Laminated resin sheet for molding, and molded article using same

Patent metadata

Field	Value
Publication number	US-11897980-B2
Application number	US-202117793729-A
Country	US
Kind code	B2
Filing date	Feb 3, 2021
Priority date	Feb 18, 2020
Publication date	Feb 13, 2024
Grant date	Feb 13, 2024

Abstract

Provided are: a laminated resin sheet for molding, which is less likely to cause an abnormal appearance during molding, and has an anti-glare layer but has excellent transparency; and a molded article using the same. This laminated resin sheet for molding comprises: a high-hardness resin layer containing a high-hardness resin; a base material layer which contains a polycarbonate resin (a1) and is disposed on one surface side of the high-hardness resin layer; and a hard coat anti-glare layer disposed on the other surface side of the high-hardness resin layer, wherein the glass transition point (Tg1) of the high-hardness resin and the glass transition point (Tg2) of the polycarbonate resin (a1) satisfy the following relationship, and the maximum valley depth (Rv) of the recesses and protrusions of the hard coat anti-glare layer is at most 0.9 μm

−10° C.≤( Tg 1− Tg 2)≤40° C.

First claim

The invention claimed is:

1. A laminated resin sheet for molding, which comprises:
a high hardness resin layer containing a high hardness resin;
a base material layer which contains a polycarbonate resin (a1) and is disposed on one surface side of the high hardness resin layer; and
a hard coat anti-glare layer disposed on the other surface side of the high hardness resin layer,
wherein the high hardness resin comprises at least one selected from the group consisting of:
Resin (B2), which is a copolymer (D) containing 6 to 77% by mass of a (meth)acrylic acid ester structural unit, 15 to 71% by mass of a styrene structural unit, and 8 to 23% by mass of an unsaturated dicarboxylic acid structural unit;
Resin (B3), which is a polymer containing a structural unit (c) represented by general formula (5) below:

Resin (B4), which is a copolymer (G) containing 5 to 20% by mass of a styrene structural unit, 60 to 90% by mass of a (meth)acrylic acid ester structural unit, and 5 to 20% by mass of an N-substituted maleimide structural unit;
Resin (B5), which is a polymer containing a structural unit (e) represented by general formula (7) below:

and
Resin (B6), which is a copolymer (H) containing 50 to 95% by mass of a styrene structural unit and 5 to 50% by mass of an unsaturated dicarboxylic acid structural unit;
wherein the glass transition point (Tg1) of the high hardness resin and the glass transition point (Tg2) of the polycarbonate resin (a1) satisfy the following relationship:
−10° C.≤( Tg 1− Tg 2)≤40° C.,

wherein the maximum valley depth (Rv) of the recesses and protrusions of the hard coat anti-glare layer is 0.9 μm or less; and
wherein the laminated resin sheet for molding has a haze of 12% or less.

2. The laminated resin sheet for molding according to claim 1 , wherein the polycarbonate resin (a1) is an aromatic polycarbonate resin.

3. The laminated resin sheet for molding according to claim 2 , wherein the aromatic polycarbonate resin contains a structural unit represented by general formula (3a):

4. The laminated resin sheet for molding according to claim 1 , wherein the content of the polycarbonate resin (a1) is 75 to 100% by mass relative to the total mass of the base material layer.

5. The laminated resin sheet for molding according to claim 1 , wherein the Resin (B3) is a copolymer further containing a structural unit (d) represented by general formula (6) below:

6. The laminated resin sheet for molding according to claim 1 , wherein the content of the high hardness resin is 70 to 100% by mass relative to the total mass of the high hardness resin layer.

7. The laminated resin sheet for molding according to claim 1 , wherein the total thickness of the base material layer and the high hardness resin layer is 0.5 to 3.5 mm.

8. The laminated resin sheet for molding according to claim 1 , wherein the ratio of the thickness of the base material layer in the total thickness of the base material layer and the high hardness resin layer is 75% to 99%.

9. The laminated resin sheet for molding according to claim 1 , wherein the pencil hardness of the surface of the hard coat anti-glare layer is 2H or harder.

10. The laminated resin sheet for molding according to claim 1 , wherein:
a laminated protective film, in which a first protective film and a second protective film are layered, is disposed on both the outermost surfaces of the laminated resin sheet for molding; and
the second protective film is disposed at the outer side.

11. The laminated resin sheet for molding according to claim 10 , which has the laminated protective film, wherein:
the first protective film is a polyolefin-based film having a melting point of 100 to 130° C.; and
the second protective film is a polyolefin-based film having a melting point of 140° C. or higher.

12. The laminated resin sheet for molding according to claim 10 , which has the laminated protective film, wherein:
the first protective film is a polyolefin-based film having a melting point of 100 to 130° C.; and
the second protective film is a PET-based film.

13. A molded article obtained by molding with use of the laminated resin sheet for molding according to claim 1 .

Assignees

• Mitsubishi Gas Chemical Co
• Mgc Filsheet Co Ltd

Inventors

• Takasaki Masato
• Tokita Atsuhiro

Classifications

• C08F220/14 Primary

  Methyl esters {, e.g. methyl (meth)acrylate} · CPC title

• B32B7/02

  Physical, chemical or physicochemical properties · CPC title

• B32B7/027

  Thermal properties · CPC title

• B32B27/08 Primary

  of synthetic resin · CPC title

• B32B27/30

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