Weatherable multilayer articles and method for their preparation

Abstract

Disclosed are weatherable multilayer articles 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) a substrate layer comprising a polypropylene, and (iv) at least one adhesive layer comprising the reaction product of an amine-functionalized polypropylene and a polyurethane, wherein the coating layer is in contiguous contact with the second layer, and the adhesive layer is in contiguous contact with the second layer and the substrate layer. Also disclosed is a method for making the multilayer article.

1 . 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) a substrate layer comprising a polypropylene, and (iv) at least one adhesive layer comprising the reaction product of an amine-functionalized polypropylene and a polyurethane, wherein the coating layer is in contiguous contact with the second layer, and the adhesive layer is in contiguous contact with the second layer and the substrate layer.  
     
     
         2 . The article of  claim 1  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.  
     
     
         3 . The article of  claim 2  wherein the 1,3-dihydroxybenzene is unsubstituted resorcinol.  
     
     
         4 . The article of  claim 1  wherein the aromatic dicarboxylic acid is selected from the group consisting of isophthalic acid, terephthalic acid, naphthalene-2,6-dicarboxylic acid, and mixtures thereof.  
     
     
         5 . The article of  claim 4  wherein the aromatic dicarboxylic acid is a mixture of isophthalic acid and terephthalic acid.  
     
     
         6 . The article of  claim 5  wherein the ratio of isophthalic-derived structural units to terephthalic-derived structural units is about 0.25-4.0:1.  
     
     
         7 . The article of  claim 5  wherein the ratio of isophthalic-derived structural units to terephthalic-derived structural units is about 0.40-2.5:1.  
     
     
         8 . The article of  claim 1  wherein the copolyestercarbonate comprises about 10% to about 99% by weight arylate blocks.  
     
     
         9 . The article of  claim 1  wherein the copolyestercarbonate comprises about 60% to about 98% by weight arylate blocks.  
     
     
         10 . The article of  claim 1  wherein the carbonate portion of the copolyestercarbonate comprises structural units derived from bisphenol A.  
     
     
         11 . The article of  claim 1  wherein the second layer comprises a bisphenol A polycarbonate.  
     
     
         12 . The article of  claim 1  wherein the second layer further comprises at least one colorant selected from the group consisting of dyes, pigments, metal flakes, and glass flakes.  
     
     
         13 . The article of  claim 1  wherein the substrate layer comprises at least one homopolypropylene or copolymer comprising structural units derived from propylene, or a blend thereof.  
     
     
         14 . The article of  claim 13  wherein the substrate layer comprises a copolymer comprising at least about 70 weight percent of structural units derived from propylene.  
     
     
         15 . The article of  claim 13  wherein the substrate layer comprises a copolymer comprising at least about 90 weight percent of structural units derived from propylene.  
     
     
         16 . The article of claim 1 wherein the amine-functionalized polypropylene is derived from reaction of a polypropylene bearing at least one amine-reactive group and an amine compound bearing at least two amine groups.  
     
     
         17 . The article of  claim 16  wherein the amine-reactive group comprises an anhydride.  
     
     
         18 . The article of  claim 16  wherein the amine compound bears two amine groups, both of which are primary, or one of which is primary and one of which is secondary.  
     
     
         19 . The article of  claim 1  wherein the polyurethane is a thermoplastic polyurethane comprising structural units derived from at least one polyol, at least one organic diisocyanate and at least one optional chain extender.  
     
     
         20 . The article of  claim 19  wherein the polyurethane has a degree of hardness in a range of between about 60° Shore A and about 75° Shore D.  
     
     
         21 . The article of  claim 19  wherein the polyurethane has a melt flow rate of about 4 to 100 grams per10 minutes as measured by ASTM D-1238.  
     
     
         22 . The article of  claim 1  wherein the ratio of polyurethane to amine-functionalized polypropylene is in a range of between about 5:95 and about 98:2.  
     
     
         23 . The article of  claim 1  wherein the adhesive layer further comprises at least one second polypropylene which is not amine-functionalized.  
     
     
         24 . The article of  claim 23  wherein the second polypropylene is the same as that polypropylene used in the substrate layer.  
     
     
         25 . The article of  claim 23  wherein the second polypropylene is present in a range of between about 5 wt. % and about 80 wt. %, based on the weight of the adhesive layer.  
     
     
         26 . The article of  claim 1  wherein the multilayer article exhibits a ninety-degree peel force of at least 700 Newtons per meter.  
     
     
         27 . The article of  claim 26  wherein the multilayer article exhibits a ninety-degree peel force of at least 1750 Newtons per meter.  
     
     
         28 . The article of  claim 1  wherein thicknesses of layers are: a coating layer of about 2-2,500 microns; a second layer of about 2-2,500 microns; and an adhesive layer of about 8-2,500 microns.  
     
