Multilayer composite composition, its manufacturing process, and article obtained thereof

Abstract

The present invention relates to a multilayer composition comprising a surface layer comprising a thermoplastic polymer A and a substrate layer comprising a polymeric composite material based thermoplastic (meth)acrylic matrix and a fibrous material as reinforcement. The multilayer composition is suitable for mechanical or structured parts or articles with a decorative surface aspect. The present invention concerns also a manufacturing process for multilayer mechanical or structured parts or articles and three-dimensional mechanical or structured parts.

What is claimed is: 
     
         1 . A multilayer mechanical or structural wind turbine part comprising
 a) a layer comprising a polymer A, and   b) a layer B comprising a polymeric composite material wherein the layers a) and b) are adhered together, and wherein said polymeric composite material comprises a polymeric thermoplastic (meth)acrylic matrix and a fibrous material as reinforcement wherein the fibrous material comprises either a fiber with an aspect ratio of the fiber of at least 1000 or the fibrous material has a two dimensional macroscopic structure.   
     
     
         2 . The multilayer mechanical or structural wind turbine part of  claim 1 , wherein said polymer A is a thermoplastic polymer. 
     
     
         3 . The multilayer mechanical or structural wind turbine part of  claim 1 , wherein said polymer A is a thermoset polymer. 
     
     
         4 . The multilayer mechanical or structural wind turbine part of  claim 1 , wherein said layers are adhered without any added adhesive. 
     
     
         5 . The multilayer mechanical or structural wind turbine part of  claim 1 , wherein said layers are laminated using heat and/or pressure. 
     
     
         6 . The multilayer mechanical or structural wind turbine part of  claim 1 , wherein said polymer A is a thermoplastic composite material of the same or different composition as thermoplastic composite material B. 
     
     
         7 . The multilayer mechanical or structural wind turbine part of  claim 1 , further comprising an additional thermoplastic composite layer adhered to the opposite side of the polymer A layer. 
     
     
         8 . The multilayer mechanical or structural wind turbine part of  claim 5 , wherein the first thermoplastic composite layer and the second thermoplastic layer have the same composition. 
     
     
         9 . The multilayer mechanical or structural wind turbine part of  claim 5 , wherein the first thermoplastic composite layer and the second thermoplastic composite layer have different compositions. 
     
     
         10 . The multilayer composition according to  claim 1 , wherein the polymer A and is selected from the group consisting of:
 (Meth)acrylic polymers   saturated polyester (PET, PBT, PLA etc.);   ABS (acrylonitrile-butadiene-styrene copolymer);   SAN (styrene-acrylonitrile copolymer);   ASA (acrylic-styrene-acrylonitrile copolymer);   polystyrene (crystalline or high-impact);   polypropylene (PP);   polyethylene (PB);   polycarbonate (PC);   PPO;   polysulfone;   PVC (polyvinylchloride);   PVDF (polyvinylidene fluoride)   chlorinated PVC (PVCC);   PU (polyurethane)   
       or mixtures thereof. 
     
     
         11 . A method for forming a multilayer mechanical or structural wind turbine part comprising,
 a) stacking at least one first thermoplastic composite layer A, at least one middle thermoplastic layer B, and at least one second thermoplastic composite layer C, wherein at least one of said first or second thermoplastic composite layer comprises a polymeric thermoplastic (meth)acrylic matrix and a fibrous material as reinforcement wherein the fibrous material comprises either a fiber with an aspect ratio of the fiber of at least 1000 or the fibrous material has a two dimensional macroscopic structure,   b) laminating said stack of at least three layers, using heat and pressure,   to form a multilayer mechanical or structural wind turbine part.   
     
     
         12 . The method of  claim 10 , wherein said lamination occurs in a closed mold. 
     
     
         13 . The method of  claim 10 , wherein said multi-layer part is further thermoformed and transformed into a final wind turbine part. 
     
     
         14 . The method of  claim 12 , wherein said multilayer mechanical or structural wind turbine part is further combined and adhered to at least one other mechanical or structural wind turbine part. 
     
     
         15 . A method for assembling a wind turbine part comprising the steps of a) positioning a first wind turbine part as claimed in  claim 1 , adjacent to a second wind turbine part comprising a thermoplastic fiber-reinforced composite, wherein said polymer A is a thermoplastic an is between the two different thermoplastic composites, and b) laminating said multilayer structure together using heat and/or pressure to adhere the adjacent parts together.