WO2018212227A1 - フィルム製造用ドープ、及びフィルムの製造方法 - Google Patents
フィルム製造用ドープ、及びフィルムの製造方法 Download PDFInfo
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- WO2018212227A1 WO2018212227A1 PCT/JP2018/018895 JP2018018895W WO2018212227A1 WO 2018212227 A1 WO2018212227 A1 WO 2018212227A1 JP 2018018895 W JP2018018895 W JP 2018018895W WO 2018212227 A1 WO2018212227 A1 WO 2018212227A1
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- Prior art keywords
- weight
- graft copolymer
- acrylic resin
- polymer
- dope
- Prior art date
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- 238000000034 method Methods 0.000 title claims abstract description 68
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 48
- 229920000578 graft copolymer Polymers 0.000 claims abstract description 223
- 239000004925 Acrylic resin Substances 0.000 claims abstract description 180
- 229920000178 Acrylic resin Polymers 0.000 claims abstract description 180
- ZWEHNKRNPOVVGH-UHFFFAOYSA-N 2-Butanone Chemical compound CCC(C)=O ZWEHNKRNPOVVGH-UHFFFAOYSA-N 0.000 claims abstract description 120
- 239000002904 solvent Substances 0.000 claims abstract description 75
- 239000010410 layer Substances 0.000 claims abstract description 62
- 229920001169 thermoplastic Polymers 0.000 claims abstract description 53
- 239000004416 thermosoftening plastic Substances 0.000 claims abstract description 53
- 239000012792 core layer Substances 0.000 claims abstract description 39
- 239000002245 particle Substances 0.000 claims abstract description 34
- 229910052739 hydrogen Inorganic materials 0.000 claims abstract description 31
- 239000001257 hydrogen Substances 0.000 claims abstract description 31
- 230000008961 swelling Effects 0.000 claims abstract description 31
- 238000005266 casting Methods 0.000 claims abstract description 26
- 229920000642 polymer Polymers 0.000 claims description 218
- 239000010408 film Substances 0.000 claims description 167
- 239000000178 monomer Substances 0.000 claims description 166
- KNCYXPMJDCCGSJ-UHFFFAOYSA-N piperidine-2,6-dione Chemical group O=C1CCCC(=O)N1 KNCYXPMJDCCGSJ-UHFFFAOYSA-N 0.000 claims description 48
- 229920002554 vinyl polymer Polymers 0.000 claims description 33
- 230000009477 glass transition Effects 0.000 claims description 30
- 125000005397 methacrylic acid ester group Chemical group 0.000 claims description 28
- VVQNEPGJFQJSBK-UHFFFAOYSA-N Methyl methacrylate Chemical group COC(=O)C(C)=C VVQNEPGJFQJSBK-UHFFFAOYSA-N 0.000 claims description 19
- PEEHTFAAVSWFBL-UHFFFAOYSA-N Maleimide Chemical compound O=C1NC(=O)C=C1 PEEHTFAAVSWFBL-UHFFFAOYSA-N 0.000 claims description 13
- 239000008188 pellet Substances 0.000 claims description 12
- 239000000470 constituent Substances 0.000 claims description 11
- 230000001681 protective effect Effects 0.000 claims description 10
- 125000004414 alkyl thio group Chemical group 0.000 claims description 9
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 claims description 9
- 238000010030 laminating Methods 0.000 claims description 7
- 239000012788 optical film Substances 0.000 claims description 7
- VANNPISTIUFMLH-UHFFFAOYSA-N glutaric anhydride Chemical group O=C1CCCC(=O)O1 VANNPISTIUFMLH-UHFFFAOYSA-N 0.000 claims description 6
- FPYJFEHAWHCUMM-UHFFFAOYSA-N maleic anhydride Chemical compound O=C1OC(=O)C=C1 FPYJFEHAWHCUMM-UHFFFAOYSA-N 0.000 claims description 5
- NIXOWILDQLNWCW-UHFFFAOYSA-M acrylate group Chemical group C(C=C)(=O)[O-] NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 claims description 4
- 239000002356 single layer Substances 0.000 claims description 4
- 238000001704 evaporation Methods 0.000 claims description 3
- 238000003475 lamination Methods 0.000 claims description 3
- 239000000758 substrate Substances 0.000 claims description 2
- 125000000686 lactone group Chemical group 0.000 claims 1
- 239000011258 core-shell material Substances 0.000 abstract description 6
- 238000006116 polymerization reaction Methods 0.000 description 239
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 84
- 239000007864 aqueous solution Substances 0.000 description 68
- YMWUJEATGCHHMB-UHFFFAOYSA-N Dichloromethane Chemical compound ClCCl YMWUJEATGCHHMB-UHFFFAOYSA-N 0.000 description 60
- 239000000203 mixture Substances 0.000 description 56
- 239000011347 resin Substances 0.000 description 55
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- -1 for example Chemical compound 0.000 description 54
- USHAGKDGDHPEEY-UHFFFAOYSA-L potassium persulfate Chemical compound [K+].[K+].[O-]S(=O)(=O)OOS([O-])(=O)=O USHAGKDGDHPEEY-UHFFFAOYSA-L 0.000 description 53
- 238000006243 chemical reaction Methods 0.000 description 43
- 125000004432 carbon atom Chemical group C* 0.000 description 38
- 239000012986 chain transfer agent Substances 0.000 description 36
- 230000003287 optical effect Effects 0.000 description 36
- 239000000243 solution Substances 0.000 description 33
- TWRXJAOTZQYOKJ-UHFFFAOYSA-L Magnesium chloride Chemical compound [Mg+2].[Cl-].[Cl-] TWRXJAOTZQYOKJ-UHFFFAOYSA-L 0.000 description 30
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 28
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 26
- 125000000217 alkyl group Chemical group 0.000 description 25
- 239000004816 latex Substances 0.000 description 24
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- 238000001035 drying Methods 0.000 description 21
- 238000002360 preparation method Methods 0.000 description 20
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 18
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 description 17
- 125000005396 acrylic acid ester group Chemical group 0.000 description 16
- 239000000126 substance Substances 0.000 description 16
- 239000003795 chemical substances by application Substances 0.000 description 15
- 229910001629 magnesium chloride Inorganic materials 0.000 description 15
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 14
- 239000011164 primary particle Substances 0.000 description 14
- 238000012546 transfer Methods 0.000 description 14
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 13
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 description 13
- 239000004327 boric acid Substances 0.000 description 13
- 239000008367 deionised water Substances 0.000 description 13
- 229910021641 deionized water Inorganic materials 0.000 description 13
- 229910001873 dinitrogen Inorganic materials 0.000 description 13
- 229910000029 sodium carbonate Inorganic materials 0.000 description 13
- 238000002156 mixing Methods 0.000 description 12
- 230000000052 comparative effect Effects 0.000 description 11
- 229920006033 core shell type graft co-polymer Polymers 0.000 description 11
- 239000004973 liquid crystal related substance Substances 0.000 description 11
- 239000003505 polymerization initiator Substances 0.000 description 11
- SOGAXMICEFXMKE-UHFFFAOYSA-N Butylmethacrylate Chemical compound CCCCOC(=O)C(C)=C SOGAXMICEFXMKE-UHFFFAOYSA-N 0.000 description 10
- 238000004090 dissolution Methods 0.000 description 10
- 238000003756 stirring Methods 0.000 description 10
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 9
- 230000000379 polymerizing effect Effects 0.000 description 9
- CQEYYJKEWSMYFG-UHFFFAOYSA-N butyl acrylate Chemical compound CCCCOC(=O)C=C CQEYYJKEWSMYFG-UHFFFAOYSA-N 0.000 description 8
- 229920006037 cross link polymer Polymers 0.000 description 8
- 239000000463 material Substances 0.000 description 8
- 238000000465 moulding Methods 0.000 description 8
- 239000002253 acid Substances 0.000 description 7
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 7
- 125000003118 aryl group Chemical group 0.000 description 7
- 150000002148 esters Chemical group 0.000 description 7
- 239000007787 solid Substances 0.000 description 7
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 6
- ZMXDDKWLCZADIW-UHFFFAOYSA-N N,N-Dimethylformamide Chemical compound CN(C)C=O ZMXDDKWLCZADIW-UHFFFAOYSA-N 0.000 description 6
- 125000005250 alkyl acrylate group Chemical group 0.000 description 6
- 230000002829 reductive effect Effects 0.000 description 6
- VZCYOOQTPOCHFL-UHFFFAOYSA-N trans-butenedioic acid Natural products OC(=O)C=CC(O)=O VZCYOOQTPOCHFL-UHFFFAOYSA-N 0.000 description 6
- GOXQRTZXKQZDDN-UHFFFAOYSA-N 2-Ethylhexyl acrylate Chemical compound CCCCC(CC)COC(=O)C=C GOXQRTZXKQZDDN-UHFFFAOYSA-N 0.000 description 5
- VZCYOOQTPOCHFL-OWOJBTEDSA-N Fumaric acid Chemical compound OC(=O)\C=C\C(O)=O VZCYOOQTPOCHFL-OWOJBTEDSA-N 0.000 description 5
- 230000008901 benefit Effects 0.000 description 5
- 238000004581 coalescence Methods 0.000 description 5
- 239000006185 dispersion Substances 0.000 description 5
- 229920001971 elastomer Polymers 0.000 description 5
- SUPCQIBBMFXVTL-UHFFFAOYSA-N ethyl 2-methylprop-2-enoate Chemical compound CCOC(=O)C(C)=C SUPCQIBBMFXVTL-UHFFFAOYSA-N 0.000 description 5
- 238000001125 extrusion Methods 0.000 description 5
- 239000011159 matrix material Substances 0.000 description 5
- 229920000058 polyacrylate Polymers 0.000 description 5
- 150000003839 salts Chemical class 0.000 description 5
- MYRTYDVEIRVNKP-UHFFFAOYSA-N 1,2-Divinylbenzene Chemical compound C=CC1=CC=CC=C1C=C MYRTYDVEIRVNKP-UHFFFAOYSA-N 0.000 description 4
- BQTPKSBXMONSJI-UHFFFAOYSA-N 1-cyclohexylpyrrole-2,5-dione Chemical compound O=C1C=CC(=O)N1C1CCCCC1 BQTPKSBXMONSJI-UHFFFAOYSA-N 0.000 description 4
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 4
- RUMACXVDVNRZJZ-UHFFFAOYSA-N 2-methylpropyl 2-methylprop-2-enoate Chemical compound CC(C)COC(=O)C(C)=C RUMACXVDVNRZJZ-UHFFFAOYSA-N 0.000 description 4
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical compound C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 description 4
- 241000251468 Actinopterygii Species 0.000 description 4
- JIGUQPWFLRLWPJ-UHFFFAOYSA-N Ethyl acrylate Chemical compound CCOC(=O)C=C JIGUQPWFLRLWPJ-UHFFFAOYSA-N 0.000 description 4
- CSNNHWWHGAXBCP-UHFFFAOYSA-L Magnesium sulfate Chemical compound [Mg+2].[O-][S+2]([O-])([O-])[O-] CSNNHWWHGAXBCP-UHFFFAOYSA-L 0.000 description 4
- BAPJBEWLBFYGME-UHFFFAOYSA-N Methyl acrylate Chemical compound COC(=O)C=C BAPJBEWLBFYGME-UHFFFAOYSA-N 0.000 description 4
- GYCMBHHDWRMZGG-UHFFFAOYSA-N Methylacrylonitrile Chemical compound CC(=C)C#N GYCMBHHDWRMZGG-UHFFFAOYSA-N 0.000 description 4
- BAVYZALUXZFZLV-UHFFFAOYSA-N Methylamine Chemical compound NC BAVYZALUXZFZLV-UHFFFAOYSA-N 0.000 description 4
- WYURNTSHIVDZCO-UHFFFAOYSA-N Tetrahydrofuran Chemical compound C1CCOC1 WYURNTSHIVDZCO-UHFFFAOYSA-N 0.000 description 4
- XYLMUPLGERFSHI-UHFFFAOYSA-N alpha-Methylstyrene Chemical compound CC(=C)C1=CC=CC=C1 XYLMUPLGERFSHI-UHFFFAOYSA-N 0.000 description 4
- 238000005452 bending Methods 0.000 description 4
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- 150000002431 hydrogen Chemical class 0.000 description 4
- 150000002596 lactones Chemical group 0.000 description 4
- 229910052751 metal Inorganic materials 0.000 description 4
- 239000002184 metal Substances 0.000 description 4
- KZCOBXFFBQJQHH-UHFFFAOYSA-N octane-1-thiol Chemical compound CCCCCCCCS KZCOBXFFBQJQHH-UHFFFAOYSA-N 0.000 description 4
- ANISOHQJBAQUQP-UHFFFAOYSA-N octyl prop-2-enoate Chemical compound CCCCCCCCOC(=O)C=C ANISOHQJBAQUQP-UHFFFAOYSA-N 0.000 description 4
- PNJWIWWMYCMZRO-UHFFFAOYSA-N pent‐4‐en‐2‐one Natural products CC(=O)CC=C PNJWIWWMYCMZRO-UHFFFAOYSA-N 0.000 description 4
- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 4
- 239000004926 polymethyl methacrylate Substances 0.000 description 4
- FBCQUCJYYPMKRO-UHFFFAOYSA-N prop-2-enyl 2-methylprop-2-enoate Chemical class CC(=C)C(=O)OCC=C FBCQUCJYYPMKRO-UHFFFAOYSA-N 0.000 description 4
- 239000012966 redox initiator Substances 0.000 description 4
- SJMYWORNLPSJQO-UHFFFAOYSA-N tert-butyl 2-methylprop-2-enoate Chemical compound CC(=C)C(=O)OC(C)(C)C SJMYWORNLPSJQO-UHFFFAOYSA-N 0.000 description 4
- PSGCQDPCAWOCSH-UHFFFAOYSA-N (4,7,7-trimethyl-3-bicyclo[2.2.1]heptanyl) prop-2-enoate Chemical compound C1CC2(C)C(OC(=O)C=C)CC1C2(C)C PSGCQDPCAWOCSH-UHFFFAOYSA-N 0.000 description 3
- SBYMUDUGTIKLCR-UHFFFAOYSA-N 2-chloroethenylbenzene Chemical compound ClC=CC1=CC=CC=C1 SBYMUDUGTIKLCR-UHFFFAOYSA-N 0.000 description 3
- WDQMWEYDKDCEHT-UHFFFAOYSA-N 2-ethylhexyl 2-methylprop-2-enoate Chemical compound CCCCC(CC)COC(=O)C(C)=C WDQMWEYDKDCEHT-UHFFFAOYSA-N 0.000 description 3
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 3
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- 150000001252 acrylic acid derivatives Chemical class 0.000 description 3
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- AOJOEFVRHOZDFN-UHFFFAOYSA-N benzyl 2-methylprop-2-enoate Chemical compound CC(=C)C(=O)OCC1=CC=CC=C1 AOJOEFVRHOZDFN-UHFFFAOYSA-N 0.000 description 3
- GCTPMLUUWLLESL-UHFFFAOYSA-N benzyl prop-2-enoate Chemical compound C=CC(=O)OCC1=CC=CC=C1 GCTPMLUUWLLESL-UHFFFAOYSA-N 0.000 description 3
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- 125000000753 cycloalkyl group Chemical group 0.000 description 3
- OIWOHHBRDFKZNC-UHFFFAOYSA-N cyclohexyl 2-methylprop-2-enoate Chemical compound CC(=C)C(=O)OC1CCCCC1 OIWOHHBRDFKZNC-UHFFFAOYSA-N 0.000 description 3
- KBLWLMPSVYBVDK-UHFFFAOYSA-N cyclohexyl prop-2-enoate Chemical compound C=CC(=O)OC1CCCCC1 KBLWLMPSVYBVDK-UHFFFAOYSA-N 0.000 description 3
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- WRAQQYDMVSCOTE-UHFFFAOYSA-N phenyl prop-2-enoate Chemical compound C=CC(=O)OC1=CC=CC=C1 WRAQQYDMVSCOTE-UHFFFAOYSA-N 0.000 description 3
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- 125000001424 substituent group Chemical group 0.000 description 3
- CIHOLLKRGTVIJN-UHFFFAOYSA-N tert‐butyl hydroperoxide Chemical compound CC(C)(C)OO CIHOLLKRGTVIJN-UHFFFAOYSA-N 0.000 description 3
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- DTGKSKDOIYIVQL-WEDXCCLWSA-N (+)-borneol Chemical group C1C[C@@]2(C)[C@@H](O)C[C@@H]1C2(C)C DTGKSKDOIYIVQL-WEDXCCLWSA-N 0.000 description 2
- JHPBZFOKBAGZBL-UHFFFAOYSA-N (3-hydroxy-2,2,4-trimethylpentyl) 2-methylprop-2-enoate Chemical compound CC(C)C(O)C(C)(C)COC(=O)C(C)=C JHPBZFOKBAGZBL-UHFFFAOYSA-N 0.000 description 2
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- 238000005160 1H NMR spectroscopy Methods 0.000 description 2
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- WNAHIZMDSQCWRP-UHFFFAOYSA-N dodecane-1-thiol Chemical compound CCCCCCCCCCCCS WNAHIZMDSQCWRP-UHFFFAOYSA-N 0.000 description 2
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- CHQMHPLRPQMAMX-UHFFFAOYSA-L sodium persulfate Substances [Na+].[Na+].[O-]S(=O)(=O)OOS([O-])(=O)=O CHQMHPLRPQMAMX-UHFFFAOYSA-L 0.000 description 1
- 238000000807 solvent casting Methods 0.000 description 1
- 238000001694 spray drying Methods 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 239000010421 standard material Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- BDHFUVZGWQCTTF-UHFFFAOYSA-M sulfonate Chemical compound [O-]S(=O)=O BDHFUVZGWQCTTF-UHFFFAOYSA-M 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 230000002522 swelling effect Effects 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 239000000057 synthetic resin Substances 0.000 description 1
- GEKDEMKPCKTKEC-UHFFFAOYSA-N tetradecane-1-thiol Chemical compound CCCCCCCCCCCCCCS GEKDEMKPCKTKEC-UHFFFAOYSA-N 0.000 description 1
- 238000009823 thermal lamination Methods 0.000 description 1
- CWERGRDVMFNCDR-UHFFFAOYSA-N thioglycolic acid Chemical class OC(=O)CS CWERGRDVMFNCDR-UHFFFAOYSA-N 0.000 description 1
- 229920001567 vinyl ester resin Polymers 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
- 230000002087 whitening effect Effects 0.000 description 1
Classifications
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- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F265/00—Macromolecular compounds obtained by polymerising monomers on to polymers of unsaturated monocarboxylic acids or derivatives thereof as defined in group C08F20/00
- C08F265/04—Macromolecular compounds obtained by polymerising monomers on to polymers of unsaturated monocarboxylic acids or derivatives thereof as defined in group C08F20/00 on to polymers of esters
- C08F265/06—Polymerisation of acrylate or methacrylate esters on to polymers thereof
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L33/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
- C08L33/04—Homopolymers or copolymers of esters
- C08L33/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, which oxygen atoms are present only as part of the carboxyl radical