     
         29 . The article of  claim 1  which is an OVAD device; exterior or interior component for aircraft, automotive, truck, military vehicle; military automobile, military aircraft, military water-borne vehicle, scooter, motorcycle, including a panel, quarter panel, rocker panel, vertical panel, horizontal panel, trim, pillar, center post, fender, door, decklid, trunklid, hood, bonnet, roof, bumper, fascia, grill, mirror housing, pillar applique, cladding, body side molding, wheel cover, hubcap, door handle, spoiler, window frame, headlamp bezel, headlamp, tail lamp, tail lamp housing, tail lamp bezel, license plate enclosure, roof rack, or running board; an enclosure, housing, panel, or part for outdoor vehicles and devices; a wind turbine blade or housing; an enclosure for an electrical or telecommunication device; outdoor furniture; aircraft component; exterior or interior component for a boat or item of marine equipment, including trim, an enclosure, or housing; an outboard motor housing; depth finder housing, personal water-craft; jet-ski; pool; spa; hot-tub; step; step covering; a building or construction application including glazing, roof, window, floor, decorative window furnishing or treatment; a treated glass cover for a pictures, paintings, poster, or display item; an optical lens; ophthalmic lens; corrective ophthalmic lens; implantable ophthalmic lens; a wall panel or door; a counter top; protected graphic; an outdoor or indoor sign; an enclosure, housing, panel, or part for an automatic teller machine (ATM); an enclosure, housing, panel, or part for a lawn or garden tractor, lawn mower, or tool, including a lawn or garden tool; window or door trim; an item of sports equipment or a toy; an enclosure, housing, panel, or part for a snowmobile; a recreational vehicle panel or component; an item of playground equipment; a shoe lace; an articles made from plastic-wood combinations; a golf course marker; a utility pit cover; a computer housing; a desk-top computer housing; a portable computer housing; a lap-top computer housing; a palm-held computer housings; a monitor housing; a printer housing; a keyboard; a FAX machine housing; a copier housing; a telephone housing; a phone bezel; a mobile phone housing; a radio sender housing; a radio receiver housing; a light fixture; lighting appliance; reflector; network interface device housing; transformer housing; air conditioner housing; cladding or seating for public transportation; cladding or seating for a train, subway, or bus; a meter housing; antenna housing; cladding for satellite dishes; an coated helmet or item of personal protective equipment; a coated synthetic or natural textile; coated photographic film or photographic print; a coated painted article; coated dyed article; coated fluorescent article; or coated foam article.  
     
     
         30 . A multilayer article comprising (i) a coating layer comprising a block copolyestercarbonate comprising structural units derived from unsubstituted resorcinol, a mixture of isophthalic acid and terephthalic acid, and bisphenol A; (ii) a second layer comprising a bisphenol A polycarbonate optionally containing at least one colorant; (iii) a substrate layer selected from the group consisting of a homopolypropylene and a copolymer comprising at least about 70 wt. % structural units derived from propylene; and (iv) an adhesive layer comprising the reaction product of an amine-functionalized polypropylene and a polyurethane; 
 wherein the coating layer is in contiguous contact with the second layer, and the adhesive layer is in contiguous contact with the second layer and the substrate layer; and wherein the multilayer article exhibits a ninety-degree peel force of at least 700 Newtons per meter.    
     
     
         31 . A film assembly 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, and (iii) an adhesive layer comprising the reaction product of an amine-functionalized polypropylene and a polyurethane.  
     
     
         32 . The film assembly of  claim 31  wherein the coating layer comprises a block copolyestercarbonate comprising structural units derived from unsubstituted resorcinol, a mixture of isophthalic acid and terephthalic acid, and bisphenol A; and the second layer comprises a bisphenol A polycarbonate optionally containing at least one colorant.  
     
     
         33 . A method for making 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) a substrate layer comprising a polypropylene, and (iv) at least one adhesive layer comprising the reaction product of an amine-functionalized polypropylene and a polyurethane, wherein the coating layer is in contiguous contact with the second layer, and the adhesive layer is in contiguous contact with the second layer and the substrate layer, 
 which method is selected from the group consisting of the method (i) comprising the steps of (a) preparing a pre-assembly of coating layer and second layer, and (b) combining said pre-assembly with separate adhesive layer and substrate layer; the method (ii) comprising the steps of (a) preparing a pre-assembly of coating layer and second layer, (b) forming the adhesive layer adjacent to the substrate layer, and (c) combining said pre-assembly with the adhesive layer/substrate layer combination; and the method (iii) comprising the steps of (a) preparing a pre-assembly of coating layer, second layer, and adhesive layer, and (b) forming said pre-assembly adjacent to the substrate layer.    
     
     
         34 . The method of  claim 33  wherein the assembly of coating layer and second layer is formed by coextrusion.  
     
     
         35 . The method of  claim 33  wherein forming said assembly adjacent to the adhesive layer is performed by lamination or compression molding.  
     
     
         36 . The method of  claim 33  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.  
     
     
         37 . The method of  claim 33  wherein the 1,3-dihydroxybenzene is unsubstituted resorcinol.  
     
     
         38 . The method of  claim 33  wherein the aromatic dicarboxylic acid is selected from the group consisting of isophthalic acid, terephthalic acid, naphthalene-2,6-dicarboxylic acid, and mixtures thereof.  
     
