Multilayered Rotomoulded Articles

Abstract

The present invention relates to rotomoulded articles. More particularly, the present invention provides a rotomoulded article comprising: (i) at least one layer A comprising fibers embedded in a polymer resin; and (ii) at least one layer B comprising from 40 to 100 wt % of an aliphatic polyester. The present invention further provides methods for the manufacture of such articles.

1 - 15 . (canceled) 
     
     
         16 . A method for preparing a rotomoulded article comprising the steps of
 (i) applying to at least a part of an interior wall of a mould at least one layer A comprising fibers embedded in a polymer resin;   (ii) adding to the mould a composition for layer B;   (iii) rotating and heating the mould;   wherein the layer B comprises:
 from 40 to 100 wt % of an aliphatic polyester,
 from 0 to 60 wt % of a polyolefin, 
 from 0 to 20 wt % of a co- or ter-polymer comprising
 (a) 50 to 99.9 wt % of ethylene or styrene monomer, 
 (b) 0.1 to 50 wt % of an unsaturated anhydride-, epoxide- or carboxylic acid-containing monomer, 
 (c) 0 to 50 wt % of a (meth)acrylic ester monomer, wherein the sum of (a), (b), and (c) is 100%, and 
 
 wherein the sum of the wt % of the aliphatic polyester, the polyolefin, and the co- or ter-polymer is 100%; and 
 
   (iii) adding to the mould a composition for at least one layer C, said layer C comprising
   from 50 to 99.4 wt % a polyolefin,   from 0.5 to 50 wt % of a polyester,   from 0.1 to 20 wt % of a co- or ter-polymer, comprising:
 a) at least 50 wt % of an ethylene or a styrene monomer, 
 b) 0.1 to 50 wt % of an unsaturated anhydride-, epoxide- or carboxylic acid-containing monomer, 
 c) 0 to 50 wt % (meth)acrylic ester monomer, wherein the sum of (a), (b), and (c) equals 100%, and 
   wherein the sum of the wt % of the polyolefin, the polyester, and the co- or ter-polymer equals 100% .   
   
     
     
         17 . The process according to  claim 16 , wherein said polymer resin is selected from the group consisting of epoxy resin, epoxy curing agents, polyurethanes, phenolics, phenols, cyanate esters, polyimides, polyesters, benzoxazines, polybenzoxazines, polybenzoxazones, polybenzimidazoles, polybenzothiazoles, polyamides, polyamidimides, polysulphones, polyether sulphones, polycarbonates, polyethylene terephthalates, cyanates, cyanate esters, and polyether ketones, and combinations thereof. 
     
     
         18 . The process according to  claim 16 , wherein said polymer resin comprises an epoxy resin. 
     
     
         19 . The process according to  claim 16 , wherein said layer A has a glass transition temperature (Tg) as determined by Differential Scanning Calorimetry (DSC) of at least 60° C. 
     
     
         20 . The process according to  claim 16 , wherein said fibers are selected from the group consisting of carbon fibers, aramid fibers, glass fibers, poly(lactic acid) (PLA) fibers, polypropylene (PP) fibers, PLA stereocomplex fibers, poly(lactic acid)-poly(butylene adipate-co-terephthalate) (PLA-PBAT) fibers, quartz fibers , polyethylene fibers, polyester fibers, graphite fibers, poly-p-phenylene-benzobisoxazole (PBO) fibers, boron fibers, silicon carbide fibers, polyamide fibers, silicon nitride fibers, aluminum oxide fibers, metal fibers, and combinations thereof. 
     
     
         21 . The process according to  claim 16 , wherein at least one layer A is adjacent to said layer B. 
     
     
         22 . The process according to  claim 16 , wherein said aliphatic polyester in layer B is a poly(lactic acid). 
     
     
         23 . The process according to  claim 16 , wherein said polyolefin in layer B is a polyethylene. 
     
     
         24 . The process according to  claim 16 , wherein layer B comprises 0.1 to 50 wt % of said (meth)acrylic ester monomer, and wherein said (meth)acrylic ester monomer is selected from methyl, ethyl, n-butyl, iso-butyl, 2-ethylhexyl, or n-octyl (meth)acrylate. 
     
     
         25 . The process according to  claim 16 , wherein said layer B comprises from 75 to 100 wt % of said aliphatic polyester. 
     
     
         26 . The process according to  claim 16 , wherein the polyolefin in said layer C is a polyethylene. 
     
     
         27 . The process according to  claim 16 , wherein said layer C is foamed. 
     
     
         28 . The process according to  claim 16 , further comprising adding to the mould a composition for a layer D comprising from 50 to 100 wt % of a polyolefin. 
     
     
         29 . The process according to  claim 16 , wherein the polyolefin of layer C is different from the polyolefin of layer B. 
     
     
         30 . The process according to  claim 16 , wherein the polyester of layer C is different from the polyester of layer B. 
     
     
         31 . The process according to  claim 16 , wherein the co- or ter-polymer of layer C is different from the co- or ter-polymer of layer B.