Stock material or miscellaneous articles – Composite – Of polycarbonate
Reexamination Certificate
2002-05-20
2003-09-16
Boykin, Terressa M. (Department: 1711)
Stock material or miscellaneous articles
Composite
Of polycarbonate
C359S273000, C359S274000, C359S275000, C428S426000, C428S428000, C428S429000, C528S196000, C528S198000
Reexamination Certificate
active
06620509
ABSTRACT:
BACKGROUND OF THE INVENTION
1) Field of the Invention
The present invention relates to a transparent resin laminate and a molded article used the same, and particularly to a transparent resin laminate with good adhesion between each resin layer, excellent in weather resistance, abrasion resistance, heat resistance and water resistance comprising polycarbonate resin base material/acrylic resin layer/cured layer and a molded article used the same. The transparent resin laminate and the molded article is applicable to the fields of windows, sun roofs and lamp covers for car, transparent roofs and dormer windows such as hothouse, soundproof walls, signboards, front boards of automatic selling machine, carports, optical materials such as spectacle lens and camera lens, guard sheets for indication of LCD and EL and membranes shielding oxygen and moisture.
2) Prior Art
Transparent organic plastic materials, particularly, a polycarbonate resin is applicable to various uses as optical materials because it is excellent in impact resistance, dimension stability, molding and fire self-extinguishing and has a high heat distortion temperature. However, they cause a problem that transparency of the most important property as a transparent material is impaired because surface hardness is low and abrasion resistance is poor.
Further, other transparent plastic materials, e.g., polymethylmethacrylate, polystyrene and polyvinyl chloride are applicable to various uses since they are excellent in transparency, light weight, easy molding and impact strength. However, molded articles also obtained from these materials cause problems that abrasion resistance, chemical resistance and solvent resistance are poorer than other materials and their surfaces are easily hurt.
In order to solve the above-mentioned problems, a polyorganosiloxane resin has been used as a coating to improve surface hardness and abrasion resistance of plastic molded articles such as a polycarbonate resin and an acrylic resin (Japanese Patent Kokai (Laid-open) No. 2-182764, 8-230127, 9-174783, 55-59929 and 58-107316).
However, when transparent plastics coated with a polyorganosiloxane resin are used outdoors, for example, in windows, sun roofs and lamp covers for car and vehicle, transparent roofs and dormer windows such as hothouse, spectacle lens and camera lens, coatings with performances capable of resisting to severe outdoor environments such as sunlight, rain, a humidity, a temperature difference between a high temperature and a low temperature are not yet sufficient in the present situation.
SUMMARY OF THE INVENTION
An object of the present invention is to solve the above-mentioned prior art problems and to provide a transparent resin laminate with good adhesion between each resin layer, excellent in weather resistance, abrasion resistance, heat resistance and water resistance and a molded article used the same.
As a result to solve the above-mentioned prior art problems, the inventors have found that a transparent resin laminate and a molded article used the same with good adhesion between each resin layer, excellent in weather resistance, abrasion resistance, heat resistance and water resistance and a molded article used the same can be obtained by using a resin laminate comprising an acrylic resin layer comprising an ultraviolet absorbent coated on at least one surface of a polycarbonate resin base material and a cured layer formed by coating a composition comprising polyorganosiloxane and specific ultraviolet absorbent in which a difference of linear expansion coefficient between each resin layer is made small, and have accomplished the present invention.
That is, the present invention provides a transparent resin laminate comprising a polycarbonate resin base material, an acrylic resin layer comprising an ultraviolet absorbent coated on at least one surface of said polycarbonate resin base material and a cured layer formed by coating a composition comprising polyorganosiloxane and a silicone-containing polymer ultraviolet absorbent on said acrylic resin layer and then curing, wherein a difference of linear expansion coefficient between said polycarbonate resin base material and said acrylic resin layer and a difference of linear expansion coefficient between said acrylic resin layer and said cured layer are 0/° C. to 5×10
−5
/° C. respectively.