     
         39 . The method of  claim 38  wherein the aromatic dicarboxylic acid is a mixture of isophthalic acid and terephthalic acid.  
     
     
         40 . The method of  claim 39  wherein the ratio of isophthalic-derived structural units to terephthalic-derived structural units is about 0.25-4.0:1.  
     
     
         41 . The method of  claim 39  wherein the ratio of isophthalic-derived structural units to terephthalic-derived structural units is about 0.40-2.5:1.  
     
     
         42 . The method of  claim 33  wherein the copolyestercarbonate comprises about 10% to about 99% by weight arylate blocks.  
     
     
         43 . The method of  claim 33  wherein the copolyestercarbonate comprises about 60% to about 98% by weight arylate blocks.  
     
     
         44 . The method of  claim 33  wherein the carbonate portion of the copolyestercarbonate comprises structural units derived from bisphenol A.  
     
     
         45 . The method of  claim 33  wherein the second layer comprises a bisphenol A polycarbonate.  
     
     
         46 . The method of  claim 33  wherein the second layer further comprises at least one colorant selected from the group consisting of dyes, pigments, metal flakes, and glass flakes.  
     
     
         47 . The method of  claim 33  wherein the substrate layer comprises at least one homopolypropylene or copolymer comprising structural units derived from propylene, or a blend thereof.  
     
     
         48 . The method of  claim 47  wherein the substrate layer comprises a copolymer comprising at least about 70 weight percent of structural units derived from propylene.  
     
     
         49 . The method of  claim 47  wherein the substrate layer comprises a copolymer comprising at least about 90 weight percent of structural units derived from propylene.  
     
     
         50 . The method of  claim 33  wherein the amine-functionalized polypropylene is derived from reaction of a polypropylene bearing at least one amine-reactive group and an amine compound bearing at least two amine groups.  
     
     
         51 . The method of  claim 50  wherein the amine-reactive group comprises an anhydride.  
     
     
         52 . The method of  claim 50  wherein the amine compound bears two amine groups, both of which are primary, or one of which is primary and one of which is secondary.  
     
     
         53 . The method of  claim 33  wherein the polyurethane is a thermoplastic polyurethane comprising structural units derived from at least one polyol, at least one organic diisocyanate and at least one optional chain extender.  
     
     
         54 . The method of  claim 53  wherein the polyurethane has a degree of hardness in a range of between about 60° Shore A and about 75° Shore D.  
     
     
         55 . The method of  claim 53  wherein the polyurethane has a melt flow rate of about 4 to 100 grams per10 minutes as measured by ASTM D-1238.  
     
     
         56 . The method of  claim 33  wherein the ratio of polyurethane to amine-functionalized polypropylene is in a range of between about 5:95 and about 98:2.  
     
     
         57 . The method of  claim 33  wherein the adhesive layer further comprises at least one second polypropylene which is not amine-functionalized.  
     
     
         58 . The method of  claim 57  wherein the second polypropylene is the same as that polypropylene used in the substrate layer.  
     
     
         59 . The method of  claim 57  wherein the second polypropylene is present in a range of between about 5 wt. % and about 80 wt. %, based on the weight of the adhesive layer.  
     
     
         60 . The method of  claim 33  wherein the multilayer article exhibits a ninety-degree peel force of at least 700 Newtons per meter.  
     
     
         61 . The method of  claim 60  wherein the multilayer article exhibits a ninety-degree peel force of at least 1750 Newtons per meter.  
     
     
         62 . The method of  claim 33  wherein thicknesses of layers are: a coating layer of about 2-2,500 microns; a second layer of about 2-2,500 microns; and an adhesive layer of about 8-2,500 microns.  
     
     
         63 . A method for making a multilayer article comprising (i) a coating layer comprising a block copolyestercarbonate comprising structural units derived from unsubstituted resorcinol, a mixture of isophthalic acid and terephthalic acid, and bisphenol A; (ii) a second layer comprising a bisphenol A polycarbonate optionally containing at least one colorant; (iii) a substrate layer selected from the group consisting of a homopolypropylene and a copolymer comprising at least about 70 wt. % structural units derived from propylene; and (iv) an adhesive layer comprising the reaction product of an amine-functionalized polypropylene and a polyurethane, 
 wherein the coating layer is in contiguous contact with the second layer, and the adhesive layer is in contiguous contact with the second layer and the substrate layer; and wherein the multilayer article exhibits a ninety-degree peel force of at least 700 Newtons per meter;    which method is selected from the group consisting of the method (i) comprising the steps of (a) preparing an assembly of coating layer and second layer, and (b) combining said assembly with separate adhesive layer and substrate layer; the method (ii) comprising the steps of (a) preparing an assembly of coating layer and second layer, (b) forming the adhesive layer adjacent to the substrate layer, and (c) combining said assembly with the adhesive layer/substrate layer combination; and the method (iii) comprising the steps of (a) preparing an assembly of coating layer, second layer, and adhesive layer, and (b) forming said assembly adjacent to the substrate layer.