Film, laminated film and laminated structure

Details Film, laminated film and laminated structure Film, laminated film and laminated structure

1999-05-17

2001-09-04

Thibodeau, Paul (Department: 1773)

Stock material or miscellaneous articles

Structurally defined web or sheet

Including components having same physical characteristic in...

C428S516000

Reexamination Certificate

active

06284355

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates to a film superior in its appearances and scratch resistance, a laminated film superior in its appearances, scratch resistance and impact resistance, and a laminated structure comprising a substrate and the film or the laminated film, wherein the substrate and the film or the laminated film are laminated together.
BACKGROUND OF THE INVENTION
As a technique for improving appearances and scratch resistance of products made of thermoplastic resins, there are known a laminated film formed by laminating a film made of thermoplastic resins with a film superior in its appearances and scratch resistance, and a laminated structure formed by laminating a substrate made of thermoplastic resins with a film superior in its appearances and scratch resistance.
With respect to the former, i.e. the laminated film, there is proposed a three-layer laminated film composed of an olefinic resin-made film, a hard acrylic resin-made film superior in its transparency and scratch resistance and an adhesive resin interposed between both films to bond them, wherein the adhesive resin is, for example, a halogen- or acid anhydride group-carrying olefinic resin, as disclosed in, for example, JPA-9-193189, JP-A-9-234836, JP-B-6-26718 and JP-B-8-2550.
With respect to the latter, i.e. the laminated structure, there is known a laminated structure obtained by injecting an olefinic resin to be molded into a substrate on an olefinic resin-made film situated so as to attach closely to an inner wall of an injection molding mold, thereby performing simultaneously both a molding of the substrate and adhesion between the substrate and the film as disclosed in, for example, JP-B-50-19132.
Each of the references referred to above is incorporated herein by reference in its entirety.
However, the former laminated film has problems such that (1) its impact resistance is lower than that of the olefinic resin made-film per se, because an acrylic resin is used, which is harder and more fragile than the olefinic resin, (2) its thickness is unduly large and its production cost is too high, because the adhesive resin has to be interposed between the acrylic resin-made film and the olefinic resin-made film, and (3) the laminated film can hardly be recycled as it is, because the acrylic resin-made film and the olefinic resin-made film are different materials in kind.
The latter laminated structure also has a problem such that the scratch resistance thereof is not satisfactory, because the olefinic resin-made film used is low in its scratch resistance.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a film that is superior in its appearances and scratch resistance.
Another object of the present invention is to provide a laminated film that is superior in its appearances, scratch resistance, impact resistance and recyclablility, and free from an unduly thick thickness and that is low in its production cost.
A further object of the present invention is to provide a laminated structure that is superior in its appearances, scratch resistance, impact resistance and recyclability, which comprises a substrate and a film or a laminated film, which are laminated together in said laminated structure.
The present inventors have undertaken extensive studies to accomplish their objects, and, as a result, have found that the desired film, laminated film and laminated structure can be obtained by using a specific propylene based resin and a specific propylene based block copolymer, and thereby the present invention has been obtained.
Firstly, the present invention provides a film(F) obtained by heat-aging a film having a haze value of not higher than about 10%, which film(F) contains a propylene based resin having a modulus of elasticity in bending at 23° C. of from about 1300 to 2800 MPa.
Secondly, the present invention provides a laminated film(LF-1) comprising:
(i)a layer containing a propylene based resin having a modulus of elasticity in bending at 23° C. of from about 1300 to 2800 Mpa; and
(ii)a layer containing a propylene based block copolymer; wherein the propylene based block copolymer is prepared by a process comprising the steps of:
(I) carrying out copolymerization of propylene with ethylene until a content of a component(A) which is a propylene-ethylene copolymer component having a content of a repeating unit derived from ethylene of from about 1.5 to 6.0% by weight reaches from about 40 to 85% by weight based on the total weight of the component(A) and a below-defined component(B), and
(II) carrying out copolymerization of propylene with ethylene in the presence of the component(A) prepared in step (I) until a content of the component(B), which is a propylene-ethylene copolymer component having a content of a repeating unit derived from ethylene of from about 7 to 17% by weight, reaches from about 15 to 60% by weight based on the total weight of the components (A) and (B);
provided that an intrinsic viscosity, [&eegr;]B, of the component(B) is from about 2 to 5 dl/g, and a ratio of [&eegr;]B to an intrinsic viscosity, [&eegr;]A, of the component(A), [&eegr;]A, is from about 0.5 to 1.8; and
provided that said propylene based resin excludes a propylene based block copolymer which has a modulus of elasticity in bending at 23° C. of not lower than about 1300 Mpa.
Thirdly, the present invention provides a laminated film(LF-2) obtained by heat-aging the above-defined laminated film(LF-1).
Fourthly, the present invention provides a laminated structure(LS-1) comprising:
(a) a substrate containing an olefinic resin; and
(b) the above-defined film(F); wherein the substrate and the film(F) are laminated together.
Fifthly, the present invention provides a laminated structure(LS-2) comprising:
(a) a substrate containing an olefinic resin; and
(b) the above-defined laminated film(LF-1); wherein the substrate and the laminated film(LF-1) are laminated together, so that the film(LF-1) layer containing the propylene based block copolymer contacts a surface of the substrate.
Sixthly, the present invention provides a laminated structure(LS-3) obtained by heat-aging the above-defined laminated structure(LS-2).
Seventhly, the present invention provides a laminated structure(LS-4) comprising:
(a) a substrate containing an olefinic resin; and
(b) a laminated film obtained by heat-aging the above-defined laminated film(LF-1);
wherein the substrate and the laminated film are laminated together.
Eighthly, the present invention provides a laminated structure(LS-5) comprising:
(a) a substrate containing an olefinic resin; and
(b) a film having a haze value of not higher than about 10%, which film contains a propylene based resin having a modulus of elasticity in bending at 23° C. of from about 1300 to 2800 Mpa;
wherein the substrate and the film are laminated together.
Lastly, the present invention provides an interior or exterior car part or a casing part of an electric or OA(office automation) appliance comprising the above-defined laminated structure LS-1, LS-2, LS-3, LS-4or LS-5.
In the specification of the present invention, the “film” includes a sheet as well as a film, and the “appearances” are understood as meaning, in particularly, glossiness and deep appearance.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.


REFERENCES:
patent: 5118566 (1992-06-01), Wilhelm et al.
patent: 0266109-A2 (1988-05-01), None
patent: 0285071-A2 (1988-10-01), None
patent: 0644032-A2 (1995-03-01), None
patent: 0763560-A1 (1997-03-01), None
patent: 50-19132B (1975-07-01), None
patent: 51-097658A (1976-08-01), None
patent: 58-215333 (1983-1

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