JPH08229980A - Transparent high-rigidity resin plate-like form and manufacture thereof - Google Patents

Abstract

PURPOSE: To manufacture a transparent high-rigidity resin plate-like form of stable quality in an efficient and economical manner by adding a glass filler component so that its amount is equal to a specific wt.% of the total weight of a molding, and injecting/charging the molten blend to laminate it to a film or a sheet in one piece. CONSTITUTION: A layer 2 of a reinforced resin composition which is integrally laminated with a transparent thermoplastic resin film or sheet 1, 1', is formed between two pieces of the film or sheet. In addition, functional layers 3, 3' provided as desired form the outer surface of a molding. A glass filler component has a difference of 0.015 or less between the refractive index of the glass filler component and that of a transparent thermoplastic resin component. The blending quantity of the glass filler component is equal to 1 to 60wt.%, preferably a range of 5 to 30 wt.%, of the total wt. of a plate-like form molding including the reinforced resin composition consisting of the transparent thermoplastic resin and the glass filler, and the thermoplastic resin film of sheet which is integrated with the reinforced resin composition.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is an alternative to a transparent window glass or a glass structure having a function or a design property applied thereto.
The present invention relates to a transparent high-rigidity resin plate and a method for manufacturing the same. Specifically, the present invention is particularly highly rigid, and has excellent transparency, lightness, safety, durability, and economic efficiency, and is suitable for many applications such as automobile parts, medical care, safety, building materials, household products, and the like. TECHNICAL FIELD The present invention relates to a resin plate and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, glazing materials such as window glass in automobile parts and building materials have a transparent glass portion and
Usually, it is composed of a metal, a resin, a frame of wood, etc. into which this is fitted. These things are heavy,
There were problems such as cracking, a large number of parts and assembling steps, low productivity, designing was a separate step, and its durability was poor.

Therefore, in order to reduce the weight, a plastic molded product formed by heat bending or injection molding of a synthetic resin extruded plate or a cast plate is applied to the glass portion instead of glass, and high rigidity is achieved. In the required applications, the improvement was attempted by adding an appropriate filler such as a glass filler.

[0004]

However, when a glass filler or the like is added, the refractive index of the glass filler (usually 1.555 for conventional glass filler) and the refractive index of the transparent resin (for example, for conventional polycarbonate resin) Usually, the difference from 1.585) is large, so there is a drawback that the transparency is impaired.

Even when the refractive index of the glass filler and the refractive index of the transparent resin are perfectly matched, the transparency depends on the interface state between the glass filler and the transparent resin, the surface state of the molded product, and the wall thickness of the molded product. It was damaged and it was very difficult to secure transparency stably. Further, if the glass portion is made of plastic, a hard coating step for imparting surface hardness and a printing step for imparting design are additionally required.

That is, in the prior art, when a plastic molded product is applied to a glass portion requiring high rigidity, transparency is impaired, and the same number of parts and assembling man-hours are required. Further, there is a problem that a hard coat and a printing process are required.

[0007]

Means for Solving the Problems The inventors of the present invention have made extensive studies as a result of solving the above problems and obtaining a method for industrially producing a transparent high-rigidity resin plate. As a glass filler to be blended with the thermoplastic resin, a glass filler having a difference in refractive index of 0.015 or less with the resin component is selected, and by applying the lamination integration technique by injection molding, the transparency is remarkably excellent and desired. The inventors have found that a high-rigidity resin plate-shaped body having functional properties and design characteristics according to the above can be economically manufactured in a relatively small number of steps, and have reached the present invention.

[0008] That is, the present invention is mounted in a mold,
Between two transparent thermoplastic resin films or sheets,
A reinforced resin composition containing a transparent thermoplastic resin component and a glass filler component, wherein the difference in refractive index between the two components is 0.
It is not more than 015, and is mixed so that the amount of the glass filler component is 1 to 60% by weight of the total weight of the molded product, and is melt-injected and filled to be laminated and integrated with the film or sheet. It is a transparent high-rigidity resin plate-shaped body characterized by the above.

