Multilayer articles comprising resorcinol arylate polyester and method for making thereof

Abstract

Multilayer articles comprising a coating layer comprising resorcinol arylate chain members bound to a support substrate via an optional intermediate tie layer. Adhesion between the layers of the multilayer article is enhanced by modifying at least a part of a surface of at least one of the layers in the multilayer article by a technique selected from at least one of: surface adhesive treatment, surface corona treatment, flame treatment, plasma surface treatment, vacuum deposition treatment, ionization radiation, chemical surface treatment, surface abrasion treatment, and surface texturing treating.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application is a divisional application of U.S. patent application Ser. No. 10 / 210,746 filed Jul. 31, 2002, which is related to and claims priority from Provisional Application No. 60 / 334,513 filed on Nov. 30, 2001, the entire contents of each are incorporated by reference herein.FIELD OF THE INVENTION[0002]This invention relates to articles having a coating layer comprising resorcinol arylate polyester chain members, and a method for preparation the multilayer articles.BACKGROUND OF THE INVENTION[0003]Compositions and weatherable multilayer articles comprising resorcinol arylate chain members are known. See Published Patent Application Nos. EP 1124878 and WO0069945. The prior art references generally discuss methods to manufacture multilayer articles by various processes including co-injection molding, coextrusion, overmolding, multi-shot injection molding, sheet molding and placement of a film of the coating layer material on the s...

AI Technical Summary

Benefits of technology

The solution achieves a high-quality, weatherable surface with improved adhesion and mechanical properties, reducing costs and time while minimizing surface imperfections and premature failures, and maintaining gloss and color uniformity.

Problems solved by technology

Producing the desired surface is expensive and time consuming and detracts from the excellent mechanical properties of the thermoset materials.

Without the proper finishing work a painted surface will not meet the automotive class “A” requirements due to imperfections in the surface from exposed glass fibers, glass fiber “read-through,”“paint popping,” long and short term waviness, “orange peel,” and variations in gloss.

In-mold coating can obviate these operations, but only at the cost of greatly increased cycle time and cost.

The process uses expensive paint systems that may be applied to the part surface while the mold is re-opened slightly, then closed to distribute and cure the coating.

Such additives reduce the “read-through” at the surface by causing minute internal voids due to the high stresses in the resin as it shrinks due to polymerization and differential shrinkage of the glass and resin as the part cools.

If the void occurs at the surface however, a defect may result in the finish.

The voids also act as stress concentrators, which may cause premature failures under additional stress or appear during the general sanding at the surface and leave a pit that the painting process can't hide.

Such films are generally highly crosslinked films based on acrylics or fluoropolymer films, which are very expensive and need special adhesive layers, adding cost and additional sources for defects and failure.

The films are generally thin due to the expense of the fluoropolymer, or brittleness if acrylic and their method of production.

The thin layers also make it difficult to maintain a uniform color when the film is non-uniformly stretched to conform to the part.

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