Recyclable Multilayer Thermoplastic Films and Methods of Making

1 . A method for making a multilayer film, comprising:

combining a base layer composition with a recycle composition to form a mixture, wherein the recycle composition comprises the base layer composition and an outer layer composition;

forming a base layer from the mixture;

disposing an outer layer adjacent to the base layer to form the multilayer film; and

recycling a material to form the recycle composition, wherein the material is selected from the group consisting of scrap base layer, scrap outer layer, scrap multilayer film, and combinations comprising at least one of the foregoing;

wherein the outer layer comprises the outer layer composition which comprises resorcinol arylate polyester chain members; and

wherein the base layer composition comprises

about 2 wt % to about 98 wt % of an aromatic carbonate polymer; and

about 2 wt % to about 98 wt % of a second polymer derived from a glycol portion and an acid portion, wherein the glycol portion comprises 1,4 cyclohexanedimethanol and ethylene glycol wherein a molar ratio of the 1,4 cyclohexanedimethanol to the ethylene glycol is about 1:1 to about 4:1, and wherein the acid portion comprises an aromatic dicarboxylic acid selected from the group consisting essentially of terphthalic acid, isophthalic acid, and combinations comprising at least one of the foregoing acids.

2 . The method of claim 1 , wherein the aromatic carbonate polymer is a carbonate of bisphenol-A, and wherein the second polymer is a polyester copolymer.

3 . The method of claim 1 , wherein the outer layer has an outermost surface comprising a sublayer comprising the resorcinol arylate polyester chain members.

4 . The method of claim 1 , wherein disposing the outer layer adjacent to the base layer further comprises co-extruding the outer layer and the base layer.

5 . The method of claim 1 , wherein the mixture comprises about 1 wt % to about 20 wt % recycle composition, based upon a total weight of the mixture.

6 . The method of claim 1 , wherein the mixture comprises about 5 wt % to about 20 wt % recycle composition.

7 . The method of claim 1 , wherein the mixture comprises about 10 wt % to about 20 wt % recycle composition.

8 . The method of claim 1 , wherein

the aromatic carbonate polymer is present in the base layer in an amount of about 2 wt % to about 85 wt %; and

the second polymer is present in the base layer in an amount of about 15 wt % to about 98 wt %.

9 . An article, comprising:

a multilayer film comprising

an outer layer comprising a polymer comprising resorcinol arylate polyester chain members; and

a base layer comprising

about 2 wt % to about 98 wt % of an aromatic carbonate polymer; and

about 2 wt % to about 98 wt % of a second polymer derived from a glycol portion and an acid portion, wherein the glycol portion comprises 1,4 cyclohexanedimethanol and ethylene glycol wherein a molar ratio of the 1,4 cyclohexanedimethanol to the ethylene glycol is about 1:1 to about 4:1, and wherein the acid portion comprises an aromatic dicarboxylic acid selected from the group consisting essentially of terphthalic acid, isophthalic acid, and combinations comprising at least one of the foregoing acids; and

a substrate adhered to the base layer, wherein the substrate comprises a material selected from the group consisting of polyurethane, polycarbonate, and combinations comprising at least one of the foregoing.

10 . The article of claim 9 , wherein the material comprises a polycarbonate blend selected from the group consisting of PC/PBT, PC/ASA, PC/ABS, and combinations comprising at least one of the foregoing.

11 . The article of claim 9 , wherein the material comprises foamed polyurethane.

12 . The article of claim 9 , wherein the substrate further comprises glass fibers.

13 . The article of claim 9 , wherein

the aromatic carbonate polymer is present in the base layer in an amount of about 2 wt % to about 85 wt %; and

the second polymer is present in the base layer in an amount of about 15 wt % to about 98 wt %.

14 . A method of making an article, comprising:

placing a multilayer film into a mold so that a cavity is formed behind the multilayer film, wherein the multilayer film comprises

an outer layer comprising resorcinol arylate polyester chain members; and

a base layer comprising

about 2 wt % to about 98 wt % of an aromatic carbonate polymer; and

about 2 wt % to about 98 wt % of a second polymer derived from a glycol portion and an acid portion, wherein the glycol portion comprises 1,4 cyclohexanedimethanol and ethylene glycol wherein a molar ratio of the 1,4 cyclohexanedimethanol to the ethylene glycol is about 1:1 to about 4:1, and wherein the acid portion comprises an aromatic dicarboxylic acid selected from the group consisting essentially of terphthalic acid, isophthalic acid, and combinations comprising at least one of the foregoing acids;

placing a substrate into the cavity, wherein the substrate comprises a material selected from the group consisting of polyurethane, polycarbonate, and combinations comprising at least one of the foregoing; and

adhering the base layer to the substrate to form the article.

15 . The method of claim 13 , wherein the substrate is injected into the cavity.

16 . The method of claim 13 , further comprising co-extruding the multilayer film.

17 . The method of claim 16 , further comprising

thermoforming the co-extruded multilayer film to form a thermoformed film;

reaction injection molding the substrate in a mold;

placing the thermoformed film in a mold such that the base layer is between the substrate and the outer layer;

forming the article.