Synthetic resin laminated sheet

Patent metadata

Field	Value
Publication number	US-10118988-B2
Application number	US-201515518321-A
Country	US
Kind code	B2
Filing date	Oct 13, 2015
Priority date	Oct 15, 2014
Publication date	Nov 6, 2018
Grant date	Nov 6, 2018

Abstract

A synthetic resin laminated sheet, in which whitening, cracking, and foaming do not occur when thermoforming is carried out, in particular when deep-draw molding is carried out, and defects do not occur during lamination of a hard coating layer; and a molded article obtained by molding the laminated sheet. A synthetic resin laminated sheet has a coating layer, which includes an acrylic resin, laminated on one surface of a substrate layer including a polycarbonate resin in which a monohydric phenol represented by general formula (1) is used as a chain terminator and is obtained by reacting the monohydric phenol with a dihydric phenol and a carbonate binding agent and has a viscosity average molecular weight of 18000-35000. (In the formula, R1 represents a C8-36 alkyl group or a C8-36 alkenyl group. R2-R5 each represent hydrogen, halogen, or an optionally substituted C1-20 alkyl group or C6-12 aryl group).

First claim

The invention claimed is:

1. A laminated synthetic resin sheet comprising a coating layer containing an acrylic resin (B) on at least one surface of a substrate layer containing a polycarbonate resin (A) with a viscosity-average molecular weight of 18,000-35,000 that is produced by reacting a dihydric phenol and a carbonate binder using a monohydric phenol represented by formula (1) below as a terminating agent:

wherein, R 1 represents an alkyl group with a carbon number of 8-36, or an alkenyl group with a carbon number of 8-36,
R 2 -R 5 each represent hydrogen, halogen or an optionally substituted or unsubstituted alkyl group with a carbon number of 1-20 or aryl group with a carbon number of 6-12, and
the substituent is halogen, an alkyl group with a carbon number of 1-20 or an aryl group with a carbon number of 6-12.

2. The laminated synthetic resin sheet according to claim 1 , wherein the dihydric phenol is expressed by formula (3) below:

wherein, R 6 -R 9 each independently represents hydrogen, halogen, an substituted or unsubstituted alkyl group with a carbon number of 1-20, an substituted or unsubstituted alkoxy group with a carbon number of 1-5, an substituted or unsubstituted aryl group with a carbon number of 6-12, an substituted or unsubstituted aralkyl group with a carbon number of 7-17, or an substituted or unsubstituted alkenyl group with a carbon number of 2-15,
the substituent is halogen, an alkyl group with a carbon number of 1-20 or an aryl group with a carbon number of 6-12, and
X represents —O—, —S—, —SO—, —SO 2 —, —CO— or any of the binding groups represented by Formulae (4) to (7) below)

wherein, R 10 and R 11 each represent hydrogen, halogen, an substituted or unsubstituted alkyl group with a carbon number of 1-20, an substituted or unsubstituted alkoxy group with a carbon number of 1-5, an substituted or unsubstituted aryl group with a carbon number of 6-12, an substituted or unsubstituted alkenyl group with a carbon number of 2-5, or an substituted or unsubstituted aralkyl group with a carbon number of 7-17,
R 10 and R 11 may bind to each other to form a carbocyclic ring or a heterocyclic ring with a carbon number of 1-20, and
c represents an integer of 0-20.

wherein, R 12 and R 13 each represent hydrogen, halogen, an substituted or unsubstituted alkyl group with a carbon number of 1-20, an substituted or unsubstituted alkoxy group with a carbon number of 1-5, an substituted or unsubstituted aryl group with a carbon number of 6-12, an substituted or unsubstituted alkenyl group with a carbon number of 2-5, or an substituted or unsubstituted aralkyl group with a carbon number of 7-17, and
R 12 and R 13 may bind to each other to form a carbocyclic ring or a heterocyclic ring with a carbon number of 1-24.

