초록 ▼

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 contacte

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.

대표청구항 ▼

We claim: 1. 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 po

We claim: 1. 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. 2. The laminate of claim 1, wherein the at least one ionomer layer has a peak melt temperature of at least greater than 70�� C. 3. The laminate of claim 1, wherein the at least one ionomer layer comprises two ionomer layers. 4. The laminate of claim 1, wherein at least one layer is pigmented. 5. The laminate of claim 1, comprising two ionomer layers secured to a tie-layer, the acid copolymer comprising ethylene (meth)acrylic acid terpolymer and the polyolefin polymer is selected from propylene polymers, ethylene polymers, and blends thereof. 6. The laminate of claim 1, wherein the polyolefin polymer is selected from ethylene polymers, ethylene copolymers, propylene polymers, propylene copolymers, propylene impact copolymer, a blend of propylene impact copolymer and ethylene plastomer, and mixtures thereof. 7. The laminate of claim 1, wherein the polyolefin polymer is present in the at least one tie-layer from 30 wt % to 70 wt %. 8. The laminate of claim 1, wherein the polyolefin polymer is present in the at least one tie-layer from 40 wt % to 60 wt %. 9. The laminate of claim 1, wherein the at least one tie-layer material comprises a blend of ethylene meth(acrylic) acid terpolymer and a propylene polymer. 10. The laminate of claim 1, wherein the at least one tie-layer material comprises a blend of ethylene meth(acrylic) acid terpolymer and an ethylene polymer. 11. The laminate of claim 1, wherein the at least one tie-layer material comprises a blend of ethylene meth(acrylic) acid terpolymer, liner low density polyethylene, and high density polyethylene. 12. The laminate of claim 1, wherein the tie-layer comprises two layers of material secured to one another, wherein a first layer is secured to the at least one ionomer. 13. The laminate of claim 1, wherein the polyolefin polymer material has a 1% secant flexural modulus of greater than 500 MPa. 14. The laminate of claim 1, wherein the polyolefin polymer material has a 1% secant flexural modulus of greater than 200 MPa. 15. The laminate of claim 1, wherein the laminate is formed into the shape of an article. 16. The laminate of claim 15, wherein the article is selected from appliance parts, automotive parts, and sporting equipment parts. 17. The laminate of claim 15, wherein the article is selected from a bumper, dashboard, interior trim, fuel tank, body panel, boat hull, airbag door, and automotive door panels. 18. 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. 19. The composite of claim 18, wherein the at least one ionomer layer has a peak melt temperature of at greater than 70�� C. 20. The composite of claim 18, wherein the at least one ionomer layer comprises two ionomer layers. 21. The composite of claim 18, wherein at least one layer is pigmented. 22. The composite of claim 18, comprising two ionomer layers secured to a tie-layer, the acid copolymer comprising ethylene (meth)acrylic acid terpolymer and the polyolefin polymer is selected from propylene polymers, ethylene polymers, and blends thereof. 23. The composite of claim 18, wherein the polyolefin polymer is selected from ethylene polymers, ethylene copolymers, propylene polymers, propylene copolymers, propylene impact copolymer, a blend of propylene impact copolymer and ethylene plastomer, and mixtures thereof. 24. The composite of claim 18, wherein the polyolefin polymer is present in the at least one tie-layer from 30 wt % to 70 wt %. 25. The composite of claim 18, wherein the polyolefin polymer is present in the at least one tie-layer from 40 wt % to 60 wt %. 26. The composite of claim 18, wherein the at least one tie-layer material comprises a blend of an ethylene (meth)acrylic acid terpolymer and a propylene polymer. 27. The composite of claim 18, wherein the at least one tie-layer material comprises a blend of ethylene (meth)acrylic acid terpolymer and an ethylene polymer. 28. The composite of claim 18, wherein the at least one tie-layer material comprises a blend of ethylene (meth)acrylic acid terpolymer, linear low density polyethylene, and high density polyethylene. 