Polycarbonate resin laminate

Patent metadata

Field	Value
Publication number	US-9522519-B2
Application number	US-201414170995-A
Country	US
Kind code	B2
Filing date	Feb 3, 2014
Priority date	Aug 1, 2011
Publication date	Dec 20, 2016
Grant date	Dec 20, 2016

Abstract

To provide a polycarbonate resin laminate having the surface hardness remarkably improved and being excellent in color and impact resistance. A polycarbonate resin laminate which comprises at least a surface layer (A) and a resin layer (B) and is characterized by satisfying the following conditions:
(i) the surface layer (A) is a layer made of a polycarbonate resin composition which comprises at least a polycarbonate resin (a) having at least structural units represented by the following formula (1) and a polycarbonate resin (b) having structural units different from the polycarbonate resin (a),
(ii) the mass ratio of the polycarbonate resin (a) to the polycarbonate resin (b) in the surface layer (A) is within a range of from 45:55 to 99:1, and
(iii) the pencil hardness of the polycarbonate resin laminate as specified by ISO 15184 and measured from the surface layer (A) side is at least H:

First claim

What is claimed is:

1. A polycarbonate resin laminate which comprises at least a surface layer (A) and a resin layer (B) and is characterized by satisfying the following conditions:
(i) the surface layer (A) is a layer made of a polycarbonate resin composition which comprises a mixture of a polycarbonate resin (a) having at least structural units represented by the following formula (1) and a polycarbonate resin (b) having structural units different from the polycarbonate resin (a),
(ii) the mass ratio of the polycarbonate resin (a) to the polycarbonate resin (b) in the surface layer (A) is within a range of from 45:55 to 99:1, and
(iii) the pencil hardness of the polycarbonate resin laminate as specified by ISO 15184 and measured from the surface layer (A) side is at least H

wherein the polycarbonate resin (b) has at least structural units represented by the following formula (2):

in the formula (2), X represents

wherein each of R 3 and R 4 which are independent of each other, is a hydrogen atom or a methyl group, and Z is a group forming, as bonded to C, a C 6-12 alicyclic hydrocarbon which may have a substituent.

2. The polycarbonate resin laminate according to claim 1 , wherein the resin layer (B) is made of a polycarbonate resin composition which contains at least the polycarbonate resin (b).

3. The polycarbonate resin laminate according to claim 2 , wherein the resin layer (B) is made of a polycarbonate resin composition which further contains the polycarbonate resin (a), and in the resin layer (B), the proportion of the polycarbonate resin (a) is from 30 to 1 mass %, and the proportion of the polycarbonate resin (b) is from 70 to 99 mass %.

4. The polycarbonate resin laminate according to claim 1 , wherein the polycarbonate resin (a) contains structural units derived from a compound represented by the following formula (8), and a content of such structural units is at least 20 ppm and at most 1,000 ppm:

in the formula (8), R 1 is a hydrogen atom or a methyl group.

5. The polycarbonate resin laminate according to claim 4 , wherein a content of the structural units derived from the compound represented by the formula (8) in the polycarbonate resin laminate is from 0.05 to 1,000 ppm.

6. The polycarbonate resin laminate according to claim 1 , wherein the polycarbonate resin (a) contains structural units derived from a compound represented by the following formula (9), and a content of such structural units is at least 10 ppm and at most 3,500 ppm

7. The polycarbonate resin laminate according to claim 6 , wherein a content of the structural units derived from the compound represented by the formula (9) in the polycarbonate resin laminate is from 0.02 to 3,500 ppm.

8. The polycarbonate resin laminate according to claim 1 , wherein the polycarbonate resin (a) contains structural units derived from a compound represented by the following formula (10), and a content of such structural units is at least 40 ppm and at most 600 ppm

9. The polycarbonate resin laminate according to claim 8 , wherein a content of the structural units derived from the compound represented by the formula (10) in the polycarbonate resin laminate is from 0.1 to 600 ppm.

10. The polycarbonate resin laminate according to claim 1 , wherein the thickness of the polycarbonate resin laminate is from 200 to 5,000 μm.

11. The polycarbonate resin laminate according to claim 1 , wherein the thickness of the surface layer (A) is from 20 to 1,000 μm, and the thickness of the resin layer (B) is from 10 to 5,000 μm.

12. The polycarbonate resin laminate according to claim 1 , wherein a yellowness index is at most 10 when a 7 mass % solution of the polycarbonate resin laminate in methylene chloride is measured in an optical path length of 50 mm.

13. The polycarbonate resin laminate according to claim 1 , wherein the polycarbonate resin composition constituting the surface layer (A) and/or the resin layer (B) contains at least one stabilizer selected from the group consisting of a phosphorus type stabilizer, a phenol type stabilizer and a sulfur type stabilizer in an amount of from 0.01 to 1 part by mass.

14. The polycarbonate resin laminate according to claim 13 , wherein the stabilizer is a phenol type stabilizer.

15. A protective window material for a portable display device, a component for a display device, a cover for a display device, a component for a protective equipment or an in-vehicle component made of the polycarbonate resin laminate as defined in claim 1 .

16. The polycarbonate resin laminate according to claim 1 , wherein the polycarbonate resin (a) contains structural units derived from a compound represented by the following formula (10), and a content of such structural units is at least 40 ppm and at most 600 ppm:

and wherein the content of the structural units derived from the compound represent ed by the formula (10) in the polycarbonate resin laminate is from 0.1 to 600 ppm.

Assignees

• Mitsubishi Chem Corp
• Mitsubishi Engineering-Plastics Corp

Inventors

• Hitomi Tatsuya
• Nishihara Ryouhei
• Hirano Kiyotaka
• Shiraishi Yoshitaka
• Yamamoto Masanori
• Yokoyama Tomonari
• Shidou Masahide

Classifications

• B32B27/365 Primary

  comprising polycarbonates · CPC title

• B32B27/18

  characterised by the use of special additives · CPC title

• B32B7/12

  using interposed adhesives or interposed materials with bonding properties · CPC title

• B32B2571/00

  Protective equipment · CPC title

• C08L2205/02

  containing two or more polymers of the same C08L -group · CPC title