Ionomer laminates and articles formed from ionomer laminates
AssigneeExxonMobil Chemical Patents Inc.
InventorsJoseph D. Domine, Jeffrey Valentage, Prasadarao Meka
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Abstract
The present invention includes a laminate and formation of a laminate having at least one layer of an ionomer and at least one layer of an acid polymer or blend of acid polymer and a thermoplastic polyolefin that can be thermoformed to form a shaped laminate. The shaped laminate can then be contacted with a plastic substrate such as a thermoplastic polyolefin to form a composite article by such means as, for example, injection molding. The laminate can be pigmented to eliminate the need to paint the surface of the plastic substrate. Impact and scratch resistant articles can be formed from the laminated substrate such as automotive parts, appliance body parts and sporting equipment.
Claims156
A laminate comprising a tie-layer having a first side and a second side, wherein the first side is secured to at least one layer of ionomer, and wherein the tie-layer comprises one or more layers of material selected from acid copolymers and blends of acid copolymer and a polyolefin polymer, and the melt indexes of adjacent laminate layers are within 4 dg/min of one another.
A composite comprising a tie-layer having a first side and a second side, wherein the first side is secured to at least one layer of ionomer, and the second side is secured to a substrate comprising at least one thermoplastic;
- and wherein the tie-layer comprises one or more layers of material selected from acid copolymers and blends of acid copolymer and a polyolefin polymer, and the melt indexes of adjacent laminate layers are within 4 dg/min of one another.
A shaped laminate comprising at least one layer of ionomer material and a tie-layer securable to a substrate material, the tie layer comprising at least one backing layer;
- and wherein the backing layer comprises a blend of at least one ethylene (meth)acrylic acid terpolymer and at least one substrate material and the melt indexes of adjacent laminate layers are within 5 dg/min of one another.
A composite article comprising at least one layer of ionomer material, a tie-layer securable to a substrate material, and a substrate material secured to the tie-layer;
- the tie layer comprising at least one backing layer secured to the substrate;
- and wherein the backing layer comprises a blend of at least one ethylene (meth)acrylic acid polymer and at least one substrate material;
- and wherein the melt indexes of adjacent composite layers are within 5 dg/min of one another.
A method of forming a laminate suitable for an impact resistant article comprising forming a laminate, the laminate having at least one layer of ionomer and a tie-layer comprising at least one layer of material selected from the group consisting of ethylene (meth)acrylic acid terpolymer and blends of ethylene (meth)acrylic acid terpolymer and a polyolefin polymer, wherein the at least one ionomer layer and tie-layer contact one another to form the laminate and the melt indexes of adjacent laminate layers are within 5 dg/min of one another.
A method of forming shaped a laminate comprising forming a laminate;
- and forming the laminate into the shape of an end use article, the laminate having at least one layer of ionomer and a tie-layer comprising an ethylene (meth)acrylic acid copolymer and a polyolefin polymer, wherein the at least one ionomer layer and tie-layer are secured to one another to form the shaped laminate and the melt indexes of adjacent laminate layers are within 5 dg/min of one another.
A method of forming a composite article comprising:
- (a) forming a laminate;
- (b) forming the laminate into a shape, the laminate having at least one layer of ionomer and a tie-layer, wherein the tie-layer comprises an ethylene (meth)acrylic acid copolymer and a polyolefin polymer and the melt indexes of adjacent laminate layers are within 5 dg/min of one another;
- and
- (c) securing a substrate to the tie-layer of the laminate to form the composite article, wherein the substrate has a 1% secant flexural modulus of greater than 100 MPa.
A method of forming a composite article comprising:
- (a) co-extruding at least two materials to form a laminate;
- (b) thermoforming or blow molding the laminate into a shape, the laminate having at least one layer of ionomer and a tie-layer having at least one layer comprising an ethylene (meth)acrylic acid polymer, and wherein the melt indexes of adjacent laminate layers are within 5 dg/min of one another;
- and
- (c) injection molding a substrate layer to the tie-layer of the laminate to form the composite article.
A composite article formed by the method comprising:
- (a) forming a laminate of at least one ionomer and a tie-layer, the at least one ionomer layer including an external layer and the tie-layer comprising at least an ethylene (meth)acrylic acid copolymer and a polyolefin polymer and including a backing layer;
- (b) forming a shape from the laminate, resulting in a shaped laminate;
- and
- (c) securing a substrate material to the shaped laminate such that the substrate material is secured to the backing layer.
Dependencies are inferred from the claim text.