Multi-layered composite article

Abstract

A composite article is used in commercial and residential decking. The composite article includes a first layer including a thermoplastic resin and a cellulosic fiber. The composite article also includes a second layer including a styrene butadiene copolymer that is disposed in contact with the first layer. The composite article further includes a third layer consisting essentially of styrene acrylonitriles and disposed in contact with the second layer as an outermost layer of the composite article. The thermoplastic resin and cellulosic fiber contribute to shear strength and compressive strength. The styrene butadiene copolymer, as a tie layer, contributes to an ability of the first layer to bond to the third layer. The styrene acrylonitriles contribute to ultraviolet light resistance, moisture resistance, mold resistance, weatherability, and resistance to warping and surface distortion, and allow the composite article to be used in outdoor environments.

1 . A composite article comprising: 
 A. a first layer comprising a thermoplastic resin and a reinforcing fiber;    B. a second layer comprising a styrene butadiene copolymer and disposed on said first layer; and    C. a third layer consisting essentially of styrene acrylonitriles and disposed on said second layer as an outermost layer of said composite article.    
   
   
       2 . A composite article as set forth in  claim 1  wherein said first, second, and third layers are co-extruded.  
   
   
       3 . A composite article as set forth in  claim 1  wherein said thermoplastic resin is selected from the group of polyalkylenes, polyaromatics, and combinations thereof.  
   
   
       4 . A composite article as set forth in  claim 1  wherein said thermoplastic resin is selected from the group of polyethylene, polypropylene, and combinations thereof.  
   
   
       5 . A composite article as set forth in  claim 1  wherein said thermoplastic resin comprises polystyrene.  
   
   
       6 . A composite article as set forth in  claim 1  wherein said reinforcing fiber is selected from the group of glass fibers, carbon fibers, metallic fibers, thermoplastic fibers, cellulosic fibers, polymeric fibers, fiberglass fibers, and combinations thereof.  
   
   
       7 . A composite article as set forth in  claim 1  wherein said styrene acrylonitriles comprise acrylonitrile styrene acrylate.  
   
   
       8 . A composite article as set forth in  claim 1  wherein said second layer is disposed in contact with said first layer.  
   
   
       9 . A composite article as set forth in  claim 8  wherein said third layer is disposed in contact with said second layer.  
   
   
       10 . A composite article as set forth in  claim 1  wherein said third layer is disposed in contact with said second layer.  
   
   
       11 . A composite article as set forth in  claim 1  wherein said first layer has a thickness of less than 2.5 inches.  
   
   
       12 . A composite article as set forth in  claim 1  wherein said second layer has a thickness of from 2 to 10 mils.  
   
   
       13 . A composite article as set forth in  claim 1  wherein said third layer has a thickness of from 1 to 40 mils.  
   
   
       14 . A composite article as set forth in  claim 1  wherein said first, second, and third layers each have top and bottom surfaces and at least one of said top and bottom surfaces is corrugated  
   
   
       15 . A composite article as set forth in  claim 1  further comprising an additive selected from the group of oxidative and thermal stabilizers, impact modifiers, lubricants, release agents, flame-retarding agents, oxidation inhibitors, oxidation scavengers, neutralizers, antiblock agents, dyes, pigments and other coloring agents, ultraviolet light absorbers and stabilizers, organic and inorganic fillers including particulate and fibrous fillers, reinforcing agents, nucleators, plasticizers, waxes, hot melt adhesives, and combinations thereof.  
   
   
       16 . A composite article as set forth in  claim 1  wherein said reinforcing fiber is present in said first layer in an amount of from 20 to 60 parts by weight per 100 parts by weight of said first layer and said second layer consists essentially of said styrene butadiene copolymer.  
   
   
       17 . A composite article as set forth in  claim 1  wherein said composite article is selected from the group of boards, footings, posts, beams, joists, planks, rails, spindles, stringers, studs, balusters, caps, panels, doors, fascia, and combinations thereof.  
   
   
       18 . A composite article comprising: 
 A. a first layer comprising a thermoplastic resin and a cellulosic fiber;    B. a second layer comprising a styrene butadiene copolymer and disposed in contact with said first layer; and    C. a third layer consisting essentially of acrylonitrile styrene acrylate and disposed in contact with said second layer as an outermost layer of said composite article.    
   
   
       19 . A composite article as set forth in  claim 18  wherein said first layer has a thickness of from 0.12 to 2 inches.  
   
   
       20 . A composite article as set forth in  claim 18  wherein said second layer has a thickness of from 2 to 5 mils.  
   
   
       21 . A composite article as set forth in  claim 18  wherein said third layer has a thickness of from 20 to 40 mils.  
   
   
       22 . A composite article as set forth in  claim 18  wherein said first, second, and third layers each have top and bottom surfaces and at least one of said top and bottom surfaces is corrugated.  
   
   
       23 . A composite article as set forth in  claim 18  further comprising an additive selected from the group of oxidative and thermal stabilizers, impact modifiers, lubricants, release agents, flame-retarding agents, oxidation inhibitors, oxidation scavengers, neutralizers, antiblock agents, dyes, pigments and other coloring agents, ultraviolet light absorbers and stabilizers, organic and inorganic fillers including particulate and fibrous fillers, reinforcing agents, nucleators, plasticizers, waxes, hot melt adhesives, and combinations thereof.  
   
   
       24 . A composite article as set forth in  claim 18  wherein said reinforcing fiber is present in said first layer in an amount of from 20 to 60 parts by weight per 100 parts by weight of said first layer and said second layer consists essentially of said styrene butadiene copolymer.  
   
   
       25 . A composite article as set forth in  claim 18  wherein said composite article is a board.  
   
   
       26 . A method of making a composite article, said method comprising the steps of: 
 forming a first layer comprising a thermoplastic resin and a reinforcing fiber;    forming a second layer comprising a styrene butadiene copolymer on the first layer; and    forming a third layer consisting essentially of styrene acrylonitriles on the second layer as an outermost layer of the composite article.    
   
   
       27 . A method as set forth in  claim 26  wherein the step of forming the first layer comprises extruding the first layer, the step of forming the second layer comprises extruding the second layer, and the step of forming the third layer comprises extruding the third layer.  
   
   
       28 . A method as set forth in  claim 27  wherein the first, second, and third layers are simultaneously extruded.  
   
   
       29 . A method as set forth in  claim 26  further comprising the step of melt-bonding the first, second, and third layers.  
   
   
       30 . A method as set forth in  claim 26  wherein the second layer is formed in contact with the first layer.  
   
   
       31 . A method as set forth in  claim 30  wherein the third layer is formed in contact with the second layer.  
   
   
       32 . A method as set forth in  claim 26  wherein the third layer is formed in contact with the second layer.