29. The composite of claim 18, wherein the tie-layer comprises at least two layers of material secured to one another, wherein a first layer is secured to the at least one ionomer. 30. The composite of claim 29, wherein a backing layer comprising a blend of at least two layers of material is secured to the substrate. 31. The composite of claim 18, wherein the polyolefin material has a 1% secant flexural modulus of greater than 500 MPa. 32. The composite of claim 18, wherein the polyolefin material has a 1% secant flexural modulus of greater than 200 MPa. 33. The composite of claim 18, wherein the composite is formed into the shape of an end use article. 34. The composite of claim 33, wherein the article is selected from appliance parts, automotive parts, and sporting equipment parts. 35. The composite of claim 33, wherein the article is selected from a bumper, dashboard, interior trim, fuel tank, body panel, boat hull, airbag door, and automotive door panels. 36. 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. 37. The shaped laminate of claim 36, wherein the shaped laminate comprises at least two ionomer layers. 38. The shaped laminate of claim 36, wherein the substrate material has a 1% secant flexural modulus of greater than 100 MPa. 39. The shaped laminate of claim 36, wherein the at least one ionomer layer comprises an external layer and a second layer. 40. The shaped laminate of claim 39, wherein the second layer includes a pigment. 41. The shaped laminate of claim 36, wherein the substrate material is selected from EPDM (ethylene-propylene-diene monomer), EP (ethylene-propylene rubber), acrylonitrile-butadiene-styrene terpolymer, acetal polymer, acrylic polymers, cellulosics, fluoroplastics, nylon and other polyamides, polyamide-imide, polycarbonate, polyester, polyetheretherketone, polyetherimide, polyethylene, polyimide, polyphenylene, polyphenylene sulfide, plastomer, polypropylene, polypropylene impact copolymers, polystyrene, polysulfone, polyurethane, polyvinyl chloride, and foams of such materials, as well as blends of these materials. 42. The shaped laminate of claim 36, wherein the substrate is present in the backing layer from 10 wt % to 80 wt % of the backing layer. 43. The shaped laminate of claim 36, wherein the ethylene (meth)acrylic acid terpolymer further comprises alkyl acrylate derived units. 44. The shaped laminate of claim 43, wherein the alkyl acrylate derived unit is selected from methyl acrylate, ethyl acrylate, propyl acrylate, butyl acrylate and combinations thereof. 45. The shaped laminate of claim 36, wherein the thickness of the shaped laminate is from 200 μm to 6000 μm. 46. The shaped laminate of claim 36, wherein the at least one ionomer layer is a blend of two or more ionomers. 47. The shaped laminate of claim 46, wherein the blend is a blend of a zinc-neutralized ionomer and a sodium-neutralized ionomer. 48. The shaped laminate of claim 46, wherein the at least one ionomer or ionomer blend has a melt index of from 0.2 dg/min to 8 dg/min. 49. An exterior automotive body part made from the shaped laminate of claim 36. 50. An appliance body part made from the shaped laminate of claim 36. 51. 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. 52. The composite article of claim 51, wherein the article comprises at least two ionomer layers. 53. The composite article of claim 51, wherein the substrate material has a 1% secant flexural modulus of greater than 100 MPa. 54. The composite article of claim 51, wherein the at least one ionomer layer comprises an external layer and a second layer. 55. The composite article of claim 51, wherein the second layer includes a pigment. 56. The composite article of claim 51, wherein the substrate material is selected from EPDM (ethylene-propylene-diene monomer), EP (ethylene-propylene rubber), acrylonitrile-butadiene-styrene terpolymer, acetal polymer, acrylic polymers, cellulosics, fluoroplastics, nylon and other polyamides, polyamide-imide, polycarbonate, polyester, polyetheretherketone, polyetherimide, polyethylene, polyimide, polyphenylene, polyphenylene sulfide, plastomer, polypropylene, polypropylene impact copolymers, polystyrene, polysulfone, polyurethane, polyvinyl chloride, and foams of such materials, as well as blends of these materials. 57. The composite article of claim 51, wherein the substrate material is present in the backing layer from 10 wt % to 80 wt % of the backing layer. 