styrenics, polycarbonate, thermoplastic polyolefin (TPO), polyamides, polyimides, polyurethanes, polyesters, polyolefins and blends thereof. 
     
     
         11 . The multi-layer polymer structure of  claim 10 , wherein said high-impact layer is a composite composition containing particles, nanoparticles, and/or fibers. 
     
     
         12 . The multi-layer polymer structure of  claim 11 , wherein said composite composition is a fiber-reinforced acrylic composite, said composite formed from a blend of one or more acrylic polymers with one or more acrylic monomers that are impregnated into said fibers, followed by polymerization. 
     
     
         13 . The multi-layer polymer structure of  claim 1 , wherein said structure further comprises a tie layer or adhesive layer between the exterior high gloss layer, and interior high impact layer. 
     
     
         14 . A multi-layer polymer structure, comprising said thin multi-layer structure of  claim 1  over a substrate, wherein said substrate is selected from the group consisting of metal; ceramics; cellulosics; thermoplastic, elastomeric, and thermoset polymers having a thickness in the range 0.1 mm to 30 mm and preferably 1.0 mm to 5 mm. 
     
     
         15 . The multi-layer polymer structure of  claim 1 , wherein said structure comprises two high gloss outer cap layers, one on either side of the internal high impact resistant layer. 
     
     
         16 . A method for restoring the gloss on a chemically or physically marred multi-layer polymer structure of  claim 1 , wherein said method includes the step of removing or hiding the mar. 
     
     
         17 . The method of  claim 15 , wherein said mar is restored through the process of buffing, polishing, wiping, chemical treating, and/or sanding said multi-layer structure, wherein said gloss is restored to within 30%, preferably 20%, and most preferably within 10% of the original gloss, as measured by a BYK Gardner Micro-Tri-Gloss 20/60/85 degree Gloss Meter, 
     
     
         18 . The multi-layer polymeric structure of  claim 1 , wherein said structure is manufactured by thermoforming, in-mold decorating, sequential injection molding, coextrusion, resin transfer molding with in-mold decoration, or 3D printing (additive manufacturing). 
     
     
         19 . An article comprising the multi-layer polymeric structure of  claim 1 , wherein said article is selected from the group consisting of exterior paneling, automotive body panels, autobody trim, recreational vehicle body panels or trims, exterior panels for recreational sporting equipment, marine equipment, exterior panels for outdoor lawn, garden and agricultural equipment and exterior paneling for marine, aerospace structures, aircraft, public transportation applications, interior paneling applications, interior automotive trims, interior panels for marine equipment, interior panels for aerospace and aircraft, interior panels for public transportation applications, and paneling for appliances, furniture, and cabinets.