- C08L33/10—Homopolymers or copolymers of methacrylic acid esters
- C08L33/12—Homopolymers or copolymers of methyl methacrylate
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
- B29C41/24—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length
- B29C41/26—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length by depositing flowable material on a rotating drum
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- B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
- B29C41/24—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length
- B29C41/28—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length by depositing flowable material on an endless belt
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- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
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- C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
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- C08F220/14—Methyl esters, e.g. methyl (meth)acrylate
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- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
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- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
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- C08F220/16—Esters of monohydric alcohols or phenols of phenols or of alcohols containing two or more carbon atoms
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- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F285/00—Macromolecular compounds obtained by polymerising monomers on to preformed graft polymers
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- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F8/00—Chemical modification by after-treatment
- C08F8/30—Introducing nitrogen atoms or nitrogen-containing groups
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- C08F8/00—Chemical modification by after-treatment
- C08F8/34—Introducing sulfur atoms or sulfur-containing groups
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- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J3/00—Processes of treating or compounding macromolecular substances
- C08J3/12—Powdering or granulating
- C08J3/126—Polymer particles coated by polymer, e.g. core shell structures
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/18—Manufacture of films or sheets
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
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- C08L33/04—Homopolymers or copolymers of esters
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L51/00—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D133/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Coating compositions based on derivatives of such polymers
- C09D133/04—Homopolymers or copolymers of esters
- C09D133/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, the oxygen atom being present only as part of the carboxyl radical
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- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D135/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a carboxyl radical, and containing at least another carboxyl radical in the molecule, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Coating compositions based on derivatives of such polymers
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- G—PHYSICS
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- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
- G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
- G02B1/14—Protective coatings, e.g. hard coatings
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- G—PHYSICS
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- G02B5/00—Optical elements other than lenses
- G02B5/30—Polarising elements
- G02B5/3025—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
- G02B5/3033—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
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- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2033/00—Use of polymers of unsaturated acids or derivatives thereof as moulding material
- B29K2033/04—Polymers of esters
- B29K2033/12—Polymers of methacrylic acid esters, e.g. PMMA, i.e. polymethylmethacrylate
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- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2333/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers
- C08J2333/04—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers esters
- C08J2333/06—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers esters of esters containing only carbon, hydrogen, and oxygen, the oxygen atom being present only as part of the carboxyl radical
- C08J2333/08—Homopolymers or copolymers of acrylic acid esters
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2333/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers
- C08J2333/04—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers esters
- C08J2333/06—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers esters of esters containing only carbon, hydrogen, and oxygen, the oxygen atom being present only as part of the carboxyl radical
- C08J2333/10—Homopolymers or copolymers of methacrylic acid esters
- C08J2333/12—Homopolymers or copolymers of methyl methacrylate
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2451/00—Characterised by the use of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives of such polymers
- C08J2451/06—Characterised by the use of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives of such polymers grafted on to homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/14—Polymer mixtures characterised by other features containing polymeric additives characterised by shape
- C08L2205/18—Spheres
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2207/00—Properties characterising the ingredient of the composition
- C08L2207/53—Core-shell polymer
Definitions
- the present invention relates to a dope for producing a film containing an acrylic resin and a graft copolymer, and a method for producing the film.
- Acrylic resins are excellent polymers that are used in large quantities in various industrial fields because they have excellent transparency, color tone, appearance, weather resistance, gloss and processability.
- films molded from acrylic resins take advantage of excellent transparency, appearance, and weather resistance, and are used for interior and exterior materials for automobiles, exterior materials for electrical appliances such as mobile phones and smartphones, floors, windows, interior and exterior walls, and lighting parts. It is used for various purposes such as road signs and other interior and exterior materials for civil engineering and construction.
- acrylic resins have been applied to optical members such as liquid crystal display devices and organic EL display devices, taking advantage of their excellent optical properties.
- acrylic resins are inferior in impact resistance.
- various methods have been proposed to develop strength by blending an acrylic resin with a graft copolymer having a rubber layer (rubber-containing graft copolymer). (For example, see Patent Documents 1 to 6).
- a core-shell type graft copolymer containing rubber as a core layer is known, and a molded body or a resin film obtained by injection molding or extrusion molding is known.
- a molded body or a resin film obtained by injection molding or extrusion molding is known.
- High quality resin film production methods include melt extrusion using a T-die, and solution casting in which a dope prepared by dissolving a resin in a solvent is cast on the surface of the support, and then the solvent is evaporated to form a film. Etc. are known.
- the melt extrusion method using a T-die there is a drawback in that the resulting film tends to have a difference in physical properties between the extrusion direction and the vertical direction, and residual orientation tends to occur.
- the solution casting method has an advantage in that since no physical pressure is applied to the film, the orientation of the polymer does not occur, and the film strength, optical properties, and the like are less likely to be directional.
- the amount of heat applied to the resin is low and the amount of heat stabilizer added can be reduced.
- the above-described core-shell type graft copolymer is generally an aggregate of primary particles, generally having a particle size of several microns to several tens of millimeters, obtained by aggregating primary particles (submicron order) produced by emulsion polymerization. It is offered as a powder product.
- the core-shell type graft copolymer powder and acrylic resin, which are aggregates are dissolved and dispersed in a solvent.
- a dope a uniform polymer solution
- the dope When the dope is turbid, dust is likely to occur in the dope, and the film obtained by the solution casting method tends to generate foreign matters due to aggregation or poor dispersion of rubber particles.
- the dope is insufficiently fluid due to its gel shape or part of it, causing troubles when performing the solution casting method, and further, when filtering with a fine filter to remove foreign substances in the dope There is concern about a significant decline in productivity such as clogging and inability to continue filtration. Therefore, it may be difficult to produce a film having good transparency, appearance, optical properties, mechanical properties and the like by the solution casting method.
- the present invention is a dope used when a film containing an acrylic resin and a core-shell type graft copolymer is produced by a solution casting method, and has a core-shell type graft having a core layer with a large particle size
- An object of the present invention is to provide a dope that generates less turbidity despite the use of a copolymer.
- the present inventors use a solvent having a hydrogen bond term ⁇ H in the Hansen solubility parameter in a specific range as a solvent contained in the dope, and, as a core-shell type graft copolymer, a swelling degree by methyl ethyl ketone falls within a specific range.
- the present inventors have found that the above-mentioned problems can be solved by using a graft copolymer adjusted as described above, and have completed the present invention.
- the present invention is a dope for film production by a solution casting method comprising a thermoplastic acrylic resin, a graft copolymer, and a solvent, wherein the graft copolymer comprises a core layer and a shell layer.
- the core layer has an average particle size of 125 to 400 nm
- the graft copolymer has a swelling degree of methyl ethyl ketone of 3.5 or more
- the solvent has a hydrogen bond term ⁇ H of 6 in the Hansen solubility parameter. It is related with dope which is 0.0 or more and 8.0 or less.
- the graft copolymer has a degree of swelling with methyl ethyl ketone of 3.6 to 5.0.
- the graft copolymer has a swellability coefficient S represented by (degree of swelling by methyl ethyl ketone / soft polymer ratio in the graft copolymer) / (soft polymer ratio in the core layer) of 10.5. ⁇ 18.0.
- the core layer has a polymer terminal structure composed of an alkylthio group.
- the shell layer is a single layer or a multilayer, and the polymer constituting the single layer or the polymer constituting the layer having the highest glass transition temperature among the multilayers has a glass transition temperature of 92 ° C. or lower. It is.
- the graft copolymer has a gel fraction of 90% or less.
- the core layer comprises 40 to 100% by weight of the methacrylic acid ester unit (a-1), 60 to 0% by weight of another monomer unit (a-2) having a double bond copolymerizable therewith, And a hard polymer (I) containing 0.01 to 10 parts by weight of a polyfunctional monomer unit as a constituent unit with respect to a total of 100 parts by weight of the above (a-1) and (a-2), an acrylic 60 to 100% by weight of the acid ester unit (b-1), 0 to 40% by weight of another monomer unit (b-2) having a double bond copolymerizable therewith, and the above (b-1) And a soft polymer (II) containing 0.1 to 5 parts by weight of a polyfunctional monomer unit as a constituent unit with respect to a total of 100 parts by weight of (b-2), and the soft polymer (II) Is bonded to the hard polymer (I), and the shell layer is formed of the methacrylic acid ester unit (c-1) 60.
- the hard polymer (I) has a polymer terminal structure composed of an alkylthio group.
- the thermoplastic acrylic resin has a weight average molecular weight of 300,000 or more.
- the thermoplastic acrylic resin has a weight average molecular weight of 170,000 or less.
- thermoplastic acrylic resin is a polymer containing 30 to 100% by weight of methyl methacrylate units and 0 to 70% by weight of other vinyl monomer units copolymerizable therewith as constituent units. .
- the thermoplastic acrylic resin has a ring structure in the main chain, and the ring structure includes a glutarimide ring structure, a lactone ring structure, a maleic anhydride-derived ring structure, a maleimide-derived ring structure, and a glutaric anhydride ring. It is at least one selected from the group consisting of structures.
- the blending amount of the thermoplastic acrylic resin is 40 to 98 parts by weight with respect to 100 parts by weight of the total blending amount of the thermoplastic acrylic resin and the graft copolymer, and the graft copolymer The blending amount is 60 to 2 parts by weight.
- the present invention also relates to a method for producing an acrylic resin film by a solution casting method, which includes a step of evaporating a solvent after casting the dope on a support surface.
- the dope is prepared by preparing a pellet containing a thermoplastic acrylic resin and a graft copolymer, and then dissolving and dispersing the pellet in the solvent.
- the present invention relates to an acrylic resin film formed from the dope.
- the acrylic resin film has a thickness of 10 to 500 ⁇ m.
- the acrylic resin film is a film for protecting the lamination to the surface of another substrate.
- the acrylic resin film is an optical film, and more preferably, the optical film is a polarizer protective film.
- the present invention relates to a polarizing plate formed by laminating a polarizer and the acrylic resin film, and also relates to a display device including the polarizing plate.
- a core-shell type graft copolymer having a core layer having a large particle size is used for producing a film containing an acrylic resin and a core-shell type graft copolymer by a solution casting method. It is possible to provide a dope that generates less turbidity despite the use of coalescence.
- the acrylic resin film produced by the solution casting method using the dope of the present invention has few foreign matters in the film and is excellent in transparency, appearance, optical properties, mechanical properties, and the like.
- the dope of the present invention contains a thermoplastic acrylic resin, a graft copolymer, and a solvent, and is a dope used for producing a film by a solution casting method.
- the thermoplastic acrylic resin and the graft copolymer are dissolved or dispersed in a solvent.
- each component will be described.
- thermoplastic acrylic resin contained in the dope of the present invention may be a resin having a vinyl monomer containing (meth) acrylic acid ester as a structural unit, and a known thermoplastic acrylic resin can be used.
- a thermoplastic acrylic resin containing a structural unit derived from a methacrylic acid ester is preferable, and an acrylic resin containing 30% by weight or more, more preferably 50% by weight or more of a methacrylic acid alkyl ester unit having 1 to 4 carbon atoms in the alkyl group.
- a resin is more preferable.
- a thermoplastic acrylic resin containing 30 to 100% by weight of methyl methacrylate units as constituent units and 70 to 0% by weight of other vinyl monomer units copolymerizable therewith is provided. Further preferred.
- vinyl monomer copolymerizable with methyl methacrylate for example, (meth) acrylic acid ester (excluding methyl methacrylate) in which the alkyl group has 1 to 10 carbon atoms is preferable.