58. The composite article of claim 51, wherein the ethylene (meth)acrylic acid polymer is a terpolymer further comprising alkyl acrylate derived units. 59. The composite article of claim 58, wherein the alkyl acrylate derived unit is selected from methyl acrylate, ethyl acrylate, propyl acrylate, butyl acrylate and combinations thereof. 60. The composite article of claim 51, wherein the thickness of the shaped laminate is from 200 μm to 6000 μm. 61. The composite article of claim 51, wherein the at least one ionomer layer is a blend of two or more ionomers. 62. The composite article of claim 61, wherein the blend is a blend of a zinc-neutralized ionomer and a sodium-neutralized ionomer. 63. The composite article of claim 61, wherein the at least one ionomer or ionomer blend has a melt index of from 0.2 dg/min to 8 dg/min. 64. The composite article of claim 51 in the form of an external automotive body part. 65. The composite article of claim 51 in the form of an appliance body part. 66. 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. 67. The method of claim 66, wherein the laminate is formed by co-extrusion. 68. The method of claim 67, wherein the ionomer melt temperatures are from greater than 200�� C. 69. The method of claim 67, wherein the co-extrusion process temperatures for the tie-layer is from 200�� C. to 255�� C. 70. The method of claim 66, wherein the laminate comprises a second ionomer layer. 71. The method of claim 66, wherein at least one ionomer layer is pigmented. 72. The method of claim 66, wherein the polyolefin polymer is selected from ethylene polymers, ethylene copolymers, propylene polymers, propylene copolymers, propylene impact copolymer, a blend of propylene impact copolymer and ethylene plastomer, and mixtures thereof. 73. The method of claim 66, further comprising the step of shaping the laminate into the shape of a desirable end use article. 74. The method of claim 73, wherein the shaping is performed by thermoforming. 75. The method of claim 73, wherein the shaping is performed by blow molding. 76. The method of claim 66, wherein the at least one ionomer layer is two ionomer layers. 77. The method of claim 66, wherein the melt indexes of adjacent laminate layers are within less than 4 dg/min of one another. 78. The method of claim 66, wherein the tie-layer comprises a blend of ethylene (meth)acrylic acid terpolymer and a polyethylene. 79. The method of claim 66, wherein the tie-layer comprises a blend of ethylene (meth)acrylic acid terpolymer, linear low density polyethylene, and high density polyethylene. 80. The method of claim 73, wherein the end use article is an external automotive body part. 81. The method of claim 73, wherein the end use article is an appliance body part. 82. 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. 83. The method of claim 82, wherein the laminate comprises two ionomer layers. 84. The method of claim 82, wherein at least one ionomer layer is pigmented. 85. The method of claim 82, wherein the polyolefin polymer is selected from ethylene polymers, ethylene copolymers, propylene polymers, propylene copolymers, propylene impact copolymer, a blend of propylene impact copolymer and ethylene plastomer, and mixtures thereof. 86. The method of claim 82, wherein the ethylene (meth)acrylic acid copolymer is a terpolymer further comprising alkyl acrylate derived units. 87. The method of claim 86, wherein the alkyl acrylate derived unit is selected from methyl acrylate, ethyl acrylate, propyl acrylate, butyl acrylate and combinations thereof. 88. The method of claim 82, wherein the thickness of the laminate is from 200 μm to 6000 μm. 89. The method of claim 82, wherein the melt indexes of adjacent laminate layers are within less than 4 dg/min of one another. 90. The method of claim 82, wherein the at least one ionomer layer is a blend of two or more ionomers. 91. The method of claim 82, wherein the blend is a blend of a zinc-neutralized ionomer and a sodium-neutralized ionomer. 92. The method of claim 91, wherein the at least one ionomer or ionomer blend has a melt index of from 0.2 dg/min to 8 dg/min. 93. The method of claim 82, wherein the laminate is formed by a co-extrusion process. 