The method for producing a transparent high-rigidity resin plate-like body of the present invention typically includes the following steps. (1) From a thermoplastic resin film or sheet, if desired, provided on one surface with a functional layer having at least one function selected from the group consisting of hard coat, antifogging, antistatic, antireflection and heat ray blocking , A step of making two punched pieces having the same shape as the surface shape of the molded product,
(2) A step of mounting the two punched pieces in an injection-molding die so that the functional layer, if a functional layer is provided, is in contact with the die, (3) attaching the die A reinforced resin composition containing a closed, transparent thermoplastic resin component and a glass filler component, wherein the difference in refractive index between both components is 0.015 or less,
The amount of the glass filler component is 1 to 60 of the total weight of the molded product.
A step of melt-injecting and blending a mixture blended so as to be in a weight% with the thermoplastic resin film or sheet so as to be integrated with the thermoplastic resin film or sheet; and (4) opening the mold to obtain a molded product. Process of taking out

The present invention will be described with reference to the accompanying drawings.
FIG. 1 is a conceptual cross-sectional view showing a transparent high-rigidity resin plate-shaped molded product of the present invention. Between the two transparent thermoplastic resin films or sheets (1) and (1 ′), a layer (2) of a reinforced resin composition laminated and integrated with these is formed, and provided as desired. Functional layer (3),
(3 ') constitutes the outer surface of the molded product.

The transparent thermoplastic resin component constituting the reinforced resin composition used in the present invention is not particularly limited, but is preferably a polycarbonate resin, a composition of polycarbonate resin and polybutylene terephthalate resin, polymethylmethacrylate resin, acrylonitrile and styrene. A copolymer of
Examples thereof include transparent resins such as polystyrene resins and copolymers of methyl methacrylate and styrene, or compositions thereof.

Aromatic polycarbonate is preferably used as the polycarbonate resin. In particular,
2,2-bis (4-hydroxyphenyl) -propane,
Obtained by a known method from at least one divalent phenolic compound exemplified by 2,2-bis (3,5-dibromo-4-hydroxyphenyl) -propane and a carbonate precursor exemplified by phosgene. The polymer can be illustrated. In particular, in the present invention, an aromatic polycarbonate resin having a viscosity average molecular weight of 15,000 to 30,000 calculated from the viscosity of a methylene chloride solution at 25 ° C. is preferable from the viewpoints of high rigidity, transparency, heat resistance and impact resistance.

The glass filler component constituting the reinforced resin composition used in the present invention has a refractive index of 0.015 or less from the refractive index of the transparent thermoplastic resin component. It is necessary and particularly preferably 0.010 or less. The difference in refractive index of both components is 0.015
If it is larger, the transparency of the high-rigidity resin plate is lowered, which is not preferable.

The shape of the glass filler is not particularly limited, and any shape such as glass fiber, glass flakes, glass beads, and glass powder can be selected as long as it is usually blended with the thermoplastic resin for injection molding. These glass fillers are preferably surface-treated with a silane coupling agent so that they are well blended with the transparent thermoplastic resin component and uniformly dispersed during blending or melt injection filling. The most widely used are glass fibers, which are so-called chopped strands. The short fibers generally have a length of 0.005 to 30 mm and a diameter of 5 to 50 μm. Further, the glass used as the filler accelerates the decomposition of the transparent thermoplastic resin, and therefore, non-alkali glass or a glass close to this is preferable.

The compounding amount of the glass filler component is such that a reinforced resin composition composed of a transparent thermoplastic resin and a glass filler and a transparent thermoplastic resin film or sheet integrated with the reinforced resin composition are used. 1-60 of total weight
%, Preferably 5 to 30% by weight. If this blending amount is too small, it becomes impossible to give rigidity to the molded product, and if it is too large, not only the deterioration of the optical properties becomes large, but also the molecular weight of the transparent thermoplastic resin is lowered in some cases, That characteristic is not utilized.