- vinyl monomers copolymerizable with methyl methacrylate include ethyl methacrylate, propyl methacrylate, butyl methacrylate, cyclohexyl methacrylate, 2-ethylhexyl methacrylate, benzyl methacrylate, Octyl acid, glycidyl methacrylate, epoxycyclohexylmethyl methacrylate, dimethylaminoethyl methacrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl methacrylate, dicyclopentanyl methacrylate, 2,2,2-trifluoroethyl methacrylate , 2,2,2-trichloroethyl methacrylate, isobornyl methacrylate, 2,
- the thermoplastic acrylic resin preferably has 30 to 100% by weight, more preferably 50 to 100% by weight, and still more preferably methyl methacrylate as a structural unit.
- the other vinyl-based monomer that is contained in an amount of 50 to 99.9% by weight, particularly preferably 50 to 98% by weight and copolymerizable with methyl methacrylate is preferably 70 to 0% by weight, more preferably 50 to 0%. % By weight, more preferably 50 to 0.1% by weight, particularly preferably 50 to 2% by weight.
- a polyfunctional monomer is not included from a viewpoint of workability and an external appearance property.
- the weight average molecular weight of the thermoplastic acrylic resin is not particularly limited, but is preferably 300,000 or more. When the weight average molecular weight is within this range, the resulting film becomes tough and easy to handle when the film is applied to various uses.
- the weight average molecular weight is also preferably 170,000 or less. When the weight average molecular weight is within this range, the viscosity of the dope is lowered, so that the dope can be adjusted to a higher concentration, film formation by the solvent casting method becomes easier, and high productivity is realized. be able to.
- the weight average molecular weight can be measured using gel permeation chromatography (GPC) under the following conditions.
- the glass transition temperature may be less than 115 ° C, but it is preferably 90 ° C or higher from the viewpoint of heat resistance during use.
- a thermoplastic acrylic resin having a glass transition temperature of 115 ° C. or higher and excellent heat resistance is preferable.
- the glass transition temperature of the thermoplastic acrylic resin is more preferably 118 ° C. or higher, further preferably 120 ° C. or higher, and most preferably 125 ° C. or higher.
- thermoplastic acrylic resin having excellent heat resistance examples include acrylic resins having a ring structure in the main chain.
- the ring structure include a glutarimide ring structure, a lactone ring structure, a maleic anhydride-derived ring structure, a maleimide-derived ring structure (including an N-substituted maleimide-derived ring structure), and a glutaric anhydride ring structure.
- numerator is also mentioned.
- thermoplastic acrylic resins having excellent heat resistance include maleimide acrylic resins (acrylic resins in which an unsubstituted or N-substituted maleimide compound is copolymerized as a copolymer component), glutarimide acrylic resins , Lactone ring-containing acrylic resins, acrylic resins containing hydroxyl groups and / or carboxyl groups, methacrylic resins, styrene monomers and other styrene-containing acrylic polymers obtained by polymerizing styrene monomers and other monomers copolymerizable therewith Acrylic polymer containing a partially hydrogenated styrene unit-containing acrylic polymer obtained by partial hydrogenation of the aromatic ring of the polymer, and a cyclic acid anhydride structure such as a glutaric anhydride structure or a structure derived from maleic anhydride Examples include coalescence.
- lactone ring-containing acrylic resin maleimide acrylic resin, glutarimide acrylic resin, glutaric anhydride structure-containing acrylic resin, and maleic anhydride anhydride from the viewpoint of improving the heat resistance of the acrylic resin film Structure-containing acrylic resin, preferably an acrylic polymer composed of 97 to 100% by weight of methyl methacrylate and 3 to 0% by weight of methyl acrylate.
- glutarimide acrylic resin from the viewpoint of excellent optical properties
- Maleimide acrylic resins are particularly preferred.
- a glutarimide acrylic resin and a maleimide acrylic resin may be used in combination. Since both resins are excellent in compatibility, they can maintain high transparency, have excellent optical characteristics, have high thermal stability, and can also have solvent resistance.
- maleimide acrylic resins examples include maleimide acrylic resins having a maleimide unit (corresponding to a maleimide-derived ring structure) represented by the following general formula (5) and a (meth) acrylic ester unit.
- R 11 and R 12 are each independently a hydrogen atom, an alkyl group having 1 to 12 carbon atoms, or an aryl group having 6 to 14 carbon atoms, and R 13 is a hydrogen atom, 7 carbon atoms or 7 carbon atoms
- Group A a halogen atom, a hydroxyl group, a nitro group, an alkoxy group having 1 to 12 carbon atoms, an alkyl group having 1 to 12 carbon atoms, and an arylalkyl group having 7 to 14 carbon atoms.
- Specific examples of the maleimide unit represented by the general formula (5) include an unsubstituted maleimide unit, an N-methylmaleimide unit, an N-phenylmaleimide unit, an N-cyclohexylmaleimide unit, and an N-benzylmaleimide unit. .
- a maleimide unit it may contain only 1 type and may contain 2 or more types.
- the maleimide acrylic resin preferably further has an aromatic vinyl unit in order to adjust optical properties.
- the glutarimide acrylic resin may be an acrylic resin having a glutarimide ring structure, and has a unit represented by the following general formula (1) and a unit represented by the following general formula (2). Is mentioned.
- R 1 and R 2 are each independently hydrogen or an alkyl group having 1 to 8 carbon atoms
- R 3 is hydrogen, an alkyl group having 1 to 18 carbon atoms, A cycloalkyl group having 3 to 12 carbon atoms, or a substituent having 5 to 15 carbon atoms including an aromatic ring.
- the unit represented by the general formula (1) is also referred to as “glutarimide unit”.
- R 1 and R 2 are each independently hydrogen or a methyl group, and R 3 is hydrogen, a methyl group, a butyl group, or a cyclohexyl group, more preferably R 1 is a methyl group, R 2 is hydrogen, and R 3 is a methyl group.
- the glutarimide acrylic resin may contain only a single type as a glutarimide unit, or a plurality of different ones or all of R 1 , R 2 , and R 3 in the general formula (1). The type may be included.
- the glutarimide unit can be formed by imidizing a (meth) acrylic acid ester unit represented by the following general formula (2). Further, an acid anhydride such as maleic anhydride, a half ester of the acid anhydride and a linear or branched alcohol having 1 to 20 carbon atoms, or an ⁇ , ⁇ -ethylenically unsaturated carboxylic acid (for example, acrylic acid)
- an acid anhydride such as maleic anhydride, a half ester of the acid anhydride and a linear or branched alcohol having 1 to 20 carbon atoms, or an ⁇ , ⁇ -ethylenically unsaturated carboxylic acid (for example, acrylic acid)
- the glutarimide unit can also be formed by imidizing methacrylic acid, maleic acid, itaconic acid, crotonic acid, fumaric acid, citraconic acid).
- the content of the glutarimide unit is not particularly limited, and can be appropriately determined in consideration of, for example, the structure of R 3 .
- the content of the glutarimide unit is preferably 1.0% by weight or more, more preferably 3.0% by weight to 90% by weight, and more preferably 5.0% by weight to 60% by weight of the total amount of the glutarimide acrylic resin. Further preferred.
- the content of the glutarimide unit is less than the above range, the resulting glutarimide acrylic resin tends to have insufficient heat resistance or its transparency may be impaired.
- it exceeds the above range the heat resistance and melt viscosity will be unnecessarily high, the molding processability will be poor, the mechanical strength during film processing will be extremely low, and the transparency will be impaired. Tend.
- the content of the glutarimide unit is calculated by the following method. Using 1 H-NMR BRUKER Avance III (400 MHz), 1 H-NMR measurement of the resin was performed to determine the content (mol%) of each monomer unit such as glutarimide unit or ester unit in the resin. The amount (mol%) is converted to the content (% by weight) using the molecular weight of each monomer unit.
- a resin comprising a glutarimide unit in which R 3 is a methyl group in the above general formula (1) and a methyl methacrylate unit
- R 3 is a methyl group in the above general formula (1)
- a methyl methacrylate unit it is derived from the O—CH 3 proton of methyl methacrylate appearing in the vicinity of 3.5 to 3.8 ppm.
- the content (% by weight) of the glutarimide unit is obtained from the following formula, from the area a of the peak a and the area b of the peak derived from the N—CH 3 proton of glutarimide that appears in the vicinity of 3.0 to 3.3 ppm: be able to.
- content (weight%) of a glutarimide unit can be calculated
- the content of the glutarimide unit in the glutarimide acrylic resin is preferably 20% by weight or less, and preferably 15% by weight or less because birefringence is easily suppressed. Is more preferable, and 10% by weight or less is more preferable.
- R 4 and R 5 are each independently hydrogen or an alkyl group having 1 to 8 carbon atoms
- R 6 is an alkyl group having 1 to 18 carbon atoms or 3 to 3 carbon atoms. 12 cycloalkyl groups or substituents having 5 to 15 carbon atoms including an aromatic ring.
- the unit represented by the general formula (2) is also referred to as “(meth) acrylic acid ester unit”.
- (meth) acryl means “methacryl or acryl”.
- R 4 and R 5 are each independently hydrogen or a methyl group
- R 6 is hydrogen or a methyl group
- 5 is a methyl group
- R 6 is a methyl group
- the glutarimide acrylic resin may contain only a single type as a (meth) acrylic acid ester unit, and any or all of R 4 , R 5 and R 6 in the general formula (2) A plurality of different types may be included.
- the glutarimide acrylic resin may further contain a unit represented by the following general formula (3) (hereinafter also referred to as “aromatic vinyl unit”) as necessary.
- R 7 is hydrogen or an alkyl group having 1 to 8 carbon atoms
- R 8 is an aryl group having 6 to 10 carbon atoms.
- the aromatic vinyl unit represented by the general formula (3) is not particularly limited, and examples thereof include a styrene unit and an ⁇ -methylstyrene unit, and a styrene unit is preferable.
- the glutarimide acrylic resin may contain only a single type as an aromatic vinyl unit, or may contain a plurality of units in which either or both of R 7 and R 8 are different.
- the content of the aromatic vinyl unit is not particularly limited, but is preferably 0 to 50% by weight, more preferably 0 to 20% by weight, and more preferably 0 to 15% by weight based on the total amount of the glutarimide acrylic resin. Is particularly preferred.
- the content of the aromatic vinyl unit is larger than the above range, sufficient heat resistance of the glutarimide acrylic resin cannot be obtained.
- the glutarimide acrylic resin does not contain an aromatic vinyl unit from the viewpoints of improvement of bending resistance and transparency, reduction of fish eyes, and improvement of solvent resistance or weather resistance.
- the glutarimide acrylic resin may further contain other units other than the glutarimide unit, the (meth) acrylic acid ester unit, and the aromatic vinyl unit, if necessary.
- other units include amide units such as acrylamide and methacrylamide, glutaric anhydride units, and nitrile units such as acrylonitrile and methacrylonitrile. These other units may be contained in the glutarimide acrylic resin by random copolymerization or may be contained by graft copolymerization.
- the graft copolymer used in the present invention is excellent in thermal stability, imparts excellent transparency and color tone to the acrylic resin film of the present invention, and further has mechanical strength such as bending resistance and crack resistance. Can be improved.
- the graft copolymer is referred to as a multi-stage polymer and a multilayer structure polymer, so-called core-shell type polymer.
- a multistage polymer is a polymer obtained by polymerizing a monomer mixture in the presence of polymer particles
- a multi-layer polymer is a monomer mixture in the presence of polymer particles (core layer).
- core layer is a polymer (core shell type polymer) which has a polymer layer (shell layer) obtained by superposing
- both refer to basically the same polymer, but the former specifies the polymer mainly by the production method, and the latter mainly specifies the polymer by the layer structure. The following description will be given mainly for the former, but the same applies to the latter viewpoint.
- the average particle size of the core layer is 125 to 400 nm. Since the average particle diameter of a core layer is 125 nm or more, the intensity
- the average particle size of the core layer is preferably 130 to 380 nm, more preferably 150 to 350 nm, still more preferably 180 to 300 nm, and particularly preferably 200 to 260 nm.
- the average particle size of the core layer of the graft copolymer in the present invention is measured using a spectrophotometer for light scattering at a wavelength of 546 nm in the state of the polymer latex of the core layer before polymerizing the shell layer. Is calculated.
- a graft copolymer that easily swells when dissolved and dispersed in a solvent used for the dope is used.
- the degree of swelling with methyl ethyl ketone is used as an index indicating the ease of swelling of the graft copolymer.
- the degree of swelling by methyl ethyl ketone indicates the ratio of the weight of methyl ethyl ketone contained in the gel polymer to the resin weight obtained by removing the weight of methyl ethyl ketone from the gel polymer obtained when the graft copolymer is dissolved and dispersed in methyl ethyl ketone. is there.
- a higher value of the degree of swelling indicates that the graft copolymer is more easily swollen by methyl ethyl ketone.
- the graft copolymer of the present invention exhibits a degree of swelling by methyl ethyl ketone of 3.5 or more. Preferably, it is 3.6 to 5.0.
- the present inventors used a graft copolymer having a degree of swelling by methyl ethyl ketone of 3.5 or more together with a solvent having a hydrogen bond term ⁇ H in the Hansen solubility parameter described later in the range of 6.0 or more and 8.0 or less. It was found that when the dope is configured, the dope is less likely to be turbid.
- the degree of swelling with methyl ethyl ketone can be measured by the following procedure. After 1 g of the graft copolymer is dissolved in 40 mL of methyl ethyl ketone, centrifugation is performed to separate the polymer component (gel polymer) insoluble in methyl ethyl ketone and the component soluble in methyl ethyl ketone. The obtained gel polymer is dried at 60 ° C. and 5 torr for 10 hours, and the dried gel polymer is recovered. From the weight of the gel polymer before drying and the weight of the gel polymer after drying, the degree of swelling by methyl ethyl ketone is calculated by the following formula.
- (Swelling degree) [(weight of gel polymer before drying) ⁇ (weight of gel polymer after drying)] / (weight of gel polymer after drying)
- the glass transition temperature of the polymer constituting the layer is 92 ° C. or lower (preferably 80 ° C. or lower, more preferably 75 ° C.
- the use of the chain transfer agent decreases the degree of cross-linking of the core layer, so that the core layer can easily absorb the solvent and the degree of swelling of the graft copolymer is improved. It is considered a thing.
- the core layer may have a polymer terminal structure including a structure derived from the chain transfer agent.
- the core layer has a polymer terminal structure composed of an alkylthio group.
- the bonding force between the polymer molecular chains is weakened in the shell layer, and the solvent easily passes through the shell layer. It is considered that the graft copolymer can easily absorb the solvent. Furthermore, according to this method, it is considered that polymer molecules in the shell layer that are aggregated or welded are easily loosened, and the graft copolymer can easily absorb the solvent.
- the glass transition temperature of the polymer constituting the layer having the highest glass transition temperature in the multilayer may be 92 ° C. or lower.
- the monomer configuration in the (III) polymerization stage or (IV) polymerization stage described later may be employed.
- the swelling property of the graft copolymer used in the present invention can also be expressed by a swelling coefficient S.
- the graft copolymer used in the present invention is mainly composed of a methacrylic ester in the inner layer portion of the core from the viewpoint of improving the balance of transparency and strength when the acrylic resin film is formed through the dope state of the present invention. It is preferable to include a polymer layer having a relatively high glass transition temperature as a component. Such a graft copolymer tends to have a lower degree of swelling than a core-shell type graft copolymer that does not have a polymer layer having a high glass transition temperature in the core inner layer portion.
