Multilayer, coextruded, ionomeric decorative surfacing

1. A multilayer sheet comprising a first layer, a second layer, a third layer; and optionally a tie layer, a recycled polymer layer, or both wherein

the sheet is a thermoformable sheet;

the combined first layer and the second layer have a thickness of 8 to 60 mils;

the first layer is a surface layer in contact with the second layer and consists essentially of ionomer and a first additive;

the second layer comprises an ionomer-polyamide blend and a second additive and is in contact with the first layer;

the ionomer-polyamide blend consists essentially of at least one polyamide forming a continuous phase or co-continuous phase with at least one ionomer dispersed therein;

the third layer is in contact with the second layer, directly or through the tie layer, and comprises a very low density polyethylene and a third additive;

the first additive, the second additive, and the third additive are individually selected from the group consisting of one or more UV stabilizer, UV absorber, antioxidant, thermal stabilizer, anti-stat additive, processing aid, fiber glass, mineral filler, anti-slip agent, plasticizer, nucleating agent, pigment, dye, flake, and mixtures of two or more thereof; and

the tie layer comprises a blend of polyethylene, ethylene/α-olefin copolymer, and ethylene elastomer; ethylene vinyl acetate; ethylene (meth)acrylate copolymer; ethylene butyl acrylate copolymer; polyethylene terephthalate and polyethylene terephthalate glycol copolymer resins; maleic anhydride modified polypropylene; copolymers containing anhydride grafts; or a mixture of two or more thereof.

2. The sheet of claim 1 wherein the sheet is a surface layer of automotive part, appliance panel, or aviation.

3. The sheet of claim 1 wherein said first layer is clear and said second layer contains pigments, dyes, flakes, or mixtures thereof.

4. The sheet of claim 1 , 2 , or 3 wherein the sheet has a thickness of 40 to 60 mils.

5. The sheet of claim 1 , 2 , or 3 wherein the sheet has a thickness of 12 to 40 mils.

6. The sheet of claim 5 wherein the sheet comprises the tie layer.

7. The sheet of claim 6 wherein the tie layer is in contact with both the second layer and the third layer.

8. The sheet of claim 1 wherein the sheet has a thickness of 80 to 180 mils.

9. An article consisting essentially of a substrate to which a multilayer sheet is adhered, wherein said multilayer sheet is as recited in claim 1 .

10. The article of claim 9 wherein the first layer is clear and the second layer is pigmented.

11. A process comprising positioning a thermoformable multilayer sheet into a mold; injection backfilling the sheet with a backfilling material under a condition effective to produce an article wherein the multilayer sheet is as recited in claim 1 having a thickness of 12 to 60 mils; the backfilling material includes thermoplastic polyolefin, polyester, sheet molding compound, acrylonitrile butyl styrene, polyvinyl chloride, polystyrene, polyurethane, low density polyethylene, linear low density polyethylene, high density polyethylene, or mixtures thereof; and the article has a Distinctness of Image (DOI) of at least 80 and a gloss that exceeds 60% at a 20 degree angle.

12. The process of claim 11 further comprising conforming said multilayer sheet to a contoured surface of a substrate in the mold.

13. The process of claim 11 further comprising thermoforming the multilayer sheet to produce a thermoformed sheet and preheating the thermoformed sheet to produce a softened sheet wherein the mold has a deep draw, is textured so as to provide a textured surface on said article, or is polished so as to provide a gloss surface attribute on said article; and the surface of the article substantially replicates the surface finish of the mold.