The reinforcing resin composition used in the present invention may contain a dye in order to give an arbitrary color tone.
For example, azo dyes, cyanine dyes, quinoline dyes, perylene dyes and the like can be selected from those usually used for coloring thermoplastic resins. The blending amount may be appropriately selected within a range that does not impair the transparency. In addition, an effective expression amount of, for example, a stabilizer, a release agent, or an ultraviolet absorber may be added within a range that does not impair the object of the present invention.

The transparent thermoplastic resin film or sheet used in the present invention usually has a thickness of 100 to 100.
0 μm, preferably 200 to 700 μm,
There is no limitation as long as it is a thermoplastic resin film or sheet having transparency. Taking into consideration that the thermoplastic resin film or sheet is laminated and integrated with the reinforced resin composition by melt injection filling, the transparent thermoplastic resin component (hereinafter referred to as an injection resin) that normally constitutes the composition is taken into consideration. It is preferable from the viewpoint of heat fusion property and optical uniformity. If desired, the film or sheet may be provided on one surface with a functional layer having at least one function selected from the group consisting of hard coat, antifogging, antistatic, antireflection, and heat ray shielding.

As the thermoplastic resin constituting the film or sheet, a polycarbonate resin or a composition thereof has good transparency and excellent impact resistance.
It is suitable for applications such as a high-rigidity resin plate-like body that requires impact resistance, for example, window glass. The polycarbonate resin is preferably aromatic polycarbonate, and may be either a homopolymer or a copolymer. An aromatic polycarbonate resin having a viscosity average molecular weight of 20,000 to 35,000 converted from the viscosity of a methylene chloride solution at 25 ° C. is preferable. Further, if possible, it is better to use a resin having a larger molecular weight than the injection resin in order to prevent the film or sheet or the functional layer or the design imparting layer, which may be formed thereon, from losing its shape.

Various conventionally known methods are used to form the functional layer on the thermoplastic resin film or sheet. In order to form the hard coat layer, a primer layer is provided if desired, and a hard coat agent such as an epoxy type, an acrylic type, an amino resin type, a polysiloxane type, or a colloidal silica type is applied, and a means such as heat or ultraviolet rays is applied. The method of hardening by can be used. For the formation of the anti-fogging layer, a method of applying an anti-fogging coating which usually contains a water-soluble or hydrophilic resin and a surfactant as essential components and curing it can be used. In addition, an antistatic layer, an antireflection layer, a heat ray blocking layer, etc. should also be formed by applying a paint that provides these functions and curing, or by vacuum-depositing a thin film layer that has these functions. You can Further, these functional layers may be a composite layer having two or more functions at the same time. Further, in addition to these functional layers, or the functional layer, it is possible to form the designability imparting layer by a method such as applying a cosmetic coating treatment in advance to give the designability.

In the present invention, a thermoplastic resin film or sheet is used for the purpose of promoting heat fusion with the reinforced resin composition at the time of melt injection and filling, and ensuring more reliable lamination integration.
It is also possible to apply a primer coat. As the resin used for the primer coat, one having a higher melt viscosity than the injection resin and being well adhered to the film or sheet is selected. For example, there is a resin of the same type as the injection resin and having a higher molecular weight, a resin mainly composed of this resin, or a resin which is cured by heat or ultraviolet rays. Specifically, when the injection resin is a polymethylmethacrylate resin or a copolymer of acrylonitrile and styrene, a solution of an acrylate or methacrylate homopolymer or copolymer resin, an acrylate or methacrylate heat or UV curable paint is used. preferable. When the injection resin is a polystyrene resin, an acrylate or methacrylate copolymer resin or a composition containing the same, specifically, an acrylate or methacrylate copolymer resin and an acrylate or methacrylate homopolymer resin composition may be mentioned. . In particular, a copolymer resin containing a flexibility-imparting monomer such as butyl acrylate as a comonomer component, for example, a copolymer of high molecular weight methyl methacrylate and butyl acrylate, or a composition containing the same is preferable. The primer coat layer can also be formed by laminating, for example, a polycarbonate resin film or sheet, a film such as an acrylate or methacrylate copolymer resin, a copolymer of ethylene and vinyl acetate, a copolymer of acrylonitrile and styrene, or the like. The laminated sheet is preferably used as a primer layer having excellent adhesiveness when a polymethylmethacrylate resin, a polystyrene resin, a copolymer of acrylonitrile and styrene, or the like is used as the injection resin.