- the graft copolymer of the present invention preferably has a gel fraction of 90% or less.
- the gel fraction is a weight ratio of components insoluble in methyl ethyl ketone of the graft copolymer to the total amount of the graft copolymer.
- the gel fraction of the graft copolymer is 90% or less, the graft copolymer contains a considerable amount of a component that is soluble in methyl ethyl ketone.
- the primary particles of the graft copolymer are easily dispersed.
- the gel fraction is more preferably 87% or less, still more preferably 85% or less, still more preferably 83% or less, and particularly preferably 80% or less.
- the lower limit of the gel fraction is not particularly limited, but if it is too low, the bending resistance of the acrylic resin film, the mechanical properties such as cracking at the time of slitting and cracking at the time of punching may decrease, so 65% or more It is preferably 68% or more, more preferably 70% or more, and most preferably 73% or more.
- the gel fraction can be measured by the following procedure. After 1 g of the graft copolymer is dissolved in 40 mL of methyl ethyl ketone, centrifugation is performed to separate the polymer component (gel polymer) insoluble in methyl ethyl ketone and the component soluble in methyl ethyl ketone. The obtained gel polymer is dried at 60 ° C. and 5 torr for 10 hours, and the dried gel polymer is recovered. A component soluble in methyl ethyl ketone is poured into 200 mL of methanol and reprecipitated to separate the methanol soluble component and the component insoluble in methanol (free polymer).
- the core layer in the graft copolymer comprises 40 to 100% by weight of the methacrylic acid ester unit (a-1) and other monomers having a double bond copolymerizable therewith.
- the unit (a-2) comprises 60 to 0% by weight, and the polyfunctional monomer unit 0.01 to 10 parts by weight with respect to the total of 100 parts by weight of the above (a-1) and (a-2)
- Hard polymer (I) containing as units, acrylate unit (b-1) 60 to 100% by weight, other monomer units (b-2) having a double bond copolymerizable therewith 0 to 100% 40% by weight and a soft polymer (II) containing 0.1 to 5 parts by weight of a polyfunctional monomer unit as a constituent unit with respect to a total of 100 parts by weight of the above (b-1) and (b-2)
- the soft polymer (II) is bonded to the hard polymer (I)
- the gel layer is composed of 60 to 100% by weight of the methacrylic acid ester unit (c-1), 40 to 0% by weight of another monomer unit (c-2) having a double bond copolymerizable therewith, and A hard polymer (III) containing 0 to 10 parts by weight
- the graft copolymer can be obtained by multistage polymerization including at least the following polymerization stages (I) to (III).
- the polymer layer formed by (I) polymerization stage to (II) polymerization stage corresponds to the core layer, and the polymer layer formed after (III) polymerization stage corresponds to the shell layer.
- copolymerizable monomer is an alkyl acrylate ester having an alkyl group having 1 to 12 carbon atoms. And / or aromatic vinyl monomers are preferred.
- the monomer mixture (a) contains 40 to 100% by weight of methacrylic acid ester, 0 to 35% by weight of acrylic acid ester, 0 to 10% by weight of aromatic vinyl monomer, and a copolymerizable double bond. It is preferably composed of 0 to 15% by polymerization of other monomers having 40 to 99.9% by weight of methacrylic acid ester, 0.1 to 35% by weight of acrylic acid ester, and 0 to 10% by weight of aromatic vinyl monomer.
- monomers having a copolymerizable double bond are more preferably 0 to 15% by polymerization, methacrylic acid ester 40 to 99.8% by weight, acrylic acid ester 0.1 to 35% by weight More preferably 0.1 to 10% by weight of an aromatic vinyl monomer, and 0 to 15% by polymerization of another monomer having a copolymerizable double bond, and a methacrylic acid ester 51 to 96. 9 layers %, Acrylic acid ester 3.1 to 29% by weight, aromatic vinyl monomer 0 to 10% by weight, and other monomer having a copolymerizable double bond 0 to 10% by weight Even more preferred. If it is this range, the thermal stability of the graft copolymer of this invention can be improved.
- methacrylic acid ester which is the main component, easily causes zipping depolymerization during high temperature molding and easily decomposes by heat.
- acrylic acid ester and aromatic vinyl monomer within the above range, zipping depolymerization is easy. It is preferable because polymerization can be easily suppressed and thermal stability can be improved.
- the monomer mixture (a) comprises 51 to 96.8% by weight of methacrylic acid ester, 3.1 to 29% by weight of acrylic acid ester, 0.1 to 10% by weight of aromatic vinyl monomer, And 0 to 10% by polymerization of another monomer having a copolymerizable double bond.
- the zipping depolymerization is suppressed as described above to improve thermal stability, and the obtained graft copolymer can be obtained without impairing optical properties such as transparency and color tone of the acrylic resin. It can mix
- the ratio of the methacrylic acid ester is 40% by weight or more, the excellent characteristics of the acrylic resin can be suitably expressed.
- methacrylic acid ester examples include methyl methacrylate, ethyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, t-butyl methacrylate, hexyl methacrylate, cyclohexyl methacrylate, 2-ethylhexyl methacrylate, octyl methacrylate, methacrylic acid.
- examples thereof include isobornyl acid, phenyl methacrylate, benzyl methacrylate and the like.
- alkyl methacrylates having 1 to 4 carbon atoms in the alkyl group are preferred, and examples include methyl methacrylate, ethyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, and t-butyl methacrylate. These may be used alone or in combination of two or more, but methyl methacrylate is particularly preferred.
- Other monomers having a copolymerizable double bond include acrylic acid esters, aromatic vinyl monomers, and copolymerizable monomers other than (meth) acrylic acid esters and aromatic vinyl monomers. It is preferably at least one selected from the group consisting of monomers, an alkyl acrylate ester having an alkyl group of 1 to 12 carbon atoms, an aromatic vinyl monomer, and a (meth) acrylate ester and It is more preferable that the monomer is one or more monomers selected from the group consisting of copolymerizable monomers other than aromatic vinyl monomers.
- Examples of the acrylate esters include alkyl acrylates having an alkyl group having 1 to 12 carbon atoms, isobornyl acrylate, phenyl acrylate, benzyl acrylate, etc., and alkyl acrylates having an alkyl group having 1 to 12 carbon atoms.
- Examples of the ester include ethyl acrylate, n-butyl acrylate, n-octyl acrylate, 2-ethylhexyl acrylate, cyclohexyl acrylate, and the like.
- Examples of the aromatic vinyl monomer include styrene, ⁇ -methylstyrene, chlorostyrene, and other styrene derivatives.
- Examples of the copolymerizable monomer other than the (meth) acrylic acid ester and the aromatic vinyl monomer include unsaturated nitrile monomers such as acrylonitrile and methacrylonitrile, acrylic acid, methacrylic acid, and croton.
- unsaturated nitrile monomers such as acrylonitrile and methacrylonitrile, acrylic acid, methacrylic acid, and croton.
- ⁇ , ⁇ -unsaturated carboxylic acids such as acids, vinyl acetate, olefinic monomers such as ethylene and propylene
- vinyl halide monomers such as vinyl chloride, vinylidene chloride and vinylidene fluoride
- N-ethylmaleimide examples thereof include maleimide monomers such as N-propylmaleimide, N-cyclohexylmaleimide, and No-chlorophenylmaleimide.
- the other monomer having a copolymerizable double bond is preferably an alkyl acrylate ester having an alkyl group having 1 to 12 carbon atoms and / or an aromatic vinyl monomer.
- the amount of the polyfunctional monomer used in the polymerization step is preferably 0.01 to 10 parts by weight, more preferably 100 parts by weight in total of the above (a-1) and (a-2). Is 0.01 to 7 parts by weight, more preferably 0.01 to 5 parts by weight, and most preferably 0.01 to 2 parts by weight.
- the amount of the polyfunctional monomer used is 0.01 parts by weight or more, the transparency of the resulting film is improved, and when it is 10 parts by weight or less, excellent mechanical properties can be imparted to the film.
- any one known as a crosslinking agent or a crosslinking monomer can be used.
- Crosslinkable monomers include allyl methacrylate, allyl acrylate, diallyl maleate, diallyl fumarate, diallyl itaconate, monoallyl maleate, monoallyl fumarate, butadiene, divinylbenzene, triallyl isocyanurate, alkylene glycol dimethacrylate. And alkylene glycol diacrylate. These may be used alone or in combination of two or more, but more preferably allyl methacrylate alone or a combination of allyl methacrylate and another polyfunctional monomer.
- the monomer mixture (a) and the polyfunctional monomer mixture are polymerized to obtain a hard polymer (I). Is preferred.
- the amount of the chain transfer agent used in the polymerization step is preferably 0.1 to 4.0 parts by weight with respect to 100 parts by weight as a total of the above (a-1) and (a-2). .
- the lower limit is more preferably 0.20 parts by weight, still more preferably 0.30 parts by weight, even more preferably 0.40 parts by weight, and particularly preferably 0.50 parts by weight.
- the upper limit is more preferably 3.5 parts by weight, still more preferably 3.0 parts by weight, even more preferably 2.5 parts by weight, even more preferably 2.0 parts by weight, and particularly preferably 1.5 parts by weight.
- the chain transfer agent works to increase the free polymer with a low molecular weight, the more the chain transfer agent is used, the lower the cross-linking degree of the core layer, the easier it is for the core layer to absorb the solvent, and the swelling of the graft copolymer. The degree is improved, the primary particles of the graft copolymer are easily dispersed, and the turbidity of the dope is hardly generated.
- the chain transfer agent is used excessively, it may be difficult to obtain sufficient mechanical properties such as bending resistance of the acrylic resin film, cracking at the time of slitting, and cracking at the time of punching.
- a graft copolymer can be obtained in which the turbidity of the dope is hardly generated and excellent mechanical properties can be imparted to the acrylic resin film.
- the chain transfer agent used in the polymerization step is not particularly limited, and chain transfer agents known in the art can be used, for example, n-butyl mercaptan, n-octyl mercaptan, n- Primary alkyl mercaptan chain transfer agents such as hexadecyl mercaptan, n-dodecyl mercaptan, n-tetradecyl mercaptan, secondary alkyl mercaptan chain transfer agents such as s-butyl mercaptan and s-dodecyl mercaptan, t-dodecyl mercaptan, Tertiary alkyl mercaptan chain transfer agents such as t-tetradecyl mercaptan, 2-ethylhexyl thioglycolate, ethylene glycol dithioglycolate, trimethylolpropane tris (thioglycolate),
- the thermal stability of the graft copolymer is improved, so alkyl mercaptan chain transfer agents and thiophenols are preferred, and alkyl mercaptan chain transfer agents are more preferred.
- alkyl mercaptan chain transfer agents and / or secondary alkyl mercaptan chain transfer agents are preferable, and primary alkyl mercaptan chain transfer agents are more preferable.
- n-octyl mercaptan and n-dodecyl mercaptan are preferable, and n-octyl mercaptan is particularly preferable.
- the hard polymer (I) obtained in the polymerization step (I) in the graft copolymer of the present invention preferably has an alkylthio group derived from an alkyl mercaptan chain transfer agent, and a primary alkyl mercaptan chain transfer agent and It is more preferable to have a primary and / or secondary alkylthio group derived from a secondary alkyl mercaptan chain transfer agent.
- the alkylthio group refers to a structure represented by the chemical formula RS- (R is an alkyl group), and the primary and / or secondary alkylthio group is the above-mentioned R is a primary and / or secondary alkyl group. It points to something.
- the other monomer having a copolymerizable double bond is at least one selected from the group consisting of methacrylic acid esters and other monomers having a copolymerizable double bond. It is preferable.
- the monomer mixture (b) is composed of 60 to 100% by weight of acrylic acid ester, 0 to 40% by weight of methacrylic acid ester, and 0 to 20% by weight of other monomer having a copolymerizable double bond.
- the acrylic ester is 60 to 100% by weight
- the methacrylic ester is 0 to 10% by weight
- the aromatic vinyl monomer is 0 to 40% by weight
- other units having a copolymerizable double bond is more preferable from the viewpoint of obtaining a film having excellent transparency and color tone.
- acrylate esters examples include alkyl acrylate esters having an alkyl group having 1 to 12 carbon atoms, isobornyl acrylate, phenyl acrylate, benzyl acrylate, and the like.
- alkyl acrylates having 1 to 12 carbon atoms in the alkyl group are preferable, and examples thereof include ethyl acrylate, n-butyl acrylate, n-octyl acrylate, 2-ethylhexyl acrylate, and cyclohexyl acrylate.
- These acrylic acid esters may be used alone or in combination of two or more.
- the alkyl acrylate ester n-butyl acrylate is preferable, and a combination of n-butyl acrylate and ethyl acrylate, or a combination of n-butyl acrylate and 2-ethylhexyl acrylate is also preferable.
- the acrylic ester used in the polymerization step (II) preferably has a content ratio of n-butyl acrylate of 50 to 100% by weight, more preferably 70 to 100% by weight, and 80 to 100% by weight. % Is particularly preferred.
- the hard polymer (I) formed in the polymerization stage and (II) the soft polymer (II) formed in the polymerization stage are bonded.
- the soft polymer (II) has a structure that covers at least a part or the whole of the particles made of the hard polymer (I) located inside the graft copolymer. A part of the soft polymer (II) may enter inside the particles made of the hard polymer (I). However, not all of the soft polymer (II) may be bonded to the hard polymer (I).
- the monomer mixture (c) preferably contains an acrylate ester.
- the amount of the acrylic ester used is preferably 0 to 40% by weight, more preferably 5 to 40% by weight, still more preferably 10 to 40% by weight, and particularly preferably 15 to 35% by weight in the monomer mixture (c). 20 to 30% by weight is most preferable.
- the graft copolymer of the present invention has a structure in which the hard polymer (III) is graft-bonded to the hard polymer (I) and / or the soft polymer (II). All of the hard polymer (III) may be graft-bonded to the hard polymer (I) and / or the soft polymer (II), or a part of the hard polymer (III) is the hard polymer (I). And / or a polymer component (free polymer) which is graft-bonded to the soft polymer (II) but the remainder is not graft-bonded to either the hard polymer (I) or the soft polymer (II). May be present.
- the polymer component which is not graft-bonded also constitutes a part of the graft copolymer of the present invention.
- methacrylic acid ester examples include methyl methacrylate, ethyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, t-butyl methacrylate, hexyl methacrylate, cyclohexyl methacrylate, 2-ethylhexyl methacrylate, octyl methacrylate, methacrylic acid.
- examples thereof include isobornyl acid, phenyl methacrylate, benzyl methacrylate and the like.
- alkyl methacrylates having 1 to 4 carbon atoms in the alkyl group are preferred, and examples include methyl methacrylate, ethyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, and t-butyl methacrylate. These may be used alone or in combination of two or more, but methyl methacrylate is particularly preferred.
- Other monomers having a copolymerizable double bond include acrylic acid esters, aromatic vinyl monomers, and copolymerizable monomers other than (meth) acrylic acid esters and aromatic vinyl monomers. It is preferably at least one selected from the group consisting of monomers, more preferably an alkyl acrylate ester having an alkyl group having 1 to 12 carbon atoms, an aromatic vinyl monomer, and (meth) acrylic. It is one or more monomers selected from the group consisting of copolymerizable monomers other than acid esters and aromatic vinyl monomers.
