US2004076846A1PendingUtilityA1

Ionomer laminates and articles formed from ionomer laminates

45
Priority: Mar 29, 2001Filed: Mar 21, 2002Published: Apr 22, 2004
Est. expiryMar 29, 2021(expired)· nominal 20-yr term from priority
Inventors:Joseph DomineJeffrey ValentagePrasadarao Meka
C08L 23/0876B29L 2031/3044C08L 23/04C08L 23/0869B29K 2715/006C08L 23/0815B32B 38/12C08L 2205/03B29C 45/14811C08L 23/142B32B 27/08B32B 7/10B32B 27/32Y10T428/25Y10T428/31938Y10T428/31928B32B 2323/043Y10T428/31855B32B 37/153B32B 2270/00Y10T428/31935B32B 2323/10B32B 2307/558Y10T428/31913B32B 2323/046B32B 2605/08B32B 2307/4026Y10T428/31909B32B 2307/584
45
PatentIndex Score
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Claims

Abstract

A laminate structure having at least one layer of an ionomer resin (a) and at least one layer of an acid polymer or a blend of an acid polymer and a thermoplastic polyolefin (b) that can be thermoformed to form a shaped article and additional polyolefin substrate can be provided. The laminate can be pigmented to eliminate the need to paint the surface of the plastic substrate. The laminate is useful in the production of automotive parts and sports equipment.

Claims

exact text as granted — not AI-modified
We claim:  
     
         1 . A laminate suitable for an impact and scratch resistant article comprising: 
 (a) an ionomer layer; and    (b) a tie-layer, wherein the ionomer layer and tie-layer contact one another to form a shaped laminate.    
     
     
         2 . The laminate of  claim 1 , wherein the ionomer layer is pigmented.  
     
     
         3 . The laminate of  claim 1 , wherein the tie-layer comprises an acid polymer, soft ionomer, polyolefin, or blends thereof.  
     
     
         4 . The laminate of  claim 3 , wherein the polyolefin is selected from polyethylene polymers, polyethylene copolymers, polypropylene polymers, polypropylene copolymers, polypropylene impact copolymer and a blend of polypropylene impact copolymer and ethylene plastomer, and mixtures thereof.  
     
     
         5 . The laminate of  claim 1 , wherein the melt indexes of adjacent laminate layers are within less than 1 to 4 dg/min of one another.  
     
     
         6 . The laminate of  claim 3 , wherein the tie-layer comprises a blend of an acid terpolymer and a polyolefin, the polyolefin present in the blend from 30 wt % to 70 wt % of the blend.  
     
     
         7 . The laminate of  claim 1 , wherein the tie-layer comprises a blend of ethylene acrylic acid terpolymer and a polypropylene.  
     
     
         8 . The laminate of  claim 1 , wherein the tie-layer comprises a blend of ethylene acrylic acid terpolymer, linear low density polyethylene, and high density polyethylene.  
     
     
         9 . A composite article suitable for an impact and scratch resistant article comprising: 
 (a) a laminate comprising an ionomer layer and a tie-layer, wherein the ionomer layer and tie-layer contact one another to form a laminate; and    (b) a substrate secured to the laminate to form the composite article.    
     
     
         10 . The composite of  claim 9 , wherein the tie-layer comprises an acid polymer, soft ionomer, polyolefin, and blends thereof.  
     
     
         11 . The composite of  claim 10 , wherein the polyolefin is selected from polyethylene polymers, polyethylene copolymers, polypropylene polymers, polypropylene copolymers, polypropylene impact copolymer and a blend of polypropylene impact copolymer and ethylene plastomer, and mixtures thereof.  
     
     
         12 . The composite of  claim 9 , wherein the substrate is a polyolefin selected from polyethylene polymers, polyethylene copolymers, polypropylene polymers, polypropylene copolymers, polypropylene impact copolymer and a blend of polypropylene impact copolymer and ethylene plastomer, and mixtures thereof.  
     
     
         13 . The composite of  claim 9 , wherein the melt indexes of adjacent laminate layers art within less than 1 to 4 dg/min of one another.  
     
     
         14 . The composite of  claim 9 , wherein the tie-layer comprises a blend of an acid terpolymer and a polyolefin, the polyolefin present in the blend from 30 wt % to 70 wt % of the blend.  
     
     
         15 . The composite of  claim 9 , wherein the tie-layer comprises a blend of ethylene acrylic acid terpolymer and a polyethylene.  
     
