Multilayer articles comprising resorcinol arylate polyester and method for making thereof

Abstract

Multilayer articles comprising a coating layer comprising resorcinol arylate chain members bound to a support substrate via an optional intermediate tie layer. Adhesion between the layers of the multilayer article is enhanced by modifying at least a part of a surface of at least one of the layers in the multilayer article by a technique selected from at least one of: surface adhesive treatment, surface corona treatment, flame treatment, plasma surface treatment, vacuum deposition treatment, ionization radiation, chemical surface treatment, surface abrasion treatment, and surface texturing treating.

What is claimed is: 
     
         1 . A process for forming a shaped article by forming a layer of a first thermoplastic resin adjacent second resin to form a composite, said first layer comprising an arylate polyester polymer and said second resin comprises a thermoformable resin, and thermoforming said composite into said shaped article. 
     
     
         2 . A method of making an article having a weatherable outer surface with a high quality finish appearance, comprising:
 shaping an outer layer comprising resorcinol arylate polyester chain members into a three-dimensional shape in a vacuum-forming apparatus;   placing said three-dimensional shape in a cavity of an injection molding apparatus; and   injecting a flowable resin into the cavity of said injection molding apparatus behind said layer comprising resorcinol arylate polyester chain members to form a multi-layer article.   
     
     
         3 . The method of  claim 2 , wherein said flowable resin is selected from the group consisting of an aromatic polycarbonate resin, an ABS resin, an ASA resin, a polyester, a polyphenylene ether, a polyphenylene ether/polystyrene blend, a copolyestercarbonate, a poly(aklyne dixarboxylate), polyamide, a TPO, or blends thereof. 
     
     
         4 . The method of  claim 2 , wherein said outer layer comprising resorcinol arylate polyester chain members further comprises an adherent layer on a surface of said outer layer, and wherein said flowable resin is injected into the cavity of said injection molding apparatus behind said adherent layer. 
     
     
         5 . The method of  claim 2 , wherein said outer layer is made by coextruding a material comprising resorcinol arylate polyester chain members and a material selected from the group consisting of an aromatic polycarbonate resin, an ABS resin, an ASA resin, a polyester, a polyphenylene ether, a polyphenylene ether/polystyrene blend, a copolyestercarbonate, a poly(aklyne dixarboxylate), polyamide, or blends thereof. 
     
     
         6 . The method of  claim 2 , wherein said outer layer comprising resorcinol arylate polyester chain members further comprises a colored adherent layer on a surface of said outer layer and wherein said flowable resin is injected into the cavity of said injection molding apparatus behind said colored adherent layer, thereby said colored adherent layer imparts color appearance on the surface of the article having a weatherable outer surface. 
     
     
         7 . An article produced in accordance with the method of  claim 2 . 
     
     
         8 . An article having a weatherable outer surface with a high quality finish appearance, said article is produced by the following method:
 thermoforming an outer layer comprising resorcinol arylate polyester chain members into a three-dimensional shape in a vacuum-forming apparatus;   placing said three-dimensional shape in a cavity of an injection molding apparatus; and   injecting a flowable resin into the cavity of said injection molding apparatus behind said layer comprising resorcinol arylate polyester chain members to form a multi-layer article.   
     
     
         9 . A method for producing an article having a weatherable outer surface with a high quality finish appearance, said method comprising:
 laminating an outer layer onto a metal substrate forming a laminate composite, wherein the outer layer comprises resorcinol arylate polyester chain members;   thermoforming said laminate composite into a three-dimensional shape in a vacuum-forming apparatus;   placing said three-dimensional shape in a cavity of an injection molding apparatus; and   injecting a flowable resin into the cavity of said injection molding apparatus behind said metal substrate of said thermoformed laminate composite to form a multi-layer article.   
     
     
         10 . The method of  claim 9 , wherein said metal substrate is a chrome foil or Al foil. 
     
     
         11 . An article produced in accordance with the method of  claim 9 . 
     
     
         12 . In a coextrusion process for preparing a composite polymer film construction having at least two layers wherein the polymers in the layers are fusion-bonded to each other and wherein: a) polymer resins forming said layers are fed into separate channels of a film die as separate streams, b) the polymer streams flow into the film die and are extruded to form an extrudate in which the polymer streams form a film having fusion-bonded layers, the improvement consists of employing resorcinol arylate polyester chain members to form a surface layer of said polymer film construction. 
     