- Examples of the acrylate esters include alkyl acrylates having an alkyl group having 1 to 12 carbon atoms, isobornyl acrylate, phenyl acrylate, benzyl acrylate, etc., and alkyl acrylates having an alkyl group having 1 to 12 carbon atoms.
- Examples of the ester include ethyl acrylate, n-butyl acrylate, n-octyl acrylate, 2-ethylhexyl acrylate, cyclohexyl acrylate, and the like.
- Examples of the aromatic vinyl monomer include styrene, ⁇ -methylstyrene, chlorostyrene, and other styrene derivatives.
- Examples of the copolymerizable monomer other than the (meth) acrylic acid ester and the aromatic vinyl monomer include unsaturated nitrile monomers such as acrylonitrile and methacrylonitrile, acrylic acid, methacrylic acid, ⁇ , ⁇ -unsaturated carboxylic acids such as crotonic acid, vinyl acetate, olefinic monomers such as ethylene and propylene, vinyl halide monomers such as vinyl chloride, vinylidene chloride and vinylidene fluoride, N-ethylmaleimide And maleimide monomers such as N-propylmaleimide, N-cyclohexylmaleimide, and No-chlorophenylmaleimide. Any of these may be used alone or in combination of two or more.
- the polyfunctional monomer and chain transfer agent used in the polymerization stage may be the same as those described in the above (I) polymerization stage.
- a polyfunctional monomer may or may not be used, but it is preferably not used from the viewpoint of imparting excellent mechanical properties to the film.
- a chain transfer agent may or may not be used, but it is preferable not to use it.
- the monomer mixture (c) may be the same as or different from the monomer mixture (a).
- the graft copolymer of the present invention may contain a polymerization stage other than the polymerization stages (I) to (III).
- the graft copolymer further includes (IV) a polymerization step after the polymerization steps (I) to (III). Further, one including a (IV) polymerization stage after the (II) polymerization stage and before the (III) polymerization stage is also one preferred embodiment. In any embodiment, (IV) The hard polymer (IV) formed by the polymerization step corresponds to the shell layer together with the hard polymer (III).
- the amount of the acrylate ester (d-2) used is more preferably 0 to 55% by weight, and 0 to 50%. % By weight is more preferred, 5 to 45% by weight is even more preferred, 10 to 40% by weight is even more preferred, 15 to 40% by weight is particularly preferred, and 20 to 40% by weight is most preferred.
- the methacrylic acid ester, acrylic acid ester, other monomer having a copolymerizable double bond, polyfunctional monomer and chain transfer agent used in the polymerization step are the above (I) to (III ) Are the same as those described above.
- a polyfunctional monomer may or may not be used, but it is preferably not used from the viewpoint of imparting excellent mechanical properties to the film.
- a chain transfer agent may or may not be used, but it is preferable not to use it.
- the monomer mixtures (a), (c) and (d) may be the same or different.
- the hard polymer (IV) is graft-bonded to the hard polymer (I) and / or the soft polymer (II) and / or the hard polymer (III). It can have the structure.
- All of the hard polymer (IV) may be graft-bonded to the hard polymer (I) and / or the soft polymer (II) and / or the hard polymer (III), or the hard polymer (IV) A part is graft-bonded to the hard polymer (I) and / or the soft polymer (II) and / or the hard polymer (III), while the remainder is the hard polymer (I), the soft polymer (II ) And the hard polymer (III) may be present as a polymer component that is not graft-bonded.
- the polymer component which is not graft-bonded also constitutes a part of the graft copolymer of the present invention.
- (I) polymerization step is a step performed before (II) polymerization step
- (II) polymerization step is a step performed before (III) polymerization step.
- the graft copolymer of the present invention is preferably polymerized in the above three stages (I), (II) and (III), and the above 4 (I), (II), (III) and (IV) 4 Those polymerized in stages are also preferred.
- the (IV) polymerization step may be a step performed before the (III) polymerization step as long as the polymerization step is performed after the (II) polymerization step.
- (III) It may be a step performed after the polymerization step. Further, another polymerization step may be carried out at any position of the polymerization steps (I) to (III) or the polymerization steps (I) to (IV).
- an acrylic polymer film formed by a solution casting method can be stretched to form a stretched film.
- a hard polymer is formed before and / or after the polymerization step (III).
- a graft copolymer produced by carrying out at least one polymerization step is preferable.
- a graft copolymer obtained by four-stage polymerization including (I) polymerization stage, (II) polymerization stage, (III) polymerization stage, and (IV) polymerization stage is more preferable.
- the (IV) polymerization stage may be either the pre-stage or the post-stage of the (III) polymerization stage as long as the polymerization stage is carried out after the (II) polymerization stage.
- the execution order of the (III) polymerization stage and the (IV) polymerization stage is not limited, but it is preferable to polymerize the (IV) polymerization stage after the (III) polymerization stage is polymerized.
- the graft copolymer comprises (I) methacrylic acid ester (a-1) 40 to 100% by weight, and another monomer (a-2) having a double bond copolymerizable therewith.
- the monomer mixture (a) comprising 60 to 0% by weight, and 0.01 to 10 parts by weight of a polyfunctional monomer with respect to 100 parts by weight in total of the above (a-1) and (a-2) And 0.1 to 4.0 parts by weight of a chain transfer agent is polymerized to obtain a hard polymer, (II) 60 to 100% by weight of acrylic acid ester (b-1) in the presence of the hard polymer, and A monomer mixture (b) comprising 0 to 40% by weight of another monomer (b-2) having a double bond copolymerizable therewith, and (b-1) and (b-2) ) Is polymerized with 0.1 to 5 parts by weight of a polyfunctional monomer for a total of 100 parts by weight of (III) In the presence of the soft polymer,
- methacrylic acid ester (d-1) 40 to 100% by weight, acrylic acid ester (d-2) 0 to 60% by weight and copolymerization
- a monomer mixture (d) comprising 0 to 5% by weight of another monomer (d-3) having a possible double bond, and (d-1), (d-2) and (d- It may be obtained by polymerizing 0 to 10 parts by weight of a polyfunctional monomer with respect to a total of 100 parts by weight of 3) to obtain a hard polymer.
- methacrylic acid ester (d-1) 40 to 100% by weight, acrylic acid ester (d-2) 0 to 60% by weight and copolymerization
- a monomer mixture (d) comprising 0 to 5% by weight of another monomer (d-3) having a possible double bond, and (d-1), (d-2) and (d- It may be obtained by polymerizing 0 to 10 parts by weight of a polyfunctional monomer with respect to a total of 100 parts by weight of 3) to obtain a hard polymer.
- the graft copolymer of the present invention may be polymerized in the presence of a chain transfer agent in a polymerization stage other than (I) the polymerization stage, if necessary.
- the total amount of chain transfer agent used in the production of the graft copolymer is preferably 0.01 to 6 parts by weight with respect to 100 parts by weight of the total amount of the monomer mixture constituting the graft copolymer of the present invention.
- the content is more preferably 0.1 to 4 parts by weight, still more preferably 0.2 to 2 parts by weight, and particularly preferably 0.24 to 1.6 parts by weight.
- the chain transfer agent used in the polymerization stage other than the polymerization stage is preferably an alkyl mercaptan chain transfer agent from the viewpoint of obtaining a graft copolymer having higher thermal stability.
- Mercaptan chain transfer agents and / or secondary alkyl mercaptan chain transfer agents are more preferable, and it is particularly preferable to use the same chain transfer agent as used in the polymerization step (I).
- the amount of chain transfer agent used in the polymerization stage is preferably more than 50% by weight and not more than 100% by weight of the total amount of chain transfer agent used in the production of the graft copolymer. More preferably, it is 70% by weight or more and 100% by weight or less, and particularly preferably 85% by weight or more and 100% by weight or less. It is also one of the preferred embodiments that no chain transfer agent is used in the polymerization stage other than (I) the polymerization stage.
- the total amount of the monomer mixture (a), (b), (c) in the polymerization stage (I) to (III) is 100 parts by weight of the total amount of the monomer mixture constituting the graft copolymer. 80 to 100 parts by weight is preferable, 90 to 100 parts by weight is more preferable, and 95 to 100 parts by weight is particularly preferable. Further, when (IV) a polymerization step is included, the content of the monomer mixture (d) is 0.1 to 20 parts by weight in a total amount of 100 parts by weight of the monomer mixture constituting the graft copolymer. It is preferably 1 to 15 parts by weight.
- the content of the monomer mixture (b) is preferably 20 to 90 parts by weight and preferably 40 to 90 parts by weight in 100 parts by weight of the total amount of the monomer mixture constituting the graft copolymer. More preferred is 45 to 85 parts by weight.
- the content of the monomer mixture (a) in the total amount of the monomer mixture constituting the graft copolymer is preferably from 0.1 to 35 parts by weight, and preferably from 1 to 30 parts by weight. More preferred is 5 to 30 parts by weight.
- the content of the monomer mixture (c) is preferably 0.1 to 40 parts by weight in 100 parts by weight of the total amount of the monomer mixture constituting the graft copolymer, and is 1 to 30 parts by weight. More preferred is 5 to 25 parts by weight.
- the ratio of the monomer mixture (a) to (b) is preferably 10:90 to 60:40 by weight ratio of the monomer mixture (a) :( b). : 60 is more preferable.
- the “monomer mixture constituting the graft copolymer” means a monomer component having one copolymerizable double bond constituting the graft copolymer, that is, a multifunctional monomer. It refers to the monomer component excluding the monomer.
- a graft copolymer obtained in the polymerization steps (I) to (III) it refers to the total amount of the monomer mixture (a), the monomer mixture (b) and the monomer mixture (c).
- the graft copolymer used in the present invention can be produced by ordinary emulsion polymerization using a known emulsifier.
- the emulsifier include anionic interfaces such as sodium alkyl sulfonate, sodium alkylbenzene sulfonate, sodium dioctyl sulfosuccinate, sodium lauryl sulfate, sodium fatty acid, and polyoxyethylene lauryl ether sodium phosphate.
- Activators, nonionic surfactants, and the like are shown. These surfactants may be used alone or in combination of two or more.
- polymerization may be performed using a phosphate ester salt (alkali metal or alkaline earth metal) such as polyoxyethylene lauryl ether sodium phosphate. preferable.
- the polymerization initiator used in the multistage polymerization to obtain the graft copolymer used in the present invention is a polymerization initiator having a 10-hour half-life temperature of 100 ° C. or less, and the heat of the acrylic resin film of the present invention. This is preferable from the viewpoint of improving stability.
- the polymerization initiator is not particularly limited as long as the 10-hour half-life temperature is 100 ° C. or less, but is preferably a persulfate, such as potassium persulfate, sodium persulfate, ammonium persulfate, and the like. Can be mentioned. Of these, potassium persulfate is particularly preferable.
- a reagent capable of generating radicals at a low temperature by a combination of an oxidizing agent such as ferrous sulfate and a reducing agent such as sodium formaldehydesulfoxylate there are redox initiators that generate radicals when used in combination.
- a redox initiator may generate a large amount of radicals at a time.
- a large amount of radicals are generated at one time.
- a bond having a relatively low energy required for cleaving the bond such as a head-to-head bond, may be generated in the polymer produced mainly.
- Such a bond is likely to become a starting point for zipping depolymerization when exposed to high temperatures such as during molding processing, which significantly impairs the thermal stability of the graft copolymer, and as a result, impairs the color tone of the film.
- the 10-hour half-life temperature of the polymerization initiator is preferably 100 ° C. or lower, more preferably 90 ° C. or lower, still more preferably 80 ° C. or lower, and particularly preferably 75 ° C. or lower.
- the polymerization initiator is preferably used at the polymerization stage (I) in the polymerization stage, and more preferably at the polymerization stage in the polymerization stage using a chain transfer agent. Further, it is particularly preferable to perform polymerization using the polymerization initiator in the entire polymerization stage of the graft copolymer.
- the total amount of the polymerization initiator used is preferably 0.01 to 1.0 part by weight with respect to 100 parts by weight of the total amount of the monomer mixture constituting the graft copolymer.
- the amount is more preferably 0.6 parts by weight, and particularly preferably 0.01 to 0.2 parts by weight.
- 0.90 parts by weight is preferable, (I) 0.01 to 0.2 parts by weight in the polymerization stage, (II) 0.01 to 0.4 parts by weight in the polymerization stage, and (III) 0 in the polymerization stage. Particularly preferred is 0.01 to 0.2 parts by weight.
- polymerization step is 29 weight% or less exceeding 1 weight% with respect to the total usage-amount of a polymerization initiator.
- the core layer of the graft copolymer refers to a crosslinked structure polymer obtained by carrying out the polymerization until (II) polymerization stage (therefore, the outermost layer of the core layer is formed by (II) polymerization stage.
- the shell layer refers to a hard polymer obtained by performing polymerization after the polymerization step (II).
- the graft copolymer latex thus obtained is coagulated by spray drying or by adding a water-soluble electrolyte such as salt or acid, and then heat-treated and then the resin component from the aqueous phase.
- the solid or powdery graft copolymer can be obtained by a known method such as separation, washing and drying. Particularly preferred is a method of coagulation using a salt.
- the salt to be used is not particularly limited, but divalent salts such as calcium salts such as calcium chloride and calcium acetate, magnesium salts such as magnesium chloride and magnesium sulfate are preferable, and magnesium salts such as magnesium chloride and magnesium sulfate are used. Is particularly preferred.
- additives such as an anti-aging agent and an ultraviolet absorber may be added.
- the fine polymerization scale it is preferable to remove the fine polymerization scale by filtering the graft copolymer latex before the coagulation operation with a filter, mesh or the like. Thereby, the fish eye, foreign material, etc. resulting from these fine superposition
- polymerization scales can be reduced and the transparency of dope of this invention can be improved.
- thermoplastic acrylic resins etc.
- a method of adding a soft polymer is also known, but in this case, the matrix resin (here, thermoplastic acrylic resin) and the soft polymer are homogeneous. There exists a fault that it mixes and the heat resistance of the film obtained is reduced.
- the graft copolymer of the present invention having a soft cross-linked polymer layer and a hard polymer layer covering the soft cross-linked polymer layer is used, in the film, the soft cross-linked polymer layer is an “island”, and a matrix resin. A discontinuous sea-island structure is formed in which the hard polymer layer becomes the “sea”.
- the soft crosslinked polymer layer may have a hard crosslinked polymer layer inside. Also, since the soft crosslinked polymer usually has a composition different from that of the matrix resin, it is difficult to uniformly disperse it in the matrix resin, resulting in deterioration of optical properties such as transparency and defects such as fish eyes. It can be a cause and a factor of lowering mechanical strength. However, the graft copolymer of the present invention having the hard polymer layer covering the soft cross-linked polymer layer makes it possible to uniformly disperse the soft cross-linked polymer layer in the matrix resin.
- “soft” means that the glass transition temperature of the polymer is less than 10 ° C. From the viewpoint of enhancing the impact absorbing ability of the soft layer and enhancing the impact resistance improving effect such as crack resistance, the glass transition temperature of the soft polymer is preferably less than 0 ° C, more preferably less than -20 ° C. preferable.
- “hard” means that the glass transition temperature of the polymer is 10 ° C. or higher.
- the glass transition temperature of the polymer (I) or (III) is less than 10 ° C., the heat resistance of the acrylic resin film of the present invention is lowered, or the crosslinked structure-containing weight is reduced when producing the crosslinked structure-containing polymer. There arises a problem that the coalescence of the coalescence and the agglomeration easily occur.