     
         16 . The composite of  claim 9 , wherein the tie-layer comprises a blend of ethylene acrylic acid terpolymer, linear low density polyethylene, and high density polyethylene.  
     
     
         17 . A composite comprising: 
 (a) a laminate comprising an ionomer layer and a tie-layer, wherein the ionomer layer and tie-layer contact one another to form a laminate; and wherein the tie-layer comprises an acid polymer, soft ionomer, polyolefin, or blends thereof; and    (c) a substrate secured to the tie-layer of the shaped laminate to form the shaped composite.    
     
     
         18 . The composite of  claim 17 , wherein the ionomer layer is pigmented.  
     
     
         19 . The composite of  claim 17 , wherein the melt indexes of adjacent laminate layers are within less than 1 to 4 dg/min of one another.  
     
     
         20 . The composite of  claim 19 , wherein the melt indexes of adjacent laminate layers arc within less than 2 to 3 dg/min of one another.  
     
     
         21 . The composite of  claim 17 , wherein the polyolefin is selected from polyethylene polymers, polyethylene copolymers, polypropylene polymers, Polypropylene copolymers, polypropylene impact copolymer and a blend of polypropylene impact copolymer and ethylene plastomer, and mixtures thereof.  
     
     
         22 . The composite of  claim 17 , wherein the substrate is a polyolefin selected from polyethylene polymers, polyethylene copolymers, polypropylene polymers, Polypropylene copolymers, polypropylene impact copolymer and a blend of polypropylene impact copolymer and ethylene plastomer, and mixtures thereof.  
     
     
         23 . The composite of  claim 17 , wherein the tie-layer comprises a blend of an acid terpolymer and a polyolefin, the polyolefin present in the blend from 30 wt % to 70 wt % of the blend.  
     
     
         24 . The composite of  claim 17 , wherein the tie-layer comprises a blend of ethylene acrylic acid terpolymer and a polypropylene.  
     
     
         25 . The composite of  claim 17 , wherein the tie-layer comprises a blend of ethylene acrylic acid terpolymer, linear low density polyethylene, and high density polyethylene.  
     
     
         26 . A method of forming a composite article comprising: 
 (a) forming a laminate;    (b) forming the laminate into a shape; wherein the laminate comprises an ionomer layer and a tie-layer; and wherein the ionomer-layer and tie-layer contact one another to form the laminate; and    (c) securing a substrate layer to the tie-layer of the laminate to form the shaped composite.    
     
     
         27 . The method of  claim 26 , wherein the ionomer layer comprises a first ionomer layer and a second ionomer layer.  
     
     
         28 . The method of  claim 27 , wherein the second ionomer layer is pigmented.  
     
     
         29 . The method of  claim 26 , wherein the tie-layer comprises an acid polymer, soft ionomer, polyolefin, and blends thereof.  
     
     
         30 . The method of  claim 26 , wherein the polyolefin is selected from polyethylene polymers, polyethylene copolymers, polypropylene polymers, polypropylene copolymers, polypropylene impact copolymer and a blend of polypropylene impact copolymer and ethylene plastomer, and mixtures thereof  
     
     
         31 . The method of  claim 26 , wherein the tie-layer comprises a blend of ethylene acrylic acid terpolymer and a polyethylene.  
     
     
         32 . The method of  claim 26 , wherein the tie-layer comprises a blend of ethylene acrylic acid terpolymer, linear low density polyethylene, and high density polyethylene.  
     
     
         33 . The method of  claim 26 , wherein the melt indexes of adjacent laminate layers are within less than 1 to 4 dg/min of one another.  
     
     
         34 . The method of  claim 26 , wherein the melt indexes of adjacent laminate layers are within less than 2 to 3 dg/min of one another.  
     
     
         35 . A method of forming a composite article suitable for an impact and scratch resistant article comprising: 
 (a) forming a laminate comprising at least two layers of material;    wherein the melt index (MI) of the layers are within 1 to 4 dg/min of one another;    (b) forming the laminate into a shape, the laminate comprising an ionomer layer and a tie-layer, wherein the ionomer layer and tie-layer contact one another to form the laminate; and    (c) securing a substrate layer to the laminate to form the composite article.    
     
     
         36 . The method of  claim 35 , wherein the ionomer layer comprises a first ionomer layer and a second ionomer layer.  
     