[0021]

[Examples] The present invention will be specifically described below with reference to Examples.
The present invention is not limited to this without departing from the gist thereof. The physical properties of the molded articles obtained in the following examples and comparative examples were measured as follows.

Bending elastic modulus: Using a test piece of a predetermined shape, which was cut out from a disk-shaped molded product, obtained in Examples or Comparative Examples, the bending elastic modulus in the thickness direction of the disk was measured according to JIS K7203. did.

Haze: obtained in Examples or Comparative Examples,
The disk-shaped molded product was used as a sample and measured using a haze meter (Suga Test Instruments Co., Ltd., trade name HGM-2DP).

Parallel light transmittance: According to JIS K7105, a disk-shaped molded product obtained in the examples or comparative examples is used as a sample.
And the average light transmittance in the thickness direction of the disk was calculated.

Izod impact strength: Using a test piece (with a notch) of a predetermined shape, which was cut out from a disk-shaped molded product, obtained in Examples or Comparative Examples, and according to JIS K7110, it was orthogonal to the thickness direction of the disk. The Izod impact strength was measured in the following direction.

Example 1 A 0.5 mm thick polycarbonate resin sheet (made by Mitsubishi Gas Chemical Co., Inc., trade name Iupilon sheet CFI-1) having a silicon thermosetting hard coat layer on one side.
The viscosity average molecular weight of the resin in the sheet is 28,000. ) Two pieces are mounted in a disk-shaped mold having a diameter of 100 mm and a thickness of 4 mm so that the hard coat layer serves as the outer surface of the molded product, and the reinforced resin composition melted in the space between both sheets is
Injection filling was performed from the side gate, and laminated integral molding was performed. As the reinforced resin composition, a polycarbonate resin (made by Mitsubishi Gas Chemical Co., Inc., trade name Iupilon S-3000) having a viscosity average molecular weight of 21,000 which is an injection resin and a refractive index of 1.585, and an average fiber diameter of 16 μm, a refractive index The glass fiber of 1.579 was pelletized by an extruder (Tanabe Plastic Co., Ltd., trade name VS-40) and used. The glass content was 10% by weight based on the total weight of the integrally molded product.

The physical properties of the molded product were measured according to the above-mentioned measuring methods. The results and the molding materials used are shown in Table 1. The following examples and comparative examples are also shown in Table 1.

Example 2 The laminated integral molding was carried out in the same manner as in Example 1 except that the glass content was 20% by weight.

Example 3 As a reinforced resin composition, a copolymer of methyl methacrylate and styrene having a refractive index of 1.555 (manufactured by Nippon Steel Chemical Co., Ltd., trade name F-71902) and an average fiber diameter of 13 μm.
Then, laminated integral molding was carried out in exactly the same manner as in Example 1 except that glass fiber having a refractive index of 1.555 was used.

Example 4 The laminated integral molding was carried out in the same manner as in Example 3 except that the glass content was 20% by weight.

Comparative Examples 1 to 4 In the above Examples 1 to 4, lamination integral molding was carried out in exactly the same manner as in the above Examples except that the polycarbonate resin sheet was not mounted.

COMPARATIVE EXAMPLE 5 Except that the above polycarbonate resin sheet was not mounted and glass fiber was not added to the injection resin,
Laminated and integral molding was carried out in exactly the same manner as in Example 1.

Comparative Example 6 Except that the above polycarbonate resin sheet was not mounted and glass fiber was not added to the injection resin,
Lamination integral molding was carried out in exactly the same manner as in Example 3.