- the coalescence preferably has a glass transition temperature of 10 ° C. or more and 92 ° C. or less.
- the glass transition temperatures of the “soft” and “hard” polymers are calculated using the Fox equation using the values described in the Polymer Handbook (Polymer Hand Book (J. Brandrup, Interscience 1989)). The calculated values are used (for example, polymethyl methacrylate is 105 ° C. and polybutyl acrylate is ⁇ 54 ° C.).
- the polymer (I) obtained in the polymerization stage is a hard polymer
- the polymer (II) obtained in the polymerization stage is a soft polymer
- the polymer (III) obtained in the polymerization stage is a hard polymer.
- the polymer (IV) obtained in the polymerization stage (IV) is a hard polymer.
- the graft copolymer having such a configuration has a good balance of appearance, transparency, weather resistance, gloss, workability, thermal stability, and the like when blended with various thermoplastic acrylic resins. Thereby, a film excellent in thermal stability, weather resistance, gloss, workability, etc. can be provided without impairing the excellent color tone, appearance, and transparency unique to the blended thermoplastic acrylic resin.
- the blending amount of the thermoplastic acrylic resin is 30 to 98 parts by weight with respect to a total of 100 parts by weight of both components.
- the blending amount of the graft copolymer is preferably 70 to 2 parts by weight, the blending amount of the thermoplastic acrylic resin is 50 to 95 parts by weight, and the blending amount of the graft copolymer is more preferably 50 to 5 parts by weight.
- the amount of the thermoplastic acrylic resin is preferably 60 to 90 parts by weight, and the amount of the graft copolymer is particularly preferably 40 to 10 parts by weight.
- a solvent having a hydrogen bond term ⁇ H in the Hansen solubility parameter of 6.0 or more and 8.0 or less is used as a solvent for dissolving and dispersing the thermoplastic acrylic resin and the graft copolymer.
- a solvent having a hydrogen bond term ⁇ H of 6.3 to 7.5 is preferable, and a solvent having 7.0 to 7.2 is more preferable.
- solubility parameter is known as an index indicating the solubility of a substance, and the term of the cohesive energy of the SP value indicates the type of interaction energy acting between molecules (London dispersion force, between dipoles). Force, hydrogen bond strength), and Hansen solubility parameters are proposed, which are expressed as London dispersion force terms, dipole force terms, and hydrogen bond force terms, respectively.
- the hydrogen bond term ⁇ H of the Hansen solubility parameter is used as an index indicating the solubility when the thermoplastic acrylic resin and the graft copolymer are dissolved in the solvent.
- the value of the hydrogen bond term ⁇ H is more correlated with the solubility of the thermoplastic acrylic resin and the graft copolymer in the solvent than the London dispersion force term or the dipole force term. It was found that the hydrogen bond term ⁇ H can be an indicator of the solubility. Details of the hydrogen bond term ⁇ H can be found in, for example, Hideki Yamamoto, “Special Feature: Polymer Compatibilization Design 1. Solubility Evaluation Using Hansen Solubility Parameter (HSP Value)”, Adhesion Technology, Vol. 34, no. 3, 2014, vol. 116, page 1-8.
- Examples of the solvent satisfying the hydrogen bond term ⁇ H include acetone (7.0), acetonitrile (6.1), ethyl acetate (7.2), ⁇ -butyrolactone (7.4), and methylene chloride (7. 1), n-butyl acetate (6.3), N-methyl-2-pyrrolidone (7.2), tetrahydrofuran (8.0) and the like.
- the numbers in parentheses indicate the hydrogen bond term ⁇ H.
- methylene chloride is more preferable because the thermoplastic acrylic resin is rapidly dissolved and the dispersibility of the graft copolymer is good.
- the solvent contained in the dope of the present invention may be composed of only a solvent that satisfies the requirement of the hydrogen bond term ⁇ H, and may not contain any solvent that does not satisfy the requirement of the hydrogen bond term ⁇ H.
- the requirements for the hydrogen bond term ⁇ H are set in addition to the solvent satisfying the requirements of the hydrogen bond term ⁇ H in consideration of the film forming property, the film releasability, and the handling property in the solution casting method. It may contain a small amount of unsatisfactory solvent.
- the content of the solvent that does not satisfy the requirement of the hydrogen bond term ⁇ H is preferably 0% or more and less than 50% by weight, more preferably 30% by weight or less, with respect to the total solvent contained in the dope. % By weight or less is more preferable, and 5% by weight or less is particularly preferable.
- the ratio of the resin component (total amount of thermoplastic acrylic resin and graft copolymer) in the dope of the present invention is not particularly limited, and the solubility or dispersion of the thermoplastic acrylic resin and graft copolymer in the solvent used. However, it is preferably 5 to 50% by weight, more preferably 10 to 45% by weight, and still more preferably 15 to 40% by weight. It is.
- the dope of the present invention is a light stabilizer, an ultraviolet absorber, a heat stabilizer, a matting agent, a light diffusing agent, a colorant, a dye, a pigment, an antistatic agent, a heat ray reflective material, a lubricant, a plasticizer, and an ultraviolet absorber.
- additives such as additives, stabilizers, fillers, or styrene resins such as acrylonitrile styrene resin and styrene maleic anhydride resin, polycarbonate resin, polyvinyl acetal resin, cellulose acylate resin, polyvinylidene fluoride and polyalkyl fluoride ( It may contain other resins such as fluorine-based resins such as (meth) acrylate resins, silicone-based resins, polyolefin-based resins, polyethylene terephthalate resins, polybutylene terephthalate resins.
- fluorine-based resins such as (meth) acrylate resins, silicone-based resins, polyolefin-based resins, polyethylene terephthalate resins, polybutylene terephthalate resins.
- the dope of the present invention has the meaning of adjusting the orientation birefringence of the film to be formed.
- a low molecular weight compound having a molecular weight of 5000 or less, preferably 1000 or less, may be appropriately contained.
- the dope of the present invention is obtained by dissolving or dispersing an acrylic resin and a graft copolymer in a solvent.
- the graft copolymer has a structure in which primary particles having a core-shell structure having a core layer having an average particle diameter of 125 to 400 nm are aggregated or welded to a size of several microns to several tens of millimeters. obtain. For this reason, in order to produce the dope of the present invention, it is preferable to disperse the graft copolymer in a solvent uniformly, preferably in a state of being dispersed to the primary particles.
- a method for dispersing such a graft copolymer in a solvent conventionally known methods can be widely applied. For example, a method of adding a graft copolymer powder to a solvent, stirring while applying shear and / or heat as appropriate, and directly dispersing the graft copolymer, and adding the graft copolymer and an acrylic resin to the solvent at the same time, Alternatively, a method of preparing a dope directly by stirring or dispersing while applying heat, or directly mixing an acrylic resin and a graft copolymer, preferably heating and melting, and then applying appropriate shearing force to melt A method of kneading and preparing a resin composition (for example, a pellet-shaped resin composition) in which a graft copolymer is dispersed in an acrylic resin and then dispersing the resin composition in a solvent to prepare a dope, etc. Although illustrated, it is not limited to this.
- the aggregated or welded primary particles are preferably dispersed in the state of primary particles. Therefore, the requirements for the graft copolymer used in the present invention are as follows.
- the graft copolymer has an action of solvent (plasticization due to swelling), an action due to heat (plasticization), and an action of crushing the aggregated or welded primary particles by shearing force. It is preferable to apply effectively.
- the graft copolymer is sufficiently satisfactorily dispersed in the dope of the present invention, and when producing the acrylic resin film of the present invention, the formation of foreign matters and fish eyes, transparency Adverse effects such as reduction can be avoided.
- the dope of the present invention is used for producing an acrylic resin film by a solution casting method.
- an acrylic resin film can be produced by casting the dope of the present invention on the support surface and then evaporating the solvent.
- the resin film manufactured by the solution casting method is also called a cast film.
- a pellet containing a thermoplastic acrylic resin and a graft copolymer and optionally the other components is prepared, and then the pellet is mixed with a solvent to prepare a dope in which each component is dissolved and dispersed in the solvent.
- a thermoplastic acrylic resin and a graft copolymer, and optionally the other components are mixed with a solvent simultaneously or sequentially to prepare a dope in which each component is dissolved and dispersed in the solvent.
- the thermoplastic acrylic resin and the graft copolymer are individually mixed in a solvent to prepare two or more dope preparation solutions, and the dope can be prepared by mixing these preparation solutions.
- These dissolution steps can be performed by appropriately adjusting the temperature and pressure.
- a method in which a thermoplastic acrylic resin and a graft copolymer, and optionally a pellet containing the other components is prepared, and then dissolved and dispersed in a solvent may be preferable.
- the obtained dope can be filtered or degassed.
- the dope is fed to a pressure die by a liquid feed pump, and the dope is cast from the slit of the pressure die onto the surface (mirror surface) of a metal or synthetic resin endless belt or drum. Then, a dope film is formed.
- the formed dope film is heated on the support, and the solvent is evaporated to form a film.
- the film thus obtained is peeled off from the support surface. Then, you may attach
- the acrylic resin film of the present invention is formed by the dope solution casting method described above.
- the thickness of the film is not particularly limited, but is preferably 500 ⁇ m or less, more preferably 300 ⁇ m or less, and particularly preferably 200 ⁇ m or less. Further, it is preferably 10 ⁇ m or more, more preferably 30 ⁇ m or more, further preferably 50 ⁇ m or more, and particularly preferably 60 ⁇ m or more. If the thickness of the film is within the above range, there is an advantage that it is difficult to be deformed when vacuum forming is performed using the film, and it is difficult to cause breakage at the deep drawing portion, and the optical characteristics are uniform, A film with good transparency can be produced.
- the acrylic resin film of the present invention has a total light transmittance of preferably 85% or more, more preferably 88% or more, and even more preferably 90% or more when measured at a film thickness of 80 ⁇ m. If the total light transmittance is in the above-mentioned range, the transparency is high, so that it can be suitably used for optical members, decoration applications, interior applications, and vacuum forming applications that require light transmission.
- the acrylic resin film of the present invention preferably has a glass transition temperature of 90 ° C or higher, more preferably 100 ° C or higher, more preferably 110 ° C or higher, still more preferably 115 ° C or higher, and 120 ° C or higher. Is particularly preferred, with 124 ° C. or higher being most preferred. When the glass transition temperature is in the above range, an acrylic resin film having excellent heat resistance can be obtained.
- the acrylic resin film of the present invention preferably has a haze of 2.0% or less, more preferably 1.5% or less, still more preferably 1.3% or less, when measured at a film thickness of 80 ⁇ m. 0% or less is particularly preferable.
- the internal haze of the film is preferably 1.5% or less, more preferably 1.0% or less, further preferably 0.5% or less, and particularly preferably 0.3% or less. If the haze and the internal haze are in the above-described ranges, the transparency is high, and therefore, it is suitable for optical members, decoration applications, interior applications, and vacuum forming applications that require light transmission.
- haze consists of the haze of a film inside and a film surface (external), and each is expressed as an internal haze and an external haze.
- the acrylic resin film of the present invention can also be used as an optical film.
- the optical anisotropy is small.
- the absolute value of the thickness direction retardation is preferably 50 nm or less, more preferably 20 nm or less, further preferably 15 nm or less, still more preferably 10 nm or less, and further preferably 5 nm or less. Most preferred.
- a film having such a retardation can be suitably used as a polarizer protective film provided in a polarizing plate of a liquid crystal display device.
- the liquid crystal display device is used as a polarizer protective film provided in the polarizing plate of the liquid crystal display device. In some cases, a problem such as a decrease in contrast may occur.
- the retardation is an index value calculated based on birefringence, and the in-plane retardation (Re) and the thickness direction retardation (Rth) can be calculated by the following equations, respectively.
- both the in-plane retardation Re and the thickness direction retardation Rth are zero.
- nx, ny, and nz are respectively the in-plane stretching direction (polymer chain orientation direction) as the X axis, the direction perpendicular to the X axis as the Y axis, and the thickness direction of the film as the Z axis.
- And represents the refractive index in the respective axial directions.
- D represents the thickness of the film
- nx-ny represents orientation birefringence.
- the MD direction of the film is the X axis, but in the case of a stretched film, the stretch direction is the X axis.
- the acrylic resin film of the present invention has an orientation birefringence value of preferably ⁇ 2.6 ⁇ 10 ⁇ 4 to 2.6 ⁇ 10 ⁇ 4 , more preferably ⁇ 2.1 ⁇ 10 ⁇ 4 to 2.1. ⁇ 10 ⁇ 4 , more preferably ⁇ 1.7 ⁇ 10 ⁇ 4 to 1.7 ⁇ 10 ⁇ 4 , still more preferably ⁇ 1.6 ⁇ 10 ⁇ 4 to 1.6 ⁇ 10 ⁇ 4 , and still more preferably ⁇ 1.5 ⁇ 10 ⁇ 4 to 1.5 ⁇ 10 ⁇ 4 , more preferably ⁇ 1.0 ⁇ 10 ⁇ 4 to 1.0 ⁇ 10 ⁇ 4 , particularly preferably ⁇ 0.5 ⁇ 10 ⁇ 4 to 0.
- orientation birefringence is within the above range, stable optical characteristics can be obtained without causing birefringence during molding. It is also very suitable as an optical film used for liquid crystal displays and the like.
- the acrylic resin film of the present invention has high toughness and high flexibility even as an unstretched film, but may be further stretched, thereby improving the mechanical strength of the acrylic resin film and improving the film thickness accuracy. You can plan.
- a stretched film (a uniaxially stretched film or a biaxially stretched film) can be produced by appropriately performing a stretching operation as the film and solvent are degassed. Stretching during film forming and stretching after film forming may be combined as appropriate.
- the stretch ratio of the stretched film is not particularly limited, and may be determined according to the mechanical strength, surface properties, thickness accuracy, and the like of the stretched film to be manufactured. Although depending on the stretching temperature, the stretching ratio is generally preferably selected in the range of 1.1 to 5 times, more preferably in the range of 1.3 to 4 times, More preferably, it is selected in the range of 1.5 to 3 times. If the draw ratio is within the above range, the mechanical properties such as the elongation rate of the film, tear propagation strength, and fatigue resistance can be greatly improved.
- the acrylic resin film of this invention can reduce the gloss of the film surface by a well-known method as needed.
- a method of adding an inorganic filler or crosslinkable polymer particles include a method of adding an inorganic filler or crosslinkable polymer particles.
- embossing the obtained film it is possible to form a surface uneven layer such as a prism shape, a pattern, a design, or a knurling, or to reduce the gloss of the film surface.
- the acrylic resin film of the present invention may be laminated with another film using a dry lamination method and / or a thermal lamination method with an adhesive, an adhesive, etc., if necessary, or hard coated on the front or back surface of the film.
- Functional layers such as a layer, an antireflection layer, an antifouling layer, an antistatic layer, a printed decorative layer, a metallic luster layer, a surface uneven layer, and a matte layer can be formed and used.
- the acrylic resin film of the present invention can be used for various applications using properties such as heat resistance, transparency, and flexibility.
