Composite film, protective cover for an electronic device, and methods of making the same

A protective cover for an electronic device, the protective cover comprising:

• a first unitary thermoplastic polymer film having first and second opposed major surfaces;
• a low surface energy abrasion resistant layer disposed on the first major surface of the first unitary thermoplastic polymer film, wherein the low surface energy abrasion resistant layer comprises an at least partially cured curable composition, the curable composition comprising components:
• a) 70 to 95 weight percent of urethane (meth)acrylate compound having an average (meth)acrylate functionality of 3 to 9, based on the total weight of components a) to d);
• b) 2 to 20 weight percent (meth)acrylate monomer having a (meth)acrylate functionality of 1 to 2, based on the total weight of components a) to d), wherein the (meth)acrylate monomer is not a urethane (meth)acrylate compound;
• c) 0.5 to 2 weight percent of silicone (meth)acrylate, based on the total weight of components a) to d);
• and
• d) optional effective amount of photoinitiator;
• a first adhesive layer proximate and securely bonded to the second major surface of the first unitary thermoplastic polymer film,
• wherein the protective cover comprises a central planar section having first and second opposed major surfaces, wherein the central planar section is bounded by at least two linear side sections, wherein the at least two linear side sections extend out of plane from the central planar section to define inner and outer surfaces of the protective cover, and wherein the low surface energy abrasion resistant layer is disposed on the outer surface of the central planar section.

A method of making a protective cover for an electronic device, the method comprising:

• thermoforming a composite film to provide a protective cover comprising a central planar section having first and second opposed major surfaces, wherein the central planar section is bounded by at least two linear side sections, and wherein the composite film comprises:
• a first unitary thermoplastic polymer film having first and second opposed major surfaces;
• a low surface energy abrasion resistant layer disposed on the first major surface of the first unitary thermoplastic polymer film, wherein the low surface energy abrasion resistant layer comprises an at least partially cured curable composition, the curable composition comprising components:
• a) 70 to 95 weight percent of urethane (meth)acrylate compound having an average (meth)acrylate functionality of 3 to 9, based on the total weight of components a) to d);
• b) 2 to 20 weight percent (meth)acrylate monomer having a (meth)acrylate functionality of 1 to 2, based on the total weight of components a) to d), wherein the (meth)acrylate monomer is not a urethane (meth)acrylate compound;
• c) 0.5 to 2 weight percent of silicone (meth)acrylate, based on the total weight of components a) to d);
• and
• d) optional effective amount of photoinitiator;
• and
• a first adhesive layer proximate and securely bonded to the second major surface of the first unitary thermoplastic polymer film,
• wherein the at least two linear side sections extend out of plane from the central planar section to define inner and outer surfaces of the protective cover, and wherein the low surface energy abrasion resistant layer is disposed on at least a portion of the outer surface.