Comparative Example 7 In the above-mentioned Example 2, the glass fiber was made to have an average fiber diameter of 13 μm.
m, except that glass fiber having a refractive index of 1.555 is used,
The laminated integral molding was carried out in the same manner as in Example 2.

[0035]

[Table 1]

The meanings of the symbols in Table 1 are as follows. Symbol Meaning PC Polycarbonate resin. Mitsubishi Gas Chemical Co., Ltd., trade name Iupilon S-3000. Viscosity average molecular weight 21,000, refractive index 1.585. MS A copolymer of methyl methacrylate and styrene. Product name F-71902 manufactured by Nippon Steel Chemical Co., Ltd. Weight average molecular weight 22900, refractive index 1.555.

[0037]

According to the present invention, a transparent high-rigidity resin plate can be manufactured with stable quality, efficiently and economically. On the surface of such a resin plate, functional layers such as a hard coat layer, an antifogging layer, an antistatic layer, an antireflection layer, a heat ray blocking layer, and various design imparting layers are added to increase extra steps. Can be easily formed. The resin plate obtained in this manner has high rigidity, transparency, lightness, safety, durability, and economic efficiency, and is used for automobile window glass, medical care, security, building materials, household products, etc. Applied to many uses.

[Brief description of drawings]

FIG. 1 is a conceptual cross-sectional view showing a transparent high-rigidity resin plate-shaped molded product of the present invention.

[Explanation of symbols]

 1, 1'Transparent thermoplastic resin film or sheet 2 Layer of reinforced resin composition 3, 3'Functional layer

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁶ Identification code Office reference number FI technical display area // B29K 101: 12 105: 32 309: 08 B29L 9:00

Claims (6)

[Claims] 1. A reinforced resin composition containing a transparent thermoplastic resin component and a glass filler component between two transparent thermoplastic resin films or sheets mounted in a mold, wherein both components are refracted. The difference in the ratio is 0.015 or less and the glass filler component is blended in an amount of 1 to 60% by weight based on the total weight of the molded article, and the mixture is melt-injected and filled to obtain the film or sheet. A transparent, high-rigidity resin plate-shaped body characterized by being laminated and integrated. 2. The thermoplastic resin component of the reinforced resin composition is a polycarbonate resin, a polymethylmethacrylate resin, a copolymer of acrylonitrile and styrene, a polystyrene resin, a copolymer of methylmethacrylate and styrene, or a composition of these resins. The transparent high-rigidity resin plate-like body according to claim 1, which is a product. 3. The transparent high-rigidity resin plate-like body according to claim 2, wherein the thermoplastic resin component is an aromatic polycarbonate or a composition thereof. 4. The above-mentioned film or sheet is provided with a functional layer having at least one function selected from the group consisting of hard coat, antifogging, antistatic, antireflection and heat ray shielding on one surface thereof, and The transparent high-rigidity resin plate-like body according to claim 1, wherein the layer constitutes an outer surface of the molded product. 5. The transparent high-rigidity resin plate-like body according to claim 1, wherein the thermoplastic resin forming the film or sheet is an aromatic polycarbonate or a composition thereof. 6. A transparent thermoplastic resin film having a functional layer having at least one function selected from the group consisting of hard coat, antifogging, antistatic, antireflection and heat ray blocking on one surface. Alternatively, a step of forming two punched pieces having the same shape as the surface shape of the molded product from the sheet, (2) so that the functional layer of the two punched pieces is in contact with the mold. A step of mounting in a mold for injection molding, (3) a reinforced resin composition containing a transparent thermoplastic resin component and a glass filler component, which is closed and has a difference in refractive index between the two components of 0. 0.15 or less, and the glass filler component is blended in an amount of 1 to 60% by weight based on the total weight of the molded product, and melt-inject-filled to form a laminate with the thermoplastic resin film or sheet. Process (4) A method for producing a transparent high-rigidity resin plate-like body, comprising the step of opening the mold and taking out a molded product.