- automotive interiors personal computer interiors, mobile interiors, solar cell interiors, solar cell backsheets; video fields such as cameras, VTRs, projector lenses, viewfinders, filters, prisms, Fresnel lenses, lens covers, Lens field such as optical disk pickup lens for CD player, DVD player, MD player, optical recording field for optical disk such as CD, DVD, MD, organic EL film, light guide plate for liquid crystal, diffusion plate, back sheet, reflection Sheets, polarizer protective films, polarizing film transparent resin sheets, retardation films, light diffusion films, films for liquid crystal displays such as prism sheets, surface protection films and other information equipment fields, optical fibers, optical switches, optical connectors, etc.
- Communication field automotive Vehicle field such as drite, tail lamp lens, inner lens, instrument cover, sunroof, etc.
- medical equipment field such as eyeglasses, contact lens, endoscope lens, medical supplies requiring sterilization, road sign, bathroom equipment, flooring, Road translucent plate, pair glass lens, daylighting window, carport, lighting lens, lighting cover, building material field such as sizing for building materials, microwave cooking container (tableware), housing for home appliances, toys, sunglasses, Can be used for stationery.
- it can be used as an alternative application of a molded product using a transfer foil sheet.
- the acrylic resin film of the present invention can be used by being laminated on a base material such as metal or plastic.
- the acrylic resin film can be laminated by laminating, wet laminating, applying an adhesive to a metal plate such as a steel plate, and then drying and bonding the film to the metal plate, dry laminating, extrusion laminating, hot Examples include melt lamination.
- the film is placed in a mold and is then placed in the mold after insert molding or laminate injection press molding in which resin is filled by injection molding, or after preforming the film.
- insert molding or laminate injection press molding in which resin is filled by injection molding can be used.
- the laminate of the acrylic resin film of the present invention is a civil engineering such as automotive interior materials, automotive exterior materials, paint replacement applications, window frames, bathroom equipment, wallpaper, flooring, lighting / light control members, soundproof walls, road signs, etc.
- Architectural parts, household goods, housing for furniture and electronic equipment, housing for office automation equipment such as facsimiles, notebook computers, copiers, front panels for LCD screens of terminals such as mobile phones, smartphones and tablets, and lighting Lenses, automotive headlights, optical lenses, optical fibers, optical disks, light guide plates for liquid crystals, optical elements, parts of electrical or electronic devices, medical supplies that require sterilization, toys or recreation items, fiber reinforced resins It can be used for composite materials.
- the acrylic resin film of the present invention is suitable for an optical film in that it has excellent heat resistance and optical properties, and can be used for various optical members.
- the front plate of the liquid crystal screen of terminals such as mobile phones, smartphones, tablets, illumination lenses, automobile headlights, optical lenses, optical fibers, optical disks, light guide plates for liquid crystals, diffusion plates, back sheets, reflection sheets, polarizing films Transparent resin sheet, retardation film, light diffusion film, prism sheet, surface protective film, optical isotropic film, polarizer protective film, transparent conductive film, liquid crystal display device periphery, organic EL device periphery, optical communication field etc. It can be applied to known optical applications.
- (III-2) shown in Table 1 was continuously added over 25 minutes, and polymerization was further continued for 60 minutes to obtain a graft copolymer latex.
- the polymerization conversion rate was 100.0%.
- the obtained latex was salted out and coagulated with magnesium chloride, washed with water and dried to obtain a white powdery graft copolymer (B2).
- the gel fraction of the graft copolymer (B2) was 93.7%.
- the emulsifier represents polyoxyethylene lauryl ether phosphate
- n-OM represents n-octyl mercaptan
- t-DM represents t-dodecyl mercaptan
- the average particle diameter was measured in the state of the latex obtained by the polymerization up to the polymerization step (II). The measurement was performed using light scattering at a wavelength of 546 nm using a U-5100 type ratio beam spectrophotometer manufactured by Hitachi High-Technologies Corporation.
- Method for measuring the gel fraction of the graft copolymer About 40 mL of methyl ethyl ketone (MEK) was added to about 1 g of the graft copolymer and allowed to stand overnight. After that, stirring with a stirrer chip for 30 minutes, using a centrifuge (Hitachi Koki Co., Ltd., CP80NX), repeating the operation of centrifuging at 30000 rpm for 1 hour at 12 ° C., 3 sets, and polymer components insoluble in MEK (gel Polymer, GP) and MEK soluble components. The obtained gel polymer was dried at 60 ° C.
- MEK methyl ethyl ketone
- MEK soluble matter it is separated into methanol soluble matter (soluble matter) and methanol insoluble matter (free polymer, FP) by putting it in about 200 ml of methanol and reprecipitation. It dried on the same conditions as the above, and collect
- the gel fraction (%) was calculated by the following formula.
- a polymethyl methacrylate resin (weight average molecular weight: 105,000) was supplied at 42.4 kg / hr, and the polymethyl methacrylate resin was melted and filled with a kneading block, and then the polymethyl methacrylate was discharged from a nozzle.
- 2.0 parts by weight of monomethylamine (Mitsubishi Gas Chemical Co., Ltd.) was injected with respect to 100 parts by weight of the resin.
- a reverse flight was placed at the end of the reaction zone to fill the resin. By-products and excess methylamine after the reaction were removed by reducing the pressure at the vent port to -0.090 MPa.
- Resin (I) was obtained by cooling the resin which came out as a strand from the die
- the set temperature of each temperature control zone of the extruder was 240 to 260 ° C., and the screw rotation speed was 72 rpm.
- the resin (I) obtained from the hopper was supplied at 41 kg / hr, and the resin was melted and filled with a kneading block. Dimethyl carbonate was injected to reduce the carboxyl groups in the resin. A reverse flight was placed at the end of the reaction zone to fill the resin. By-products after reaction and excess dimethyl carbonate were removed by reducing the pressure at the vent port to -0.092 MPa.
- the resin that emerged as a strand from a die provided at the exit of the extruder was cooled in a water tank and then pelletized with a pelletizer to obtain a glutarimide acrylic resin (A2).
- a glutarimide acrylic resin (A2) About the said glutarimide acrylic resin (A2), the imidation ratio, glutarimide content, glass transition temperature, and refractive index were measured according to the said method. As a result, the imidation ratio was 13 mol%, the glutarimide content was 7% by weight, the glass transition temperature was 125 ° C., and the refractive index was 1.50.
- Example 13 Without pelletization, 6 g of graft copolymer (B13), 9 g of acrylic resin (A2), and 60 g of methylene chloride were mixed and allowed to stand for 30 minutes, and then stirred for 1 minute by hand shaking and allowed to stand for 6 hours. The mixture is stirred for 1 minute by shaking, left for 12 hours, stirred for 1 minute by shaking, left for 20 minutes, and stirred for 5 hours with a stirrer chip, so that acrylic resin (A2), graft copolymer A dope containing (B13) and methylene chloride was prepared (the solid content concentration in the dope was 20 wt%, and the graft copolymer concentration in the resin component was 40 wt%).
- ⁇ Measurement method of haze of dope> Using a turbidimeter (Nippon Denshoku Industries Co., Ltd., NDH 4000), the haze of the dope obtained in each Example and Comparative Example was measured using a quartz cell with an optical path length of 10 mm in accordance with JIS K7136. . The haze value of each obtained dope was evaluated according to the following criteria.
- the haze value is less than 20%, and no undispersed lump is observed in the dope.
- Example 1 ⁇ Method of measuring dissolution rate> About Example 1 and Comparative Example 1, the dissolution rate when preparing the dope was measured by the following procedure. A stirrer chip, 8 g of solvent, and 2 g of pellets were placed in a container, stirred with a magnetic stirrer at a rotation speed of 200 rpm, and the time until complete dissolution was measured visually, and this was taken as the dissolution rate. The results are shown in Table 5.
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Abstract
Description
本発明のドープに含まれる熱可塑性アクリル系樹脂は、(メタ)アクリル酸エステルを含むビニル系単量体を構成単位とする樹脂であればよく、公知の熱可塑性アクリル系樹脂を使用できる。特に、メタクリル酸エステル由来の構造単位を含む熱可塑性アクリル系樹脂が好ましく、アルキル基の炭素数が1~4のメタクリル酸アルキルエステル単位を30重量%以上、より好ましくは50重量%以上含むアクリル系樹脂がより好ましい。熱安定性の観点から、構成単位としてメタクリル酸メチル単位30~100重量%、および、これと共重合可能な他のビニル系単量体単位70~0重量%を含有する熱可塑性アクリル系樹脂がさらに好ましい。
測定機器:HLC-8220GPC(東ソー)