     
         13 . The coextrusion process of  claim 11 , wherein said surface layer comprising resorcinol arylate polyester chain members is fusion bonded to an adherent layer comprising a material selected from the group consisting of an aromatic polycarbonate resin, an ABS resin, an ASA resin, a polyester, a polyphenylene ether, a polyphenylene ether/polystyrene blend, a copolyestercarbonate, a poly(aklyne dixarboxylate), polyamide, or blends thereof. 
     
     
         14 . In an adhesive method for bonding together surfaces of a first layer and second layer, in which method a hot melt adhesive heated above its melting point is placed between the surfaces to be bonded together, said surfaces are assembled together and the assembly is cooled to ambient temperature to solidify such adhesive; the improvement which comprises:
 fabricating said first layer from a resin comprising resorcinol arylate polyester chain members, and   fabricating said second layer from paper, metal, fabric, or a resin selected an aromatic polycarbonate resin, an ABS resin, an ASA resin, a polyester, a polyphenylene ether, a polyphenylene ether/polystyrene blend, a copolyestercarbonate, a poly(aklyne dixarboxylate), polyamide, or blends thereof.   
     
     
         15 . A method for forming a multilayer article, said method comprising the step of:
 tacking a first layer onto a second layer by bringing the respective films into contacting array, wherein the first layer comprises resorcinol arylate polyester chain members, and wherein the second layer comprises at least one of a thermoplastic polycarbonate, a thermoplastic polyester, a polyolefin, a polyamide, a polyacrylonitrile, a polystyrene, a polyvinyl chloride;   forming a continuous strip of laminated joint film; and   subjecting said continuous strip of laminated joint film to sufficient heat and pressure for bonding and thermofusing the first layer and second layer of said laminated joint film, forming a substantially fully fused laminated joint film.   
     
     
         16 . The method of  claim 15 , wherein at least one of said first film layer and second film layer includes a tie-layer on a surface, for contacting with a surface of another of said film layer to facilitate tacking said film layers together. 
     
     
         17 . The method of  claim 15 , wherein the tie-layer comprises polyurethane. 
     
     
         18 . The method of  claim 15 , wherein an adhesion of the tie-layer to the substrate layer provides a ninety-degree peel force of at least 1,750 Newtons per meter. 
     
     
         19 . The method of  claim 15 , wherein at least a part of a surface of at least one of said first and second layers is modified by a technique selected from at least one of: surface adhesive treatment, surface corona treatment, flame treatment, plasma surface treatment, vacuum deposition treatment, ionization radiation, chemical surface treatment, surface abrasion treatment, and surface texturing treating. 
     
     
         20 . A coextrusion process, wherein said surface layer comprising of resorcinol arylate polyester chain members is fusion bonded to an adherent 2 nd  layer comprising a material selected from the group consisting of an aromatic polycarbonate resin, copolyestercarbonate, a poly(aklyne dicarboxylate), a resorcinol arylate polyester, a polyresorcinol arylate BPA carbonate copolymer, PMMA or blends thereof and, wherein said 2 nd  adherent layer is fusion bonded to a 3 rd  layer comprising of a material selected from the group selected from an aromatic polycarbonate resin, copolyestercarbonate, a poly(aklyne dicarboxylate), a resorcinol arylate polyester, a polyresorcinol arylate BPA carbonate copolymer, PMMA, or blends thereof and 3 rd  layer is bonded to a tie layer. 
     
     
         21 . The coextrusion process of  claim 20 , wherein said
 surface layer comprising of resorcinol arylate polyester chain members is fusion bonded to an adherent 2 nd  layer comprising a material selected from the group consisting of an aromatic polycarbonate resin, copolyestercarbonate, a poly(aklyne dicarboxylate), a resorcinol arylate polyester, a polyresorcinol arylate BPA carbonate copolymer, PMMA, or blends thereof and   said 2 nd  adherent layer is fusion bonded to a 3 rd  layer comprising of a material selected from the group selected from an aromatic polycarbonate resin, copolyestercarbonate, a poly(aklyne dicarboxylate), a resorcinol arylate polyester, a polyresorcinol arylate BPA carbonate copolymer, PMMA, or blends thereof.