Low heat build-up capstock system and extrusion technology for solid and foamed profiles in dark colors

Abstract

A weatherable, low heat build-up capstock system comprising an acrylic cap, a pigment system that is IR transparent to a greater degree than existing pigment systems, an IR reflective substrate, and an extrusion system for same.

1 . A heat build-up resistant extrudate with a dark-colored capstock, comprising: 
 an IR reflective substrate portion formed of a first thermoplastic resin that is substantially reflective of solar infrared radiation,    a dark-colored capstock portion that is formed of a second thermoplastic resin that is significantly transmissive of solar infrared radiation and that covers at least a portion of the reflective substrate, and    wherein the extrudate exhibits a predicted horizontal heat build-up under ASTM D4803 of less than about 58° Fahrenheit.    
     
     
         2 . The extrudate with a dark-colored capstock of  claim 1 , wherein, 
 the dark-colored capstock portion is less than about 30 thousandths of an inch thick, and    the first thermoplastic resin contains greater than about 8 parts TiO 2  per hundred parts base resin.    
     
     
         3 . The extrudate with a dark-colored capstock of  claim 2 , wherein the dark-colored capstock is less than about 20 thousandths of an inch thick.  
     
     
         4 . The extrudate with a dark-colored capstock of  claim 2 , wherein the dark-colored capstock is less than about 10 thousandths of an inch thick and the first thermoplastic resin contains between 8 and 11 parts TiO 2  per hundred base resin.  
     
     
         5 . The extrudate with a dark-colored capstock of  claim 2 , wherein the dark-colored capstock is between about 4 thousandths and about 8 thousandths of an inch thick and the first thermoplastic resin contains between 8 and 11 parts TiO 2  per hundred base resin.  
     
     
         6 . The extrudate with a dark-colored capstock of  claim 1 , further comprising a base portion formed of a third thermoplastic resin, wherein, 
 the IR reflective substrate portion covers at least part of the surface of the base portion,    and the dark-colored capstock portion covers at least part of the surface of the IR reflective substrate portion.    
     
     
         7 . The extrudate with a dark-colored capstock of  claim 6 , wherein the third thermoplastic resin is a rigid, solid thermoplastic.  
     
     
         8 . The extrudate with a dark-colored capstock of  claim 6 , wherein the third thermoplastic resin is a rigid, foamed thermoplastic resin.  
     
     
         9 . The extrudate with a dark-colored capstock of  claim 6 , wherein the base portion is formed of a rigid, foamed thermoplastic resin and wood flour composite.  
     
     
         10 . The extrudate with a dark-colored capstock of  claim 6 , wherein the base portion is formed of a rigid, foamed thermoplastic resin and mineral filler composite.  
     
     
         11 . A heat build-up resistant extrudate with a dark-colored capstock, comprising: 
 an IR reflective substrate portion formed of a first thermoplastic resin containing between about 8 and 11 parts TiO 2  per hundred resin that is substantially reflective of solar infrared radiation,    a dark-colored capstock portion between about 4 thousandths and about 8 thousandths of an inch thick that is formed of a second thermoplastic resin that is significantly transmissive of solar infrared radiation and that covers at least a portion of the reflective substrate,    wherein the extrudate exhibits a predicted horizontal heat build-up under ASTM D4803 of less than about 52° Fahrenheit.    
     
     
         12 . The extrudate with a dark-colored capstock of  claim 11 , further comprising a base portion formed of a third thermoplastic resin, wherein, 
 the IR reflective substrate portion covers at least part of the surface of the base portion,    and the dark-colored capstock portion covers at least part of the surface of the IR reflective substrate portion.    
     
     
         13 . The extrudate with a dark-colored capstock of  claim 11 , wherein the third thermoplastic resin is a rigid, solid thermoplastic.  
     
     
         14 . The extrudate with a dark-colored capstock of  claim 11 , wherein the third thermoplastic resin is a rigid, foamed thermoplastic resin.  
     
