JP5587527B2 - 構造用プラスチックに対する接着性が改善されたアクリルポリマーキャップストック - Google Patents
構造用プラスチックに対する接着性が改善されたアクリルポリマーキャップストック Download PDFInfo
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- JP5587527B2 JP5587527B2 JP2001215156A JP2001215156A JP5587527B2 JP 5587527 B2 JP5587527 B2 JP 5587527B2 JP 2001215156 A JP2001215156 A JP 2001215156A JP 2001215156 A JP2001215156 A JP 2001215156A JP 5587527 B2 JP5587527 B2 JP 5587527B2
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- Prior art keywords
- acrylic
- weight
- layer
- product
- methyl methacrylate
- Prior art date
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- Y10T428/31924—Including polyene monomers
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31855—Of addition polymer from unsaturated monomers
- Y10T428/31909—Next to second addition polymer from unsaturated monomers
- Y10T428/31928—Ester, halide or nitrile of addition polymer
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- Laminated Bodies (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
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Description
本発明のその他の目的、特徴及び利点は、以下の説明から明らかになるであろう。
本発明は、フィードブロック同時押出を用いることによって容易に成形することができる複合材料においてHIPS及び同様の構造用プラスチック用のキャップストックとして用いることができるアクリル組成物を提供することに関する。本発明は、構造用プラスチックに対する接着性が改善されたキャップストックを形成させるために用いることができるアクリル樹脂組成物に関する。
・構造用プラスチックの溶融流と、
・アクリル酸エステルポリマーとアクリルポリマー系添加剤とのブレンドの溶融流と
を押出機排出導管中で一緒にして、導管の断面に形状一致し且つ構造用プラスチックと前記ブレンドとの間の境界面が比較的はっきり画定された単一の層状化された溶融材料流を形成させ、次いでシート成形押出ダイ(一般的にはそのダイリップが前記の境界面に対して位置合わせされたもの)に前記層状化溶融材料流を通すことを含む。
(a)ポリメチルメタクリレート、又はメタクリル酸アルキル/アクリル酸アルキルコポリマーをベースとするマトリックス10〜95%;
(b)改質剤0〜60%;
(c)次のものから成るアクリルポリマー系添加剤5〜40%:
・メタクリル酸メチル5〜90%、
・メタクリル酸C2〜C6(好ましくはC4)アルキル10〜95%、及び
・メタクリル酸又はアクリル酸若しくはそのC1〜C5エステル0〜10%。
本明細書において用語「分子量」とは、重量平均分子量を意味する。分子量は、慣用のゲル透過クロマトグラフィー法により、キャリブレーション用のメタクリレート標準物質を用いて概算される。用語「ダルトン」とは、原子質量単位を意味する。
(1)メタクリル酸アルキルホモポリマー、
(2)メタクリル酸アルキルと別のメタクリル酸アルキル、アクリル酸アルキル又はメタクリル酸とのコポリマー、
(3)アクリル酸アルキルホモポリマー、及び
(4)アクリル酸アルキルと別のアクリル酸アルキル又はメタクリル酸アルキルとのコポリマー
を意味する。
中心部(コア)/外殻部(シェル)の粒子構造は乳化法によってグラフトさせることによって達成することができ、これはしばしば耐衝撃性改良剤を製造するための好ましい方法とされる。
