Multilayer sheet, methods for making and using the same, and articles comprising the multilayer sheet

1. A multilayer sheet, comprising:

a substrate comprising

a cap layer comprising a polymeric material; and

a core layer, wherein when joined, the cap layer forms a first surface of the substrate and the core layer forms a second surface of the substrate;

a first coating layer disposed on the first surface of the substrate, wherein the first coating is a hard coating with a Taber Abrasion as measured according to ASTM D1044-05 of less than or equal to 5%; and

a second coating layer disposed on the second surface of the substrate, wherein the second coating is a flexible coating with a Taber Abrasion as measured according to ASTM D1044-05 of greater than or equal to 7%;

wherein the multilayer sheet passes a ball drop test from a distance of greater than or equal to 50 centimeters.

2. The multilayer sheet of claim 1 ,

wherein the first coating layer comprises a urethane acrylate oligomer having an acrylate functionality of 2 to 15, and an acrylate monomer having a functionality of 1 to 5; and

wherein the second coating layer comprises a urethane acrylate.

3. The multilayer sheet of claim 1 , wherein the distance is greater than or equal to 70 centimeters.

4. The multilayer sheet of claim 1 , wherein the core layer comprises dimethyl bisphenol cyclohexane polycarbonate.

5. The multilayer sheet of claim 1 ,

wherein the substrate comprises a material selected from the group consisting of polymethyl methacrylate, polycarbonate, and combinations comprising at least one of the foregoing, wherein the substrate has a first surface and a second surface;

and

wherein the multilayer sheet passes a ball drop test from a distance of greater than or equal to 70 centimeters and wherein the first coating layer has a pencil hardness as measured according to ASTM D3363-05 of greater than or equal to 4H.

6. The multilayer sheet of claim 5 ,

wherein at least one of the first coating layer and the second coating layer comprises an acrylate oligomer and a photoinitiator;

wherein the photoinitiator comprises at least one of hydroxycyclohexylphenyl ketone; hydroxymethylphenylpropanone; dimethoxyphenylacetophenone; 2-methyl-1-[4-(methylthio)phenyl]-2-morpholinopropanone-1; 1-(4-isopropylphenyl)-2-hydroxy-2-methylpropan-1-one; 1-(4-dodecylphenyl)-2-hydroxy-2-methylpropan-1-one; 4-(2-hydroxyethoxy) phenyl-(2-hydroxy-2-propyl) ketone; diethoxyacetophenone; 2,2-di-sec-butoxyacetophenone; diethoxy-phenyl acetophenone; bis (2,6-dimethoxybenzoyl)-2,4-, 4-trimethylpentylphosphine oxide; 2,4,6-trimethylbenzoyldiphenylphosphine oxide; 2,4,6-trimethylbenzoylethoxyphenylphosphine oxide; and combinations comprising at least of the foregoing; and

wherein the urethane acrylate of the second coating layer comprises an aliphatic urethane tetraacrylate.

7. The multilayer sheet of claim 1 , wherein the cap layer comprises at least one of polycarbonate, and polymethyl methacrylate.

8. The multilayer sheet of claim 1 , wherein at least one of the first coating layer and the second coating layer comprises an acrylate oligomer and a photoinitiator.

9. The multilayer sheet of claim 1 , wherein the first coating layer further comprises a photoinitiator, and wherein the photoinitiator comprises is selected from hydroxycyclohexylphenyl ketone; hydroxymethylphenylpropanone; dimethoxyphenylacetophenone; 2-methyl-1-[4-(methylthio)phenyl]-2-morpholinopropanone-1; 1-(4-isopropylphenyl)-2-hydroxy-2-methylpropan-1-one; 1-(4-dodecylphenyl)-2-hydroxy-2-methylpropan-1-one; 4-(2-hydroxyethoxy) phenyl-(2-hydroxy-2-propyl) ketone; diethoxyacetophenone; 2,2-di-sec-butoxyacetophenone; diethoxy-phenyl acetophenone; bis (2,6-dimethoxybenzoyl)-2,4-, 4-trimethylpentylphosphine oxide; 2,4,6-trimethylbenzoyldiphenylphosphine oxide; 2,4,6-trimethylbenzoylethoxyphenylphosphine oxide; and combinations comprising at least one of the foregoing.

10. The multilayer sheet of claim 1 , wherein the first coating layer comprises 30 to 90 weight percent of the urethane acrylate oligomer; 5 to 50 weight percent of the acrylate monomer; and 0 to 10 weight percent of an optional photoinitiator, wherein weight percent is based upon the total weight of the coating composition.

11. The multilayer sheet of claim 1 , wherein the urethane acrylate oligomer comprises an aliphatic urethane acrylate oligomer and wherein the acrylate monomer comprises a methacrylate monomer.

12. The multilayer sheet of claim 1 , wherein the urethane acrylate of the second coating layer comprises an aliphatic urethane tetraacrylate.

13. An article comprising the multilayer sheet of claim 1 .

14. The multilayer sheet of claim 1 ,

wherein at least one of the first coating layer and the second coating layer comprises an acrylate oligomer and a photoinitiator;

wherein the photoinitiator comprises at least one of hydroxycyclohexylphenyl ketone; hydroxymethylphenylpropanone; dimethoxyphenylacetophenone; 2-methyl-1-[4-(methylthio)phenyl]-2-morpholinopropanone-1; 1-(4-isopropylphenyl)-2-hydroxy-2-methylpropan-1-one; 1-(4-dodecylphenyl)-2-hydroxy-2-methylpropan-1-one; 4-(2-hydroxyethoxy) phenyl-(2-hydroxy-2-propyl) ketone; diethoxyacetophenone; 2,2-di-sec-butoxyacetophenone; diethoxy-phenyl acetophenone; bis (2,6-dimethoxybenzoyl)-2,4-, 4-trimethylpentylphosphine oxide; 2,4,6-trimethylbenzoyldiphenylphosphine oxide; 2,4,6-trimethylbenzoylethoxyphenylphosphine oxide; and combinations comprising at least of the foregoing; and

wherein the urethane acrylate of the second coating layer comprises an aliphatic urethane tetraacrylate.

15. A method of making the multilayer sheet of claim 1 , comprising:

forming a substrate comprising a cap layer, wherein the substrate has a first surface and a second surface;

applying a first coating layer on the first surface; and

applying a second coating layer on the second surface.

16. The method of claim 15 , wherein the substrate comprises bisphenol-A polycarbonate, dimethyl bisphenol cyclohexane polycarbonate, and combinations comprising at least one of the foregoing.

17. An article made by the method of claim 16 .

18. The method of claim 15 , further comprising co-extruding a core layer with the cap layer, wherein the core layer forms the second surface of the substrate, and wherein the second coating layer is applied to the second surface.