Multilayer articles and methods of making and using the same

Abstract

Multilayer articles comprise a thermoformable substrate, a base layer, and an optional transparent protective layer. Methods of making and using the paint film composites, and shaped articles made thereby, are also disclosed.

What is claimed is: 
     
         1 . A multilayer article comprising:
 a thermoformable substrate having a first major surface and a second major surface opposite the first major surface; and   a base layer having a first major surface contacting and permanently adhered to the second major surface of the thermoformable substrate, the base layer comprising a polymeric material and being substantially isotropic, wherein the polymeric material comprises a polyurethane, the polyurethane having hard segments in an amount of from 35 to 65 percent by weight, and the first major surface of the base layer being permanently adhered and covalently bonded to the second major surface of the thermoformable substrate.   
     
     
         2 . A multilayer article comprising:
 a thermoformable substrate having a first major surface and a second major surface opposite its first major surface; and   a base layer having a first major surface contacting and permanently adhered to the second major surface of the thermoformable substrate, the base layer comprising a polymeric material, wherein the polymeric material comprises a polyurethane, the polyurethane having hard segments in an amount of from 35 to 65 percent by weight, and the base layer having a second major surface opposite its first major surface, each of the first and second major surfaces of the base layer being a substantial inverse image of a major surface of first and second respective corresponding forming webs, and the first major surface of the base layer being permanently adhered and covalently bonded to the second major surface of the thermoformable substrate.   
     
     
         3 . A multilayer article comprising:
 a thermoformable substrate having a first major surface and a second major surface opposite its first major surface;   a base layer having a first major surface and a second major surface opposite its first major surface, the first major surface of the base layer contacting and permanently adhered to the second major surface of the thermoformable substrate, and the base layer comprising a first polymeric material;   a transparent protective layer having a first major surface and a second major surface opposite its first major surface, the first major surface of the transparent protective layer contacting and permanently adhered to the second major surface of the base layer, and wherein the transparent protective layer comprises a second polymeric material the second polymeric material comprising a polyurethane, the polyurethane having hard segments in an amount of from 35 to 65 percent by weight; and   at least one of the base layer and the transparent protective layer being substantially isotropic, at least one of the thermoformable substrate and the base layer comprising a colorant, and a combination of the base layer and the thermoformable substrate being opaque or translucent.   
     
     
         4 . A multilayer article comprising:
 a thermoformable substrate having first major surface and a second major surface opposite its first major surface;   a base layer having a first major surface and a second major surface opposite its first major surface, the first major surface of the base layer contacting and permanently adhered to the second major surface, and the base layer comprising a first polymeric material;   a transparent protective layer having a first major surface and a second major surface opposite its first major surface, the first major surface of the transparent protective layer contacting and permanently adhered to the second major surface of the base layer, and the transparent protective layer comprising a second polymeric material, the second polymeric material comprising a polyurethane, the polyurethane having hard segments in an amount of from 35 to 65 percent by weight; and   at least one of the thermoformable substrate and the base layer comprising a colorant, a combination of the base layer and the thermoformable substrate being opaque or translucent, and:   i) each of the first and second major surfaces of the base layer being a substantial inverse image of a major surface of first and second respective corresponding forming webs;   ii) each of the first and second major surfaces of the transparent protective layer being a substantial inverse image of a major surface of third and fourth respective corresponding forming webs; or   iii) both i) and ii).   
     
     
         5 . A multilayer article comprising:
 a thermoformable substrate having first major surface and a second major surface opposite its first major surface;   an adhesive layer;   a base layer having a first major surface and a second major surface opposite its first major surface, the first major surface of the base layer being permanently adhered to the second major surface of the thermoformable substrate by the adhesive layer, the base layer comprising a first polymeric material;   a transparent protective layer having a first major surface and a second major surface opposite its first major surface, the first major surface of the transparent protective layer contacting and permanently adhered to the second major surface of the base layer, and the transparent protective layer comprising a second polymeric material and being substantially isotropic, the second polymeric material comprising a polyurethane, and the polyurethane having hard segments in an amount of from 35 to 65 percent by weight; and   at least one of the thermoformable substrate and the base layer comprising a colorant, and a combination of the base layer and the thermoformable substrate being opaque or translucent.   
     
     
         6 . A multilayer article comprising:
 a thermoformable substrate having first major surface and a second major surface opposite its first major surface;   an adhesive layer;   a base layer having a first major surface and a second major surface opposite its first major surface, the first major surface of the base layer being permanently adhered to the second major surface by the adhesive layer, the base layer comprising a first polymeric material;   a transparent protective layer having a first major surface and a second major surface opposite its first major surface, the first major surface of the transparent protective layer contacting and permanently adhered to the second major surface of the base layer, the transparent protective layer comprising a second polymeric material, the second polymeric material comprising a polyurethane, the polyurethane having hard segments in an amount of from 35 to 65 percent by weight; and   at least one of the thermoformable substrate and the base layer comprising a colorant, a combination of the base layer and the thermoformable substrate being opaque or translucent, and:   i) each of the first and second major surfaces of the base layer being a substantial inverse image of a major surface of first and second respective corresponding forming webs;   ii) each of the first and second major surfaces of the transparent protective layer being a substantial inverse image of a major surface of third and fourth respective corresponding forming webs; or   iii) both i) and ii).