     
         15 . The extrudate with a dark-colored capstock of  claim 11 , wherein the base portion is formed of a rigid, foamed thermoplastic resin and wood flour composite.  
     
     
         20 . A method of producing a low heat build-up extrudate with a dark-colored capstock, comprising: 
 feeding an IR reflective substrate formed of a first thermoplastic resin that is substantially reflective of solar infrared radiation into a first extruder,    feeding a dark-colored capstock that is formed of a second thermoplastic resin that is significantly transmissive of solar infrared radiation into a second extruder,    outputting the first and second extruders to an extrusion die that forms the extrudate into a predetermined shape where the dark-colored capstock is less than 30 thousandths of an inch thick and covers at least a portion of the IR reflective substrate.    
     
     
         21 . The method of  claim 20  wherein the first thermoplastic resin contains greater than about 8 parts TiO 2  per hundred resin.  
     
     
         22 . The method of  claim 21 , wherein the extrusion die forms the dark-colored capstock portion into a layer less than about 20 thousandths of an inch thick.  
     
     
         23 . The method of  claim 21 , wherein the extrusion die forms the dark-colored capstock portion into a layer less than about 10 thousandths of an inch thick and the first thermoplastic resin contains between about 8 and 11 parts TiO 2  per hundred resin.  
     
     
         24 . The method of  claim 21 , wherein the extrusion die forms the dark-colored capstock portion into a layer less than about 8 thousandths of an inch thick and the first thermoplastic resin contains between about 8 and 11 parts TiO 2  per hundred resin.  
     
     
         25 . The method of  claim 21 , wherein the extrusion die forms the dark-colored capstock portion into a layer between 4 and 8 thousandths of an inch thick and the first thermoplastic resin contains between about 8 and 11 parts TiO 2  per hundred resin.  
     
     
         26 . The method of  claim 21 , further comprising: 
 operatively coupling a calibrator to the downstream end of the extrusion die, and    utilizing means for heat-treating the dark-colored capstock portions of the extrudate.    
     
     
         27 . The method of  claim 26 , wherein the means for heat-treating comprises Leister heaters.  
     
     
         28 . The method of  claim 26 , wherein the means for heat-treating comprise; 
 a heating tube having upstream and downstream end and which surrounds the extrudate, and    at least one leister heater directed so that it blows hot air into at least one end of the heating tube such that it heats the surface of the extrudate.    
     
     
         29 . The method of  claim 28 , wherein the surface temperature of the extrudate at the downstream end of the heating tube exceeds a temperature of 115° F.  
     
     
         30 . The method of  claim 28 , wherein the surface temperature of the extrudate at the downstream end of the heating tube exceeds a temperature of 145° F.  
     
     
         31 . The method of  claim 25 , further comprising: 
 operatively coupling a calibrator to the downstream end of the extrusion die, and    operatively coupling a heating tube having upstream and downstream end and which surrounds the extrudate, and includes at least one Leister heater directed so that it blows hot air into at least one end of the heating tube such that it heats the surface of the extrudate such that the surface temperature of the extrudate at the downstream end of the heating tube exceeds a temperature of 145° F.    
     
     
         32 . The method of  claim 20 , further comprising the feeding a third thermoplastic resin into a third extruder, 
 outputting the third extruder to the extrusion die that forms the extrudate into a predetermined shape including a base portion formed of a third thermoplastic resin, wherein, 
 the IR reflective substrate portion covers at least part of the surface of the base portion,  
 and the dark-colored capstock portion covers at least part of the surface of the IR reflective substrate portion.  
   
     
     
         33 . The method of  claim 32 , wherein the third thermoplastic resin is a rigid, solid thermoplastic.  
     
     
         34 . The method of  claim 32 , wherein the third thermoplastic resin is a rigid, foamed thermoplastic resin.  
     