94. The method of claim 93, wherein the at least one ionomer layer is co-extruded at a temperature of from 180�� C. to 230�� C. 95. The method of claim 93, wherein the final material melt temperature of the co-extruded ionomer is from greater than 200�� C. 96. The method of claim 93, wherein the tie-layer materials are co-extruded at a temperature of from 200�� C. to 255�� C. 97. The method of claim 93, wherein the final melt temperature of the co-extruded tie-layer materials is from 190�� C. to 250�� C. 98. The method of claim 82, wherein the laminate is shaped by thermoforming. 99. The method of claim 82, wherein the laminate is shaped by blow molding. 100. An external automotive body part made by the method of claim 82. 101. An appliance body part made by the method of claim 82. 102. 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. 103. The method of claim 102, wherein the laminate comprises two ionomer layers. 104. The method of claim 102, wherein at least one ionomer layer is pigmented. 105. The method of claim 102, wherein the polyolefin polymer is selected from ethylene polymers, ethylene copolymers, propylene polymers, propylene copolymers, propylene impact copolymer, a blend of propylene impact copolymer and ethylene plastomer, and mixtures thereof. 106. The method of claim 102, wherein the securing step is further defined by injection molding the substrate to the tie-layer of the shaped laminate. 107. The method of claim 102, wherein the securing step is further defined by spraying the substrate to the tie-layer of the shaped laminate. 108. The method of claim 102, wherein the substrate is a polyolefin selected from ethylene polymers, ethylene copolymers, propylene polymers, propylene copolymers, propylene impact copolymer, a blend of propylene impact copolymer and ethylene plastomer, and mixtures thereof. 109. The method of claim 102, wherein the laminate is thermoformed into the shaped laminate. 110. The method of claim 102, wherein the laminate is blow molded to form the shaped laminate. 111. The method of claim 102, wherein the tie-layer comprises a blend of ethylene (meth)acrylic acid terpolymer and a polypropylene. 112. The method of claim 102, wherein the tie-layer comprises a blend of ethylene (meth)acrylic acid terpolymer, linear low density polyethylene, and high density polyethylene. 113. An external automotive body part made by the method of claim 102. 114. An appliance body part made by the method of claim 102. 115. 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. 116. The method of claim 115, wherein the laminate has a second ionomer layer. 117. The method of claim 115, wherein the tie-layer further comprises at least one layer of material selected from an ethylene (meth)acrylic acid polymer, a polyolefin polymer, or blends thereof. 118. The method of claim 117, wherein the polyolefin polymer is selected from ethylene polymers, ethylene copolymers, propylene polymers, propylene copolymers, propylene impact copolymer, a blend of propylene impact copolymer and ethylene plastomer, and mixtures thereof. 119. The method of claim 115, wherein the tie-layer comprises a blend of an ethylene (meth)acrylic acid terpolymer and a polyolefin, the polyolefin present in the blend from 30 wt % to 70 wt % of the blend. 120. The method of claim 115, wherein the at least one ionomer layer is extruded at a material melt temperature of greater than 200�� C. 121. The method of claim 115, wherein the substrate is a polyolefin polymer selected from ethylene polymers, ethylene copolymers, propylene polymers, propylene copolymers, propylene impact copolymer, a blend of propylene impact copolymer and ethylene plastomer, and mixtures thereof. 122. The method of claim 115, wherein the tie-layer comprises a blend of ethylene (meth)acrylic acid terpolymer and a polypropylene. 123. The method of claim 115, wherein the tie-layer comprises a blend of etheylene (meth)acrylic acid terpolymer, linear low density polyethylene, and high density polyethylene. 124. The method of claim 115, wherein the at least one ionomer layer is co-extruded at a temperature of from 180�� C. to 230�� C. 125. The method of claim 115, wherein the final melt temperature of the co-extruded ionomer is from 200�� C. to 220�� C. 126. The method of claim 115, wherein the tie-layer materials are co-extruded at a temperature of from 200�� C. to 255�� C. 127. The method of claim 115, wherein the final melt temperature of the co-extruded tie-layer materials is from 190�� C. to 250�� C. 128. The method of claim 115, wherein the substrate material has a 1% secant flexural modulus of greater than 100 MPa. 129. An external automotive body part made by the method of claim 115. 