wherein, R 14 -R 17 each represent hydrogen, halogen, an substituted or unsubstituted alkyl group with a carbon number of 1-20, an substituted or unsubstituted alkoxy group with a carbon number of 1-5, an substituted or unsubstituted aryl group with a carbon number of 6-12, an substituted or unsubstituted alkenyl group with a carbon number of 2-5, or an substituted or unsubstituted aralkyl group with a carbon number of 7-17, and
R 14 and R 15 , and R 16 and R 17 may respectively bind to each other to form a carbocyclic ring or a heterocyclic ring with a carbon number of 1-20,
the substituent in Formulae (3) to (6) above is halogen, an alkyl group with a carbon number of 1-20 or an aryl group with a carbon number of 6-12, and

wherein, R 18 -R 27 each represent a hydrogen atom or an alkyl group with a carbon number of 1-3.

3. A laminated synthetic resin sheet according to claim 1 , wherein the monohydric phenol represented by Formula (1) above is at least one selected from the group consisting of 2-hexyldecyl para-hydroxybenzoate, hexadecyl para-hydroxybenzoate, dodecyl para-hydroxybenzoate and 2-ethylhexyl para-hydroxybenzoate.

4. The laminated synthetic resin sheet according to claim 1 , wherein an elongational viscosity of the polycarbonate resin (A) shows a strain softening property at a strain rate of 0.01-5.0/sec.

5. The laminated synthetic resin sheet according to claim 1 , wherein an absolute value of the difference in the glass-transition temperature between the polycarbonate resin (A) and the acrylic resin (B) is within 30° C.

6. The laminated synthetic resin sheet according to claim 1 , wherein a hard coat layer is laminated on a surface of the acrylic resin (B) layer opposite to the polycarbonate resin (A) layer.

7. The laminated synthetic resin sheet according to claim 6 , wherein the thickness of the hard coat layer is 1-20 μm.

8. A thermoformed article produced by thermoforming the laminated synthetic resin sheet according to claim 1 to have a deep-drawn height of 5 mm or more.

9. The thermoformed article according to claim 8 , wherein the radius R of a part thermoformed into a right-angled shape is within 3.0 mm.

10. An in-mold molded article produced by forming a print layer on the substrate layer side of the laminated synthetic resin sheet according to claim 1 upon thermoforming, and further injection molding a molten resin on the print layer side to form a backing layer.

11. A laminated synthetic resin sheet comprising a coating layer containing an acrylic resin (B) laminated on at least one surface of a substrate layer containing a polycarbonate resin (A) with a viscosity-average molecular weight of 18,000-35,000 and having a terminal group represented by formula (1-a) below resulting from a monohydric phenol terminating agent:

wherein, R 1 represents an alkyl group with a carbon number of 8-36 or an alkenyl group with a carbon number of 8-36,
R 2 -R 5 each represent hydrogen, halogen or a substituted or unsubstituted alkyl group with a carbon number of 1-20 or an aryl group with a carbon number of 6-12, and
the substituent is halogen, an alkyl group with a carbon number of 1-20 or an aryl group with a carbon number of 6-12.

Assignees

• Mitsubishi Gas Chemical Co
• Mgc Filsheet Co Ltd

Inventors

• NAKAYASU Yasuyoshi
• Ogasawara Ken
• Sugiyama Genki
• Shimizu Hidetaka

Classifications

• C08G64/14 Primary

  containing a chain-terminating or -crosslinking agent · CPC title

• B29C45/14

  incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles {(B29C45/1671 takes precedence)} · CPC title

• C08G64/081

  containing sulfur · CPC title

• B29C51/00

  Shaping by thermoforming {, i.e. shaping sheets or sheet like preforms after heating}, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor {(blow moulding of tubular preforms B29C49/00, deforming of tubular or hollow preforms B29C67/0014)} · CPC title

• B32B27/30

  comprising vinyl {(co)polymers; comprising acrylic (co)polymers} · CPC title