     
         35 . The method of  claim 32 , wherein the base portion is formed of a rigid, foamed thermoplastic resin and wood flour composite.  
     
     
         36 . The method of  claim 32 , wherein the base portion is formed of a rigid, foamed thermoplastic resin and mineral filler composite.  
     
     
         40 . An extrusion line for the production of a low heat build-up extrudate with a dark-colored capstock, comprising: 
 a first extruder for extruding a first thermoplastic resin that is substantially reflective of solar infrared radiation,    a second extruder for extruding a second thermoplastic resin that is significantly transmissive of solar infrared radiation,    an extrusion die operatively coupled to the outputs of the first and second extruders wherein the extrusion die has upstream and downstream ends and forms the extrudate into a final extrudate of a predetermined profile at the downstream end that exhibits a predicted horizontal heat build-up under ASTM D4803 of less than about 58° Fahrenheit and wherein the extrudate comprises: 
 an IR reflective substrate portion that covers at least a portion of the extrudate and that is formed of the first thermoplastic resin, and  
 a dark-colored capstock portion that is formed of the second thermoplastic resin that covers at least a portion of the reflective substrate.  
   
     
     
         41 . The extrusion line of  claim 40 , wherein the first thermoplastic portion contains greater than about 8 parts TiO 2  per hundred resin and the dark-colored capstock portion is less than about 30 thousandths of an inch thick.  
     
     
         42 . The extrusion line of  claim 41 , wherein the dark-colored capstock portion is less than about 20 thousandths of an inch thick.  
     
     
         43 . The extrusion line of  claim 41 , wherein the dark-colored capstock portion is less than about 10 thousandths of an inch thick.  
     
     
         44 . The extrusion line of  claim 41 , wherein the dark-colored capstock portion is less than about 8 thousandths of an inch thick.  
     
     
         45 . The extrusion line of  claim 41 , wherein the dark-colored capstock portion is between 4 and 8 thousandths of an inch thick.  
     
     
         46 . The extrusion line of  claim 41 , further comprising: 
 a calibrator operatively coupled to the downstream end of the extrusion die, and    means for heat treating the dark-colored capstock portion of the extrudate.    
     
     
         47 . The extrusion line of  claim 46 , wherein the means for heat-treating comprises Leister heaters.  
     
     
         48 . The extrusion line of  claim 46 , wherein the means for heat-treating comprise; 
 a heating tube having upstream and downstream end and which surrounds the extrudate, and    at least one Leister heater directed so that it blows hot air into at least one end of the heating tube such that it heats the surface of the extrudate.    
     
     
         49 . The extrusion line of  claim 48 , wherein the surface temperature of the extrudate at the downstream end of the heating tube exceeds a temperature of 115° F.  
     
     
         50 . The extrusion line of  claim 48 , wherein the surface temperature of the extrudate at the downstream end of the heating tube exceeds a temperature of 145° F.  
     
     
         51 . The extrusion line of  claim 40 , further comprising, a third extruder for extruding a third thermoplastic resin wherein, 
 the extrusion die is operatively coupled to the output of the third extruder,    the extrusion die forms the extrudate into a final extrudate of a predetermined profile that includes a base portion formed of the third thermoplastic resin, and    the IR reflective substrate portion covers at least part of a surface of the base portion,    and the dark-colored capstock portion covers at least part of a surface of the IR reflective substrate portion.    
     
     
         52 . The extrusion line of  claim 51 , wherein the third thermoplastic resin is a is a rigid, solid thermoplastic.  
     
     
         53 . The extrusion line of  claim 51 , wherein the third thermoplastic resin is a rigid, foamed thermoplastic resin.  
     
     
         54 . The extrusion line of  claim 51 , wherein the base portion is formed of a rigid, foamed thermoplastic resin and wood flour composite.  
     
     
         55 . The extrusion line of  claim 51 , wherein the base portion is formed of a rigid, foamed thermoplastic resin and mineral filler composite.