     
         37 . The method of  claim 35 , wherein the tie-layer comprises an acid polymer, soft ionomer, polyolefin, or blends thereof.  
     
     
         38 . The method of  claim 37 , wherein the polyolefin is selected from polyethylene polymers, polyethylene copolymers, polypropylene polymers, polypropylene copolymers, polypropylene impact copolymer and a blend of polypropylene impact copolymer and ethylene plastomer, and mixtures thereof  
     
     
         39 . The method of  claim 35 , wherein the ionomer layer is pigmented.  
     
     
         40 . The method of  claim 35 , wherein the substrate is a polyolefin selected from polyethylene polymers, polyethylene copolymers, polypropylene polymers, polypropylene copolymers, polypropylene impact copolymer and a blend of polypropylene impact copolymer and ethylene plastomer, and mixtures thereof.  
     
     
         41 . The method of  claim 35 , wherein the melt indexes of adjacent laminate layers are within less than 1 to 4 dg/min of one another.  
     
     
         42 . The method of  claim 35 , wherein the tie-layer comprises a blend of ethylene acrylic acid terpolymer and a polyethylene.  
     
     
         43 . The method of  claim 35 , wherein the tie-layer comprises a blend of ethylene acrylic acid terpolymer and a polypropylene.  
     
     
         44 . The method of  claim 35 , wherein the tie-layer comprises a blend of ethylene acrylic acid terpolymer, linear low density polyethylene, and high density polyethylene.  
     
     
         45 . The method of  claim 35 , wherein the melt indexes of adjacent laminate layers are within less than 2 to 3 dg/min of one another.  
     
     
         46 . The method of  claim 35 , wherein the laminate is shaped by thermoforming the laminate.  
     
     
         47 . A composite suitable for impact and scratch resistant articles formed by the method comprising: 
 (a) forming a laminate comprising at least two layers of material; wherein the melt index (MI) of the layers are within 1 to 4 dg/min of one another;    (b) forming the laminate into a shape, the laminate comprising a first ionomer layer and a second ionomer layer and a tie-layer, wherein the second ionomer layer and tie-layer contact one another to form the laminate; and    (c) securing a substrate layer to the laminate to form the composite article.    
     
     
         48 . The composite of  claim 47 , wherein the first ionomer layer and the second ionomer layer are co-extruded.  
     
     
         49 . The composite of  claim 47 , wherein the tie-layer comprises a blend of an acid terpolymer and a polyolefin, the polyolefin present in the blend from 30 wt % to 70 wt % of the blend.  
     
     
         50 . The composite of  claim 50 , wherein the first ionomer layer is clear and the second ionomer layer is pigmented.  
     
     
         51 . The composite of  claim 47 , wherein the tie-layer comprises an acid polymer, soft ionomer, polyolefin, or blends thereof.  
     
     
         52 . The composite of  claim 51 , wherein the polyolefin is selected from polyethylene polymers, polyethylene copolymers, polypropylene polymers, polypropylene copolymers, polypropylene impact copolymer and a blend of polypropylene impact copolymer and ethylene plastomer, and mixtures thereof  
     
     
         53 . The composite of  claim 47 , wherein the first ionomer layer or second ionomer layer is pigmented.  
     
     
         54 . The composite of  claim 47 , wherein the securing step is further defined by injection molding the substrate to the tie-layer.  
     
     
         55 . The composite of  claim 47 , wherein the substrate is a polyolefin selected from polyethylene polymers, polyethylene copolymers, polypropylene polymers, polypropylene copolymers, polypropylene impact copolymer and a blend of polypropylene impact copolymer and ethylene plastomer, and mixtures thereof.  
     
     
         56 . The composite of  claim 47 , wherein the melt indexes of adjacent laminate layers are within less than 1 to 4 dg/min of one another.  
     
     
         57 . The composite of  claim 47 , wherein the tie-layer comprises a blend of ethylene acrylic acid terpolymer and a polyethylene.  
     
     
         58 . The composite of  claim 47 , wherein the tie-layer comprises a blend of ethylene acrylic acid terpolymer and a polypropylene.  
     
     
         59 . The composite of  claim 47 , wherein the tie-layer comprises a blend of ethylene acrylic acid terpolymer, linear low density polyethylene, and high density polyethylene.  
     
     
         60 . The composite of  claim 47 , wherein the melt indexes of adjacent laminate layers are within less than 2 to 3 dg/min of one another.

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