Further, the present invention provides a mold article for window glass and sun roof of car obtained by inserting the above-mentioned transparent resin laminate into a mold of an injection molder and injecting another polycarbonate resin to its polycarbonate resin base material side and then injection molding to integrate.
The present invention provides a molded article for window glass and sun roof of car obtained by bending the above-mentioned transparent resin laminate.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described in detail below.
The transparent resin laminate comprises polycarbonate resin base material/acrylic resin layer/cured layer.
It is preferable that the polycarbonate resin base material has a weight average molecular weight of 24000 to 53000. In the above-mentioned range of weight average molecular weight, its linear expansion coefficient is in the range of 6×10
−5
/° C. to 8×10
−5
/° C. The larger the weight average molecular weight of the polycarbonate resin is, the larger the linear expansion coefficient of the polycarbonate resin becomes.
The form of the polycarbonate resin material is a molded article, a film, a sheet or a board.
The cured layer is formed by coating a composition comprising a silicone-containing polyorganosiloxane and a polymer ultraviolet (hereinafter, “UV”) absorbent on the acrylic resin.
It is preferable that the polyorganosiloxane is a hydrolyzate and/or a partial condensed product obtained by hydrolysis and condensation of organosilane represented by the general formula R
1
n
Si(OR
2
)
4−n
wherein n is an integer of 0 to 2 and it is a heat curing type.
R
1
in the organosilane is an organic group having 1 to 8 carbon atoms. Examples of R
1
include alkyl groups such as methyl group, ethyl group, n-propyl group, n-butyl group, i-butyl group, sec-butyl group, n-hexyl group and n-heptyl group, &ggr;-chloropropyl group, vinyl group, 3,3,3-trifluoropropyl group, glycidoxypropyl group, &ggr;-methacryloxypropyl group, &ggr;-mercaptopropyl group, phenyl group and 3,4-epoxycyclohexylethyl group. R
2
in the organosilane is an alkyl group having 1 to 5 carbon atoms or an acyl group having 1 to 4 carbon atoms. Examples of R
2
include methyl group, ethyl group, n-propyl group, n-butyl group, i-butyl group, sec-butyl group, tert-butyl group, acetyl group, propionyl group and butyryl group.
Examples of the organosilane include tetramethoxysilane, tetraethoxysilane, methyltrimethoxysilane, methyltriethoxysilane, ethyltrimethoxysilane, ethyltriethoxysilane, n-propyltrimethoxysilane, n-propyltriethoxysilane, i-propyltrimethoxysilane, i-propyltriethoxysilane, &ggr;-chloropropyltrimethoxysilane, &ggr;-chloropropylethoxysilane, vinyltrimethoxysilane, vinyltriethoxysilane 3,3,3-trifluoropropyltrimethoxysilane, 3,3,3-trifluoropropyltriethoxysilane, &ggr;-glycidoxypropyltrimethoxysilane, &ggr;-glycidoxypropyltriethoxysilane, &ggr;-methacryloxypropyltrimethoxysilane, &ggr;-methacryloxypropytriethoxysilane, &ggr;-mercaptopropyltrimethoxysilane, &ggr;-mercaptopropyltriethoxysilane, phenyl trimethoxysilane, phenyltriethoxysilane, 3,4-epoxycyclohexylethyltrimethoxysilane, 3,4-epoxycyclohexylethyltriethoxysilane, dimethyldimethoxysilane, diethyldimethoxysilane, diethyldiethoxysilane, di-n-propyldimethoxysilane, di-n-propyldiethoxysilane, di-i-propyldimethoxysilane, di-i-propyldiethoxysilane, diphenyldimethoxysilane and diphenyldiethoxysilane, among which tetramethoxysilane, tetraethoxysilane, methyltrimethoxysilane, methyltriethoxysilane, dimethyldimethoxysilane and dimethyldiethoxysilane are preferable.
The organosilane can be used alone or in the combination of two species or more. Further,
Kimura Takeshi
Sugimori Seiji
Yamamoto Takaichi
Boykin Terressa M.
Mitsubishi Gas Chemical Company Inc.
Sughrue & Mion, PLLC
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