Acrylic resin laminate film, manufacturing method therefor, and melamine decorative board

Patent metadata

Field	Value
Publication number	US-10562283-B2
Application number	US-201414894009-A
Country	US
Kind code	B2
Filing date	May 27, 2014
Priority date	May 27, 2013
Publication date	Feb 18, 2020
Grant date	Feb 18, 2020

Abstract

Provided is an acrylic resin laminate film which has an excellent bonding property, resistance to water blushing, and an excellent external appearance. This acrylic resin laminate film is provided with: an acrylic resin layer (I) comprising an acrylic resin composition (A); and an acrylic resin layer (II) comprising a resin composition (B) that contains a reactive group-containing acrylic resin (B-1). (B) contains 10-100 mass % of (B-1), and 0-90 mass % of (B-2), which is an acrylic resin other than (B-1), with respect to 100 mass % of the total of (B-1), and (B-2), and further contains 0-50 parts by mass of (C), which is an additive other than (B-1), and (B-2), with respect to 100 parts by mass of the total of (B-1), and (B-2). (B-1) contains a monomer unit which has a substituent that reacts with an amino group, or a methylol group. The content of the monomer unit that has the reactive substituent is 3 mass % or more with respect to 100 mass % of (B).

First claim

The invention claimed is:

1. An acrylic resin laminate film comprising:
a first acrylic resin layer (I) consisting of an acrylic resin composition (A) containing acrylic rubber particles (A-1) having a multilayer structure of two or more layers in which a layer containing a hard polymer (a-2) as an outer layer is formed on a layer containing an elastic copolymer (a-1) as an inner layer; and
a second acrylic resin layer (II) consisting of a resin composition (B) containing
40 to 100% by mass of a first acrylic resin (B-1) containing a monomer unit having a secondary hydroxyl group in an amount of 5% by mass or more and up to 50% by mass with respect to 100% by mass of the resin composition (B);
0 to 60% by mass of a second acrylic resin (B-2) other than the first acrylic resin (B-1) with respect to 100% by mass of the first acrylic resin (B-1) and the second acrylic resin (B-2) in total; and
0 to 50 parts by mass of an additive (C) other than the first acrylic resin (B-1) and the second acrylic resin (B-2) with respect to 100 parts by mass of the first acrylic resin (B-1) and the second acrylic resin (B-2) in total.

2. The acrylic resin laminate film according to claim 1 , wherein a glass-transition temperature of the first acrylic resin (B-1) is 0° C. to 90° C.

3. The acrylic resin laminate film according to claim 1 , wherein a content of an aromatic vinyl monomer unit in the first acrylic resin (B-1) is 0% to 3% by mass with respect to 100% by mass of the first acrylic resin (B-1).

4. The acrylic resin laminate film according to claim 1 , wherein the resin composition (B) is composed of the first acrylic resin (B-1) and the additive (C).

5. The acrylic resin laminate film according to claim 1 , wherein a thickness of the acrylic resin laminate film is 100 μm or less.

6. The acrylic resin laminate film according to claim 1 , wherein a thickness of the second acrylic resin layer (II) is 30 μm or less.

7. The acrylic resin laminate film according to claim 1 , wherein the resin composition (B) contains 0.1 to 5 parts by mass of the additive (C).

8. The acrylic resin laminate film according to claim 1 , wherein the content of the monomer unit having the secondary hydroxyl group is 10% by mass or more and up to 50% by mass with respect to 100% by mass of the resin composition (B).

9. The acrylic resin laminate according to claim 1 , wherein the monomer unit having the secondary hydroxyl group is selected from the group consisting of hydroxypropyl methacrylate, hydroxybutyl methacrylate, hydroxypropyl acrylate and hydroxybutyl acrylate.

10. The acrylic resin laminate film according to claim 1 , wherein the resin composition (B) comprises 5% to 60% by mass of the second acrylic resin (B-2) other than the first acrylic resin (B-1) with respect to 100% by mass of the first acrylic resin (B-1) and the second acrylic resin (B-2) in total.

11. The acrylic resin laminate film according to claim 1 , wherein the resin composition (B) comprises 0.1 to 50 parts by mass the additive (C) other than the first acrylic resin (B-1) and the second acrylic resin (B-2) with respect to 100% by mass of the first acrylic resin (B-1) and the second acrylic resin (B-2) in total.

12. A method for manufacturing the acrylic resin laminate film according to claim 1 , the method utilizing a co-extrusion method in manufacturing of the acrylic resin laminate film.

13. A method for manufacturing the acrylic resin laminate film according to claim 1 , the method utilizing a coating method in manufacturing of the acrylic resin laminate film.

14. A method, comprising applying the acrylic resin laminate film according to claim 1 as a protective film to a base material.

15. A method of protecting a surface of a melamine decorative board comprising applying the acrylic resin laminate film according to claim 1 as a film.

16. A melamine decorative board comprising the acrylic resin laminate film according to claim 1 and a melamine base material laminated in the order of the first acrylic resin layer (I), the second acrylic resin layer (II), and the melamine base material.

17. An acrylic resin laminate film comprising:
a first acrylic resin layer (I) composed of an acrylic resin composition (A) containing acrylic rubber particles (A-1) having a multilayer structure of two or more layers in which a layer containing a hard polymer (a-2) as an outer layer is formed on a layer containing an elastic copolymer (a-1) as an inner layer; and
a second acrylic resin layer (II) composed of a resin composition (B) containing
40 to 100% by mass of a first acrylic resin (B-1) containing a monomer unit having a secondary hydroxyl group in an amount of 5% by mass or more and up to 50% by mass with respect to 100% by mass of the resin composition (B), wherein the first acrylic resin composition (B-1) has a glass-transition temperature of 15° C. to 80° C.;
0 to 60% by mass of a second acrylic resin (B-2) other than the first acrylic resin (B-1) with respect to 100% by mass of the first acrylic resin (B-1) and the second acrylic resin (B-2) in total; and
0 to 50 parts by mass of an additive (C) other than the first acrylic resin (B-1) and the second acrylic resin (B-2) with respect to 100 parts by mass of the first acrylic resin (B-1) and the second acrylic resin (B-2) in total, and
a hydroxyl value of the resin composition (B) is 15 mgKOH/g to 300 mgKOH/g.

18. The acrylic resin laminate film according to claim 17 , wherein the hydroxyl value of the resin composition (B) is 20 mgKOH/g to 120 mgKOH/g.

19. The acrylic resin laminate film according to claim 17 , wherein the hydroxyl value of the resin composition (B) is 25 mgKOH/g to 180 mgKOH/g.

Assignees

• Mitsubishi Rayon Co
• Mitsubishi Chem Corp

Inventors

• Nakaya Fuminori
• Shouji Keiko
• Abe Junichi

Classifications

• B29C48/21

  the layers being joined at their surfaces · CPC title

• B32B7/00

  Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers · CPC title

• B32B7/10

  at least one layer having inter-reactive properties · CPC title

• Y10T428/31935

  Ester, halide or nitrile of addition polymer · CPC title

• B32B27/306

  comprising vinyl acetate or vinyl alcohol (co)polymers · CPC title