Claims
- 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, said method comprising the steps of:
providing an outer layer comprising resorcinol arylate polyester chain members; shaping said 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 provide 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 one 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 outerlayer 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 one 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:
providing an outer layer comprising resorcinol arylate polyester chain members; thermoforming said 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 provide 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:
providing an outer layer comprising resorcinol arylate polyester chain members; laminating said outer layer onto a metal substrate forming a laminate composite; 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 provide 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. A laminated sheet construction containing a first laminae intimately fusion-bonded to a second lamina, wherein said first laminae comprising resorcinol arylate polyester chain members and said second laminae being independently fabricated 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. 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.
- 16. A multilayer article having a weatherable outer surface with a high quality finish appearance, said article comprising:
an outer layer comprising resorcinol arylate polyester chain members; a second layer comprising at least one of polyurethane, a polyester, a polyamide, a silicone, an epoxy, a phenolic, an acrylic, a styrene block copolymer, polyvinyl acetate, ethylene/vinyl acetate copolymer, polyvinyl chloride, polyolefin, a modified polyolefin, or blends thereof.
- 17. The article of claim 16, further comprising a substrate layer comprising at least one of a thermoplastic polycarbonate, a thermoplastic polyester, a polyurethane, a polyolefin, a polyamide, a polyacrylonitrile, a polystyrene, a polyvinyl chloride, a polyvinyl acetate, or blends thereof.
- 18. The article of claim 16, wherein at least one surface of at least said coating layer, said second layer, and said substrate layer 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, surface texturing treating.
- 19. The article of claim 16, further comprising a substrate layer comprising woven fibers or glass fibers.
- 20. The multilayer article of claim 16, wherein said article is prepared in a co-extrusion process 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 article.
- 21. A multilayer article containing a first laminae intimately fusion-bonded to a second lamina, wherein said first laminae comprising resorcinol arylate polyester chain members and said second laminae being a tie-layer independently fabricated from at least one of a polyurethane, a polyester, a polyamide, a silicone, an epoxy, a phenolic, an acrylic, a styrene block copolymer, polyvinyl acetate, ethylene/vinyl acetate copolymer, polyvinyl chloride, polyolefin, a modified polyolefin, or blends thereof,
- 22. A multilayer structure comprising:
(a) an outer layer comprising resorcinol arylate polyester chain members having pigments uniformly dispersed therein imparting uniform color to said layer, (b) a tie-layer, and (c) a substrate layer comprising at least one of a thermoplastic polycarbonate, a thermoplastic polyester, a polyolefin, a polyamide, a polyacrylonitrile, a polystyrene, a polyvinyl chloride, wherein at least a part of a surface of at least one of said outer layer, said tie-layer, and said substrate layer 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.
- 23. A method for forming a multilayer article, said method comprising the step of:
providing a first layer comprising resorcinol arylate polyester chain members; providing a second layer comprising at least one of a thermoplastic polycarbonate, a thermoplastic polyester, a polyolefin, a polyamide, a polyacrylonitrile, a polystyrene, a polyvinyl chloride; tacking said first layer onto said second layer by bringing the respective films into contacting array, 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.
- 24. The method of claim 23, wherein at least one of said first film layer and second film layer includes a tie-layer on at least one surface, for contacting with a surface of another of said film layer to facilitate tacking said film layers together.
- 25. The method of claim 23, 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;
- 26. A coextrusion process, wherein said surface layer comprising of resorcinol arylate polyester chain members is fusion bonded to an adherent 2nd 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 there of and, wherein said 2nd adherent layer is fusion bonded to a 3rd 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 there of and 3rd layer is bonded to a tie layer
- 27. The coextrusion process of claim 26, wherein said
surface layer comprising of resorcinol arylate polyester chain members is fusion bonded to an adherent 2nd 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 there of and said 2nd adherent layer is fusion bonded to a 3rd 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 there of.