本発明の積層品を製造するのに使用し得る装置は、各々の物質(下記の例のアクリル樹脂組成物及びHIPS樹脂)を溶融させて移送するための押出機、押出機からの2つの溶融流を一緒にするためのフィードブロック、及び慣用の単一マニホールドシートダイから成る装置を含むもので、該ダイから、二層の押出物が慣用の3ロールスタック艶出しユニット、冷却ラック、及び引張ロールに出ていく。この装置は、当分野で良く知られている。
接着力について本明細書中で使用するテストは、下記の手順から成る。テストの初めの部分は、かみそりの刃を2つ層の間に押し込み、次いで2つ層を物理的に引き離すことから成る。接着力レーティングシステムを下記の通りに設定した:不良、並み、良好及び優秀並びに不良/並み、並み/良好、良好/優秀の下位範疇。2人の異なる分析者が各々のテストを少なくとも3度再現した。不一致が存在した稀な場合では、テストを再ランし、分析者は多かったレーティングに合意した。
例1は、PMMAキャップストック中のMMA/BMAポリマーがHIPSへの接着力を高める利点について例示する。全アクリル樹脂層(商用の耐衝撃性アクリル樹脂にBMAを含有するアクリルコポリマー系添加剤を加える)中にほんの3.6%のBMAが、HIPSへの接着力の驚くべき利点をもたらすことが立証される。
例2は、HIPSとのアクリルの接着力に対しての、特定のアクリルコポリマーの利点(効果)、並びにコポリマー中に必要なBMA及びEAの量を例示する。メタクリル酸ブチル(BMA)を添加剤として使用しない場合には、接着力の向上を達成するためには、MMAベースのコポリマー中に所定のレベルを超える量のBMAが必要であることがわかる。例Bにおけるアクリルポリマーを、アクリル樹脂層についてゾーン温度450°F〜475°F(232°〜246℃)及びHIPS層についてゾーン温度460°F(238℃)に設定したKillion押出機によってHIPSの上に同時押出する。使用したHIPSはAmoco I 400Eであり、これはAmoco Chemicalsにより販売されている耐衝撃性で中庸流動性の汎用HIPSである。
例3は、BMAを32%有するコポリマーP(MMA/BMA)が、ポリスチレン(Dow PS)にどんな具合で接着するかを立証する。表にしたアクリルポリマーを、Carver Press上でポリスチレンの上に380°F(193℃)及び1500psi(10MPa)で2分間圧縮成形する。接着力の利点を得るのに、上述した圧縮成形条件下でアクリルコポリマー中にBMAを14%よりも多く必要とするが、コポリマーを添加剤としてアクリル樹脂層に加える場合には、必要とするBMAはたった3.6%であることがわかる。
例4は、ポリマー系添加剤P(MMA64.4、BMA35.4)及びP(MMA36.6及びBMA63.4)がHIPSへのアクリルの接着力にどのように影響を与えるかを例示する。
温度が上記のVSサンプル及びHFI10サンプルの接着力に与える効果を求めるために、例4のBを10%有する及び有しない、並びに例4のAを10%有する及び有しない、VSサンプル及びHFI−10サンプルを、Carver Press上でHIPSの上に様々な温度で圧縮成形する。下記の表(例5)において、データは、殆どすべての場合において、例4のBを有するアクリル樹脂が、添加剤の内のいずれをも持たないアクリル樹脂と比べて、HIPSとの接着力の向上をもたらしたことを示す。このデータはまた、例4のAを加えると、例4のBを加えた場合と比べて接着力の向上がもたらされることも示す。使用したHIPSは、Huntsman Chemical Companyにより販売されている潤滑剤をもたない汎用HIPSであるHuntsman PS 840 JINである。
*=標準のアクリル誘導体のHIPSへの良好な接着は非常に狭い加工条件下で達成されるだけであり、例えば表中のHFI10の場合では350°F(177℃)において達成されるだけである。しかし、本明細書中に示す本発明の技術進歩は、実用的な同時押出加工条件を拡大することが強調されるべきである。
VS=Plexiglas(登録商標)VS
HFI 10=Plexiglas(登録商標)HFI 10
例6は、様々な銘柄のアクリル樹脂中の例4の添加剤Aが、様々な銘柄のHIPSへの接着力に与える決定的な効果を例示する。例6では、アクリル樹脂と例4のプラスチック添加剤A10重量%とのブレンドを調製し、次いでこれらのブレンドをHIPSの上に同時押出する。ブレンドをおよそ480°F(249℃)、278rpmの二軸スクリュー押出機上で、速度45ポンド/時(20kg/時)で調製する。同時押出を、シート押出ダイに送り込まれる2つの一軸スクリュー押出機(主押出機ではHIPS基材、及びサテライト押出機ではアクリル樹脂)から成る同時押出ライン上でランする。シートダイ温度を420°F(216℃)に設定する。HIPSを用いる主押出機を各々のゾーンについて380°F(193℃)に設定する。サテライト押出機を各々のゾーンについて430°F〜450°F(221℃〜232℃)に設定する。バレット温度は380°F(193℃)である。アダプター温度を420°F(216℃)に設定し、ロール温度を140°F(60℃)に設定する。