130. An appliance body part made by the method of claim 115. 131. 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. 132. The composite article of claim 131, wherein the laminate is blow molded to form the shaped laminate. 133. The composite article of claim 131, wherein the laminate is thermoformed to form the shaped laminate. 134. The composite article of claim 131, wherein the substrate material is injection molded onto the shaped laminate to form the composite article. 135. The composite article of claim 131, wherein the substrate is blow molded onto the shaped laminate to form the composite article. 136. The composite article of claim 131, wherein the article comprises at least two ionomer layers. 137. The composite article of claim 131, wherein at least one ionomer layer includes a pigment. 138. The composite article of claim 131, wherein the at least two ionomer layers comprise an external layer and a second layer. 139. The composite article of claim 138, wherein the second layer includes a pigment. 140. The composite article of claim 131, wherein the backing layer is a blend of an ethylene (meth)acrylic acid polymer and a substrate material, the substrate material present in the backing layer from 10 wt % to 80 wt % of the backing layer. 141. The composite article of claim 131, wherein the substrate material is selected from EPDM (ethylene-propylene-diene monomer), EP (ethylene-propylene rubber), acrylonitrile-butadiene-styrene terpolymer, acetal polymer, acrylic polymers, cellulosics, fluoroplastics, nylon and other polyamides, polyamide-imide, polycarbonate, polyester, polyetheretherketone, polyetherimide, polyethylene, polyimide, polyphenylene, polyphenylene sulfide, plastomer, polypropylene, polypropylene impact copolymers, polystyrene, polysulfone, polyurethane, polyvinyl chloride, and foams of such materials, as well as blends of these materials. 142. The composite article of claim 131, wherein the tie-layer an ethylene (meth)acrylic terpolymer further comprising alkyl acrylate derived units. 143. The composite article of claim 142, wherein the alkyl acrylate derived unit is selected from methyl acrylate, ethyl acrylate, propyl acrylate, butyl acrylate and combinations thereof. 144. The composite article of claim 131, wherein the thickness of the shaped laminate is from 200 μm to 6000 μm. 145. The composite article of claim 131, wherein the at least one ionomer layer is a blend of two or more ionomers. 146. The composite article of claim 145, wherein the blend is a blend of a zinc-neutralized ionomer and a sodium-neutralized ionomer. 147. The composite article of claim 145, wherein the at least one ionomer or ionomer blend has a melt index of from 0.2 dg/min to 8 dg/min. 148. The composite article of claim 131, wherein the laminate is formed by a co-extrusion process. 149. The composite article of claim 148, wherein the at least one ionomer layer is co-extruded at a temperature of from 180�� C. to 230�� C. 150. The composite article of claim 148, wherein the final melt temperature of the co-extruded ionomer is from 200�� C. to 220�� C. 151. The composite article of claim 148, wherein the tie-layer materials are co-extruded at a temperature of from 200�� C. to 255�� C. 152. The composite article of claim 148, wherein the final melt temperature of the co-extruded tie-layer materials is from 190�� C. to 250�� C. 153. The composite article of claim 131, wherein the substrate material has a 1% secant flexural modulus of greater than 100 MPa. 154. The composite article of claim 131, wherein the composite article is in the form of an automotive body part selected from bumpers, grills, deck lids, rocker panels, body panels, fenders, doors, hoods, mirror housings, wheel covers, trim, pillar trim, dash boards, seat covers, instrument panels, cup and personal containers and holders. 155. The composite article of claim 131, wherein the at least one ionomer layer is a copolymer of ethylene derived units and acrylic acid derived units neutralized with sodium and zinc ions to from 10% to 50%. 156. The composite article of claim 131, wherein the composite article in the form of an appliance body part.