- 28. A multilayer article comprising (i) a coating layer comprising a block copolyestercarbonate comprising structural units derived from at least one 1,3-dihydroxybenzene and at least one aromatic dicarboxylic acid, (ii) a second layer comprising a polymer comprising carbonate structural units, (iii) an adhesive layer comprising a polyurethane, and (iv) a substrate layer, wherein the coating layer is in contiguous superposed contact with the second layer, and the adhesive layer is in contiguous contact with the second layer and the substrate layer.
- 29. The article of claim 28 wherein the coating layer comprises at least one 1,3-dihydroxybenzene selected from the group consisting of unsubstituted resorcinol, 2-methyl resorcinol, and mixtures thereof.
- 30. The article of claim 29 wherein the 1,3-dihydroxybenzene is unsubstituted resorcinol.
- 31. The article of claim 28 wherein the aromatic dicarboxylic acid is selected from the group consisting of isophthalic acid, terephthalic acid, naphthalene-2,6-dicarboxylic acid, and mixtures thereof.
- 32. The article of claim 31 wherein the aromatic dicarboxylic acid is a mixture of isophthalic acid and terephthalic acid.
- 33. The article of claim 32 wherein the ratio of isophthalic-derived structural units to terephthalic-derived structural units is about 0.25-4.0:1.
- 34. The article of claim 33 wherein the ratio of isophthalic-derived structural units to terephthalic-derived structural units is about 0.40-2.5:1.
- 35. The article of claim 28 wherein the copolyestercarbonate comprises about 10% to about 99% by weight arylate blocks.
- 36. The article of claim 28 wherein the copolyestercarbonate comprises about 60% to about 98% by weight arylate blocks.
- 37. The article of claim 28 wherein the carbonate portion of the copolyestercarbonate comprises structural units derived from bisphenol A.
- 38. The article of claim 28 wherein the second layer comprises a bisphenol A polycarbonate.
- 39. The article of claim 38 wherein the second layer further comprises at least one colorant selected from the group consisting of dyes, pigments, metal flakes, and glass flakes.
- 40. The article of claim 28 wherein the adhesive layer comprises at least one polyurethane comprising structural units derived from at least one polyol selected from the group consisting of polyether polyols, polyester polyols, and polyols based on polybutadiene.
- 41. The article of claim 40 wherein the adhesion of the polyurethane adhesive layer to the polycarbonate-comprising layer provides a ninety-degree peel force of at least 700 Newtons per meter.
- 42. The article of claim 41 wherein the adhesion of the polyurethane adhesive layer to the polycarbonate-comprising layer provides a ninety-degree peel force of at least 1750 Newtons per meter.
- 43. The article of claim 41 wherein the substrate layer comprises at least one material selected from the group consisting of a thermoplastic resin, a thermoset resin, a metal, a ceramic, a glass, and a celluosic material.
- 44. The article of claim 41 wherein thicknesses of layers are as follows:
(a) said coating layer is about 2-2,500 microns, (b) said second layer is about 2-2,500 microns; (c) said adhesive layer is about 8-2,500 microns.
- 45. A multilayer article having a weatherable outer surface with a high quality finish appearance, comprising a three-layer structure of:
(a) two outer layers comprising resorcinol arylate polyester chain members; (b) an inner layer being sandwiched between said two outer layers, said inner layer comprising at least one of polyurethane, a polycarbonate, a polyester, a polyamide, a silicone, an epoxy, a phenolic, an acrylic, a styrene block copolymer, polyvinyl acetate, ethylene/vinyl acetate copolymer, polyvinyl chloride, polyolefin, a modified polyolefin, or blends thereof.
- 46. The multilayer article of claim 45, in the form of a sheet or a film.
- 47. The multilayer article of claim 45, further formed into shape by a forming process.
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is related to and claims priority from Provisional Application No. 60/334,513 filed on Nov. 30, 2001, the entire contents of which are incorporated by reference herein.
Provisional Applications (1)
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Number |
Date |
Country |
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60334513 |
Nov 2001 |
US |