C−MMA60%/BMA40%
D−MMA67%/BMA31%/EA2%
E−MMA68%/BMA32%
F−MMA80%/BMA20%
Claims (12)
- ポリスチレン構造用プラスチックの層の上に厚さ0.1〜2.5mmの保護層が設けられて成る複合材料製品であって、前記保護層が、
(a)ポリメチルメタクリレート、又はメタクリル酸メチルとアクリル酸C1〜C4アルキル0.1〜20重量%とのコポリマーをベースとするマトリックス10〜95重量%;
(b)改質剤0〜60重量%;
(c)次のもの:
・メタクリル酸メチル20〜80重量%、及び
・メタクリル酸ブチル20〜80重量%
から成り且つ40000〜300000の分子量を有する、層間の接着強度を高めるアクリルポリマー系添加剤5〜40重量%:
を含む、前記複合材料製品。
- ポリスチレン構造用プラスチック及び厚さ0.1〜2.5mmの保護層から成る請求項1に記載の複合材料製品の製造方法であって、
・ポリスチレン構造用プラスチックの溶融流と、
・アクリル酸エステルポリマーとアクリルポリマー系添加剤とのブレンドの溶融流と
を押出機排出導管中で一緒にして、導管の断面に形状一致する単一の層状化された溶融材料流を形成させ、次いでダイリップが前記構造用プラスチックと前記ブレンドの間の境界面に対して位置合わせされたシート成形押出ダイに前記の層状化された溶融材料流を通すことを含む、前記方法。
- 前記アクリルポリマー系添加剤がメタクリル酸メチル50〜80重量%及びメタクリル酸ブチル20〜50重量%から成り且つ40000〜100000の分子量を有する、請求項1記載の複合材料製品。
- 次の(a)並びに(b)の2つの層から成る同時押出製品:
(a)ポリスチレン構造用プラスチックから成る第一の層;
(b)次の(i)及び(ii)から成る第二の層:
(i) ポリメチルメタクリレート、又はメタクリル酸メチルとアクリル酸C1〜C4アルキル0.1〜20重量%とのコポリマーをベースとするマトリックス10〜95重量%、並びに
(ii)次のもの:
・メタクリル酸メチル20〜80重量%、及び
・メタクリル酸ブチル20〜80重量%
から成り且つ40000〜300000の分子量を有する、層間の接着強度を高めるアクリルポリマー系添加剤。
- 前記ポリスチレンが耐衝撃性ポリスチレン又は結晶質ポリスチレンである、請求項4記載の製品。
- 前記アクリルポリマー系添加剤が
(a)メタクリル酸メチル50〜80重量%、及び
(b)メタクリル酸ブチル20〜50重量%
から成る、請求項4記載の製品。
- 前記の第二の層が
(i)メチルメタクリレート樹脂60〜95重量%及び
(ii)アクリルポリマー系添加剤5〜40重量%
から成る、請求項4記載の製品。
- 前記の第1の層が顔料、染料、充填剤、PS、アクリル樹脂又はHIPS再生材料を含有する、請求項4記載の製品。
- 次の(a)並びに(b)の2つの層から成る同時押出製品:
(a)耐衝撃性ポリスチレンから成る第一の層50〜95重量%;
(b)次の(i)及び(ii)から成る第二の層5〜50重量%:
(i) ポリメチルメタクリレート、又はメタクリル酸メチルとアクリル酸C1〜C4アルキル0.1〜20重量%とのコポリマーをベースとするマトリックス60〜95重量%、並びに
(ii)次のもの:
・メタクリル酸メチル20〜80重量%、及び
・メタクリル酸ブチル20〜80重量%
から成り且つ40000〜300000の分子量を有する、層間の接着強度を高めるコポリマーであるアクリルポリマー系添加剤5〜40重量%。
- 前記アクリルポリマー系添加剤がメタクリル酸メチル50〜80重量%及びメタクリル酸ブチル20〜50重量%から成り且つ40000〜300000の分子量を有する、請求項9記載の製品。
- 前記アクリルポリマー系添加剤がメタクリル酸メチル20〜50重量%及びメタクリル酸ブチル50〜80重量%から成り且つ40000〜100000の分子量を有する、請求項9記載の製品。
- 衛生用途、家電製品ハウジング、家電製品ライナー、家電製品ドア、建築用ドア、窓トリム、シャッター、自動車部品又は農業装置において用いられる請求項9記載の製品。
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US21870300P | 2000-07-17 | 2000-07-17 | |
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US6420050B2 (en) * | 2000-02-03 | 2002-07-16 | Ferro Corporation | Multilayer composite structure with formulated acrylic cap |
-
2001
- 2001-06-14 US US09/881,087 patent/US6852405B2/en not_active Expired - Lifetime
- 2001-07-09 AU AU54282/01A patent/AU777062B2/en not_active Ceased
- 2001-07-09 NZ NZ51283901A patent/NZ512839A/xx not_active IP Right Cessation
- 2001-07-11 EP EP20010305961 patent/EP1174465B1/en not_active Expired - Lifetime
- 2001-07-11 DE DE2001602420 patent/DE60102420T2/de not_active Expired - Lifetime
- 2001-07-11 AT AT01305961T patent/ATE262560T1/de active
- 2001-07-12 CA CA 2353036 patent/CA2353036C/en not_active Expired - Lifetime
- 2001-07-16 BR BR0102927A patent/BR0102927B1/pt not_active IP Right Cessation
- 2001-07-16 AR ARP010103397 patent/AR030248A1/es active IP Right Grant
- 2001-07-16 JP JP2001215156A patent/JP5587527B2/ja not_active Expired - Fee Related
- 2001-07-16 KR KR1020010042725A patent/KR100826458B1/ko active IP Right Grant
- 2001-07-17 MX MXPA01007232A patent/MXPA01007232A/es active IP Right Grant
- 2001-07-17 TW TW90117449A patent/TWI297712B/zh not_active IP Right Cessation
- 2001-07-17 CN CNB011230428A patent/CN1270890C/zh not_active Expired - Fee Related
Also Published As
Publication number | Publication date |
---|---|
MXPA01007232A (es) | 2003-05-19 |
BR0102927A (pt) | 2002-03-05 |
AR030248A1 (es) | 2003-08-13 |
EP1174465B1 (en) | 2004-03-24 |
CA2353036C (en) | 2011-01-25 |
ATE262560T1 (de) | 2004-04-15 |
BR0102927B1 (pt) | 2010-08-10 |
KR100826458B1 (ko) | 2008-05-02 |
CA2353036A1 (en) | 2002-01-17 |
EP1174465A1 (en) | 2002-01-23 |
US20020025420A1 (en) | 2002-02-28 |
AU777062B2 (en) | 2004-09-30 |
KR20020007226A (ko) | 2002-01-26 |
DE60102420D1 (de) | 2004-04-29 |
JP2002097333A (ja) | 2002-04-02 |
CN1270890C (zh) | 2006-08-23 |
CN1392046A (zh) | 2003-01-22 |
DE60102420T2 (de) | 2005-03-03 |
US6852405B2 (en) | 2005-02-08 |
NZ512839A (en) | 2002-11-26 |
TWI297712B (en) | 2008-06-11 |
AU5428201A (en) | 2002-01-24 |
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