検出器 :RI検出器(装置内蔵)
溶媒 :テトラヒドロフラン
ガードカラム:TSKguardcolumn SuperHZ-H(4.6×35mm)(東ソー)
分析カラム:TSKgel SuperHZM-H(6.0×150mm)(東ソー)
測定温度:40℃
標準物質:標準ポリスチレン(東ソー)
本発明のドープに含まれる熱可塑性アクリル系樹脂のガラス転移温度は使用する条件と用途に応じて設定することができる。優れた耐熱性が要求される用途でなければ、ガラス転移温度が115℃未満であってもよいが、使用時の耐熱性の観点から90℃以上であることが好ましい。一方、耐熱性が要求される用途に対しては、ガラス転移温度が115℃以上の耐熱性に優れた熱可塑性アクリル系樹脂が好ましい。熱可塑性アクリル系樹脂のガラス転移温度は118℃以上がより好ましく、120℃以上がさらに好ましく、125℃以上が最も好ましい。
一般式(5)で表されるマレイミド単位の具体例としては、無置換のマレイミド単位、N-メチルマレイミド単位、N-フェニルマレイミド単位、N-シクロヘキシルマレイミド単位、N-ベンジルマレイミド単位等が挙げられる。マレイミド単位としては1種類のみを含有してもよいし、2種類以上を含有してもよい。
[メタクリル酸メチル単位の含有量A(mol%)]=100×a/(a+b)
[グルタルイミド単位の含有量B(mol%)]=100×b/(a+b)
[グルタルイミド単位の含有量(重量%)]=100×(b×(グルタルイミド単位の分子量))/(a×(メタクリル酸メチル単位の分子量)+b×(グルタルイミド単位の分子量))
なお、モノマー単位として上記以外の単位を含む場合においても、樹脂中の各モノマー単位の含有量(mol%)と分子量から、同様にグルタルイミド単位の含有量(重量%)を求めることができる。
本発明に用いられるグラフト共重合体は熱安定性に優れており、本発明のアクリル系樹脂フィルムに、優れた透明性及び色調を付与し、さらに耐折り曲げ性や耐割れ性などの機械的強度を向上させることができる。
(膨潤度)=[(乾燥前ゲルポリマー重量)-(乾燥後ゲルポリマーの重量)]/(乾燥後ゲルポリマーの重量)
グラフト共重合体が示すメチルエチルケトンによる膨潤度を上記範囲に設定するには、コア層を重合させる際に、特に後述する(I)重合段階で連鎖移動剤の存在下で重合を行なう方法や、シェル層(シェル層が多層であるときにはその多層のうち最もガラス転移温度の高い層)を構成する重合体のガラス転移温度が92℃以下(好ましくは80℃以下、より好ましくは75℃以下、さらに好ましくは70℃以下、特に好ましくは60℃以下)になるよう当該重合体を構成する単量体を選択する方法などが挙げられる。これらの方法はそれぞれ単独で使用してもよいが、組合せて使用することが好ましい。ただし、本発明における膨潤度の設定方法はこれらの方法に限定されるわけではない。
膨潤度係数S=(メチルエチルケトンによる膨潤度/グラフト共重合体中の軟質重合体比率)/(コア層中の軟質重合体比率)
本発明のグラフト共重合体は、ゲル分率が90%以下であることが好ましい。ゲル分率とは、グラフト共重合体全量に対して、グラフト共重合体のメチルエチルケトンに不溶な成分が占める重量比率である。グラフト共重合体のゲル分率が90%以下であると、グラフト共重合体に、メチルエチルケトンに可溶な成分が相当量含まれていることになり、その可溶成分のために、ドープ中でグラフト共重合体の一次粒子がばらけやすくなる。ゲル分率は87%以下がより好ましく、85%以下がさらに好ましく、83%以下がよりさらに好ましく、80%以下が特に好ましい。ゲル分率の下限値は特に限定されないが、低すぎるとアクリル系樹脂フィルムの耐折り曲げ性、スリット時の割れ、打ち抜き時の割れなどの機械的特性が低下する場合があるため、65%以上が好ましく、68%以上がより好ましく、70%以上がさらに好ましく、73%以上が最も好ましい。
(ゲル分率)=(乾燥後ゲルポリマーの重量)/(乾燥後ゲルポリマーの重量+乾燥後フリーポリマーの重量+乾燥後メタノール可溶分の重量)×100
本発明の好適な実施態様によると、グラフト共重合体におけるコア層は、メタクリル酸エステル単位(a-1)40~100重量%、これと共重合可能な二重結合を有する他の単量体単位(a-2)60~0重量%、ならびに、前記(a-1)および(a-2)の合計100重量部に対して多官能性単量体単位0.01~10重量部を構成単位として含む硬質重合体(I)と、アクリル酸エステル単位(b-1)60~100重量%、これと共重合可能な二重結合を有する他の単量体単位(b-2)0~40重量%、ならびに、前記(b-1)および(b-2)の合計100重量部に対して多官能性単量体単位0.1~5重量部を構成単位として含む軟質重合体(II)とを有し、軟質重合体(II)は、硬質重合体(I)に結合しており、シェル層は、メタクリル酸エステル単位(c-1)60~100重量%、これと共重合可能な二重結合を有する他の単量体単位(c-2)40~0重量%、ならびに、前記(c-1)および(c-2)の合計100重量部に対して多官能性単量体単位0~10重量部を構成単位として含む硬質重合体(III)を含み、硬質重合体(III)は、硬質重合体(I)および/または軟質重合体(II)にグラフト結合している。
(I)重合段階では、メタクリル酸エステル(a-1)40~100重量%、および、これと共重合可能な二重結合を有する他の単量体(a-2)60~0重量%からなる単量体混合物(a)、ならびに前記(a-1)および(a-2)の合計100重量部に対して多官能性単量体0.01~10重量部及び連鎖移動剤0.1~4.0重量部を重合して硬質重合体(I)を得ることが好ましい。
(II)重合段階では、アクリル酸エステル(b-1)60~100重量%、および、これと共重合可能な二重結合を有する他の単量体(b-2)0~40重量%からなる単量体混合物(b)、ならびに前記(b-1)および(b-2)の合計100重量部に対して多官能性単量体0.1~5重量部及び連鎖移動剤0~2.0重量部を重合して軟質重合体(II)を得ることが好ましい。
(III)重合段階では、メタクリル酸エステル(c-1)60~100重量%、およびこれと共重合可能な二重結合を有する他の単量体(c-2)40~0重量%からなる単量体混合物(c)、ならびに前記(c-1)および(c-2)の合計100重量部に対して多官能性単量体0~10重量部及び連鎖移動剤0~6重量部を重合して硬質重合体(III)を得ることが好ましい。
本発明のグラフト共重合体は、前記(I)~(III)の重合段階以外の重合段階を含んでもよい。
本発明のドープには、熱可塑性アクリル系樹脂およびグラフト共重合体を溶解分散させるための溶剤として、ハンセン溶解度パラメーターにおける水素結合項δHが6.0以上8.0以下である溶剤を用いる。このような溶剤を用いてドープを構成することで、熱可塑性アクリル系樹脂およびグラフト共重合体の溶剤への良好な溶解性または分散性を実現することができる。前記水素結合項δHが6.3以上7.5以下を示す溶剤が好ましく、7.0以上7.2以下を示す溶剤がより好ましい。
本発明のドープは、適宜、光安定剤、紫外線吸収剤、熱安定剤、艶消し剤、光拡散剤、着色剤、染料、顔料、帯電防止剤、熱線反射材、滑剤、可塑剤、紫外線吸収剤、安定剤、フィラー等の公知の添加剤、または、アクリロニトリルスチレン樹脂やスチレン無水マレイン酸樹脂などのスチレン系樹脂、ポリカーボネート樹脂、ポリビニルアセタール樹脂、セルロースアシレート樹脂、ポリフッ化ビニリデンやポリフッ化アルキル(メタ)アクリレート樹脂などのフッ素系樹脂、シリコーン系樹脂、ポリオレフィン系樹脂、ポリエチレンテレフタレート樹脂、ポリブチレンテレフタレート樹脂等その他の樹脂を含有するものであってもよい。
本発明のドープは、溶剤中に、アクリル系樹脂およびグラフト共重合体が溶解または分散したものである。先述のように、グラフト共重合体は、平均粒子径が125~400nmのコア層を有するコアシェル型構造を持つ一次粒子が、数ミクロン乃至数十ミリメートルの大きさに凝集あるいは溶着した構造を有し得る。このため、本発明のドープを製造するためには、グラフト共重合体を溶剤に均一に、好ましくは一次粒子までばらけた状態で、分散させることが好ましい。
本発明のドープは、溶液流延法によってアクリル系樹脂フィルムを製造するのに使用される。具体的には、本発明のドープを支持体表面に流延した後、溶剤を蒸発させることによりアクリル系樹脂フィルムを製造することができる。このように溶液流延法によって製造された樹脂フィルムを、キャストフィルムともいう。
本発明のアクリル系樹脂フィルムは、前述したドープの溶液流延法により形成されるものである。該フィルムの厚みは特に限定されないが、500μm以下であることが好ましく、300μm以下であることがより好ましく、200μm以下であることが特に好ましい。また、10μm以上であることが好ましく、30μm以上であることがより好ましく、50μm以上であることがさらに好ましく、60μm以上であることが特に好ましい。フィルムの厚みが上記範囲内であれば、当該フィルムを用いて真空成形を実施する際に変形しにくく、深絞り部での破断が発生しにくいという利点があり、さらに、光学特性が均一で、透明性が良好なフィルムを製造することができる。一方、フィルムの厚みが上記範囲を超えると、成形後のフィルムの冷却が不均一になり、光学特性が不均一になる傾向がある。また、フィルムの厚みが上記範囲を下回ると、フィルムの取扱が困難になることがある。
Rth=((nx+ny)/2-nz)×d
上記式中において、nx、ny、およびnzは、それぞれ、面内において伸張方向(ポリマー鎖の配向方向)をX軸、X軸に垂直な方向をY軸、フィルムの厚さ方向をZ軸とし、それぞれの軸方向の屈折率を表す。また、dはフィルムの厚さを表し、nx-nyは配向複屈折を表す。なお、フィルムのMD方向をX軸とするが、延伸フィルムの場合は延伸方向をX軸とする。
本発明のアクリル系樹脂フィルムは未延伸フィルムとしても靭性が高く柔軟性に富むものであるが、さらに延伸してもよく、これにより、アクリル系樹脂フィルムの機械的強度の向上、膜厚精度の向上を図ることができる。
本発明のアクリル系樹脂フィルムは、必要に応じて、公知の方法によりフィルム表面の光沢を低減させることができる。そのような方法としては、例えば、無機充填剤または架橋性高分子粒子を添加する方法が挙げられる。また、得られるフィルムにエンボス加工を施すことにより、プリズム形状やパターン、意匠、ナーリングなどの表面凹凸層を形成したり、フィルム表面の光沢を低減させることも可能である。
<グラフト共重合体(B1)の製造>
撹拌機付き8L重合装置に、以下の物質を仕込んだ。
脱イオン水 180部
ポリオキシエチレンラウリルエーテルリン酸 0.002部
ホウ酸 0.5部
炭酸ナトリウム 0.05部
水酸化ナトリウム 0.01部
重合機内を窒素ガスで充分に置換した後、内温を80℃にし、過硫酸カリウム0.03部を2%水溶液で入れ、次いで表1に示した(I)を81分かけて連続的に添加した。さらに60分重合を継続することにより、(I)の重合物を得た。重合転化率は98.6%であった。
<グラフト共重合体(B2)の製造>
撹拌機付き8L重合装置に、以下の物質を仕込んだ。
脱イオン水 175部
ポリオキシエチレンラウリルエーテルリン酸 0.01部
ホウ酸 0.5部
炭酸ナトリウム 0.05部
重合機内を窒素ガスで充分に置換した後、内温を80℃にし、表1に示した(I)の26%を重合機に一括で追加し、その後ソディウムホルムアルデヒドスルフォキシレ-ト0.06部、エチレンジアミン四酢酸-2-ナトリウム0.006部、硫酸第一鉄0.001部、t-ブチルハイドロパーオキサイド0.02部を追加し、その15分後にt-ブチルハイドロパーオキサイド0.03部を追加し、さらに15分重合を継続した。次に、水酸化ナトリウム0.01部を2%水溶液で添加し、ポリオキシエチレンラウリルエーテルリン酸0.09部を追加し、(I)の残り74%を60分かけて連続的に添加した。添加終了30分後にt-ブチルハイドロパーオキサイド0.07部を追加し、さらに30分重合を継続することにより、(I)の重合物を得た。重合転化率は100.0%であった。
<グラフト共重合体(B3)の製造>
撹拌機付き8L重合装置に、以下の物質を仕込んだ。
脱イオン水 180部
ポリオキシエチレンラウリルエーテルリン酸 0.03部
ホウ酸 0.5部
炭酸ナトリウム 0.05部
重合機内を窒素ガスで充分に置換した後、内温を80℃にし、過硫酸カリウム0.03部を2%水溶液で入れ、次いで表1に示した(I)のポリオキシエチレンラウリルエーテルリン酸以外を24分かけて連続的に添加した。(I)の追加開始から15分目にポリオキシエチレンラウリルエーテルリン酸0.21部を追加し、20分目に水酸化ナトリウム0.003部を2%水溶液で追加した。さらに60分重合を継続することにより、(I)の重合物を得た。重合転化率は95.6%であった。
<グラフト共重合体(B4)の製造>
撹拌機付き8L重合装置に、以下の物質を仕込んだ。
脱イオン水 180部
ポリオキシエチレンラウリルエーテルリン酸 0.003部
ホウ酸 0.5部
炭酸ナトリウム 0.05部
水酸化ナトリウム 0.01部
重合機内を窒素ガスで充分に置換した後、内温を80℃にし、過硫酸カリウム0.03部を2%水溶液で入れ、次いで表1に示した(I)を81分かけて連続的に添加した。さらに60分重合を継続することにより、(I)の重合物を得た。重合転化率は98.9%であった。
<グラフト共重合体(B5)の製造>
撹拌機付き8L重合装置に、以下の物質を仕込んだ。
脱イオン水 180部
ポリオキシエチレンラウリルエーテルリン酸 0.003部
ホウ酸 0.5部
炭酸ナトリウム 0.05部
水酸化ナトリウム 0.01部
重合機内を窒素ガスで充分に置換した後、内温を80℃にし、過硫酸カリウム0.03部を2%水溶液で入れ、次いで表1に示した(I)を81分かけて連続的に添加した。さらに60分重合を継続することにより、(I)の重合物を得た。重合転化率は100.0%であった。
<グラフト共重合体(B6)の製造>
撹拌機付き8L重合装置に、以下の物質を仕込んだ。
脱イオン水 180部
ポリオキシエチレンラウリルエーテルリン酸 0.003部
ホウ酸 0.5部
炭酸ナトリウム 0.05部
水酸化ナトリウム 0.01部
重合機内を窒素ガスで充分に置換した後、内温を80℃にし、過硫酸カリウム0.03部を2%水溶液で入れ、次いで表1に示した(I)を81分かけて連続的に添加した。さらに60分重合を継続することにより、(I)の重合物を得た。重合転化率は99.2%であった。
<グラフト共重合体(B7)の製造>
撹拌機付き8L重合装置に、以下の物質を仕込んだ。
脱イオン水 180部
ポリオキシエチレンラウリルエーテルリン酸 0.003部
ホウ酸 0.5部
炭酸ナトリウム 0.05部
水酸化ナトリウム 0.01部
重合機内を窒素ガスで充分に置換した後、内温を80℃にし、過硫酸カリウム0.03部を2%水溶液で入れ、次いで表1に示した(I)を81分かけて連続的に添加した。さらに60分重合を継続することにより、(I)の重合物を得た。重合転化率は98.5%であった。
<グラフト共重合体(B8)の製造>
撹拌機付き8L重合装置に、以下の物質を仕込んだ。
脱イオン水 180部
ポリオキシエチレンラウリルエーテルリン酸 0.003部
ホウ酸 0.5部
炭酸ナトリウム 0.05部
水酸化ナトリウム 0.01部
重合機内を窒素ガスで充分に置換した後、内温を80℃にし、過硫酸カリウム0.03部を2%水溶液で入れ、次いで表2に示した(I)を81分かけて連続的に添加した。さらに60分重合を継続することにより、(I)の重合物を得た。重合転化率は98.7%であった。
<グラフト共重合体(B9)の製造>
撹拌機付き8L重合装置に、以下の物質を仕込んだ。
脱イオン水 180部
ポリオキシエチレンラウリルエーテルリン酸 0.003部
ホウ酸 0.5部
炭酸ナトリウム 0.05部
水酸化ナトリウム 0.01部
重合機内を窒素ガスで充分に置換した後、内温を80℃にし、過硫酸カリウム0.03部を2%水溶液で入れ、次いで表2に示した(I)を81分かけて連続的に添加した。さらに60分重合を継続することにより、(I)の重合物を得た。重合転化率は99.6%であった。
<グラフト共重合体(B10)の製造>
撹拌機付き8L重合装置に、以下の物質を仕込んだ。
脱イオン水 180部
ポリオキシエチレンラウリルエーテルリン酸 0.003部
ホウ酸 0.5部
炭酸ナトリウム 0.05部
水酸化ナトリウム 0.01部
重合機内を窒素ガスで充分に置換した後、内温を80℃にし、過硫酸カリウム0.03部を2%水溶液で入れ、次いで表2に示した(I)を81分かけて連続的に添加した。さらに60分重合を継続することにより、(I)の重合物を得た。重合転化率は99.0%であった。
<グラフト共重合体(B11)の製造>
撹拌機付き8L重合装置に、以下の物質を仕込んだ。
脱イオン水 180部
ポリオキシエチレンラウリルエーテルリン酸 0.003部
ホウ酸 0.5部
炭酸ナトリウム 0.05部
水酸化ナトリウム 0.01部
重合機内を窒素ガスで充分に置換した後、内温を80℃にし、過硫酸カリウム0.03部を2%水溶液で入れ、次いで表2に示した(I)を81分かけて連続的に添加した。さらに60分重合を継続することにより、(I)の重合物を得た。重合転化率は99.0%であった。
<グラフト共重合体(B12)の製造>
撹拌機付き8L重合装置に、以下の物質を仕込んだ。
脱イオン水 180部
ポリオキシエチレンラウリルエーテルリン酸 0.003部
ホウ酸 0.5部
炭酸ナトリウム 0.05部
水酸化ナトリウム 0.01部
重合機内を窒素ガスで充分に置換した後、内温を80℃にし、過硫酸カリウム0.03部を2%水溶液で入れ、次いで表2に示した(I)を81分かけて連続的に添加した。さらに60分重合を継続することにより、(I)の重合物を得た。重合転化率は99.3%であった。
<グラフト共重合体(B13)の製造>
撹拌機付き8L重合装置に、以下の物質を仕込んだ。
脱イオン水 180部
ポリオキシエチレンラウリルエーテルリン酸 0.003部
ホウ酸 0.5部
炭酸ナトリウム 0.05部
水酸化ナトリウム 0.01部
重合機内を窒素ガスで充分に置換した後、内温を80℃にし、過硫酸カリウム0.03部を2%水溶液で入れ、次いで表2に示した(I)を81分かけて連続的に添加した。さらに60分重合を継続することにより、(I)の重合物を得た。重合転化率は98.6%であった。
平均粒子径は、前記(II)重合段階までの重合で得られたラテックスの状態で測定した。測定装置として、株式会社 日立ハイテクノロジーズのU-5100形レシオビーム分光光度計を用いて、546nmの波長の光散乱を用いて求めた。
グラフト共重合体約1gにメチルエチルケトン(MEK)約40mLを加え、1晩静置した。その後30分間スターラーチップで攪拌し、遠心分離機(日立工機株式会社、CP80NX)を用い、30000rpmで1時間、12℃で遠心分離を行う作業を3セット繰り返し、MEKに不溶なポリマー成分(ゲルポリマー、GP)と、MEKに可溶な成分に分離した。得られたゲルポリマーをEYELA社、VOS-450VD真空乾燥機で60℃、5torrで10時間乾燥させることで、乾燥したゲルポリマーを回収した。さらに、MEK可溶分に関しても、約200mlのメタノールに投入し、再沈殿することで、メタノール可溶分(可溶分)と、メタノール不溶分(フリーポリマー、FP)に分離し、それぞれを、上記と同じ条件で乾燥させて、乾燥したフリーポリマーと、乾燥した可溶分を回収した。ゲル分率(%)は以下の式で算出した。
(ゲル分率)=(乾燥後GP重量)/(乾燥後GP重量+乾燥後FP重量+乾燥後可溶分重量)×100
(グラフト共重合体のMEK膨潤度の測定方法)
上記と同様にして、MEKに不溶なポリマー成分(ゲルポリマー、GP)を分離した後、上記と同じ条件で乾燥させて乾燥したゲルポリマーを回収した。乾燥前のGP(MEKを含んだ状態のGP)の重量と、乾燥後のGPの重量から、以下の式により、メチルエチルケトンによる膨潤度を算出した。
(膨潤度)=[(乾燥前GP重量)-(乾燥後GP重量)]/(乾燥後GP重量)
(製造例14)
<グルタルイミドアクリル系樹脂(A2)の製造>
使用した押出機は口径40mmの噛合い型同方向回転式二軸押出機(L/D=90)である。押出機の各温調ゾーンの設定温度を250~280℃、スクリュー回転数は85rpmとした。ポリメタクリル酸メチル樹脂(重量平均分子量:10.5万)を42.4kg/hrで供給し、ニーディングブロックによって上記ポリメタクリル酸メチル樹脂を溶融、充満させた後、ノズルから上記ポリメタクリル酸メチル樹脂100重量部に対して2.0重量部のモノメチルアミン(三菱ガス化学株式会社製)を注入した。反応ゾーンの末端にはリバースフライトを入れて樹脂を充満させた。反応後の副生成物および過剰のメチルアミンをベント口の圧力を-0.090MPaに減圧して除去した。押出機出口に設けられたダイスからストランドとして出てきた樹脂を、水槽で冷却した後、ペレタイザでペレット化することにより、樹脂(I)を得た。
<ペレットの作製>
アクリル系樹脂(A1)90重量部と、表3に記載のグラフト共重合体(B)10重量部とを、ベント付単軸押出機(HW-40-28:40m/m、L/D=28、田端機械(株)製)を用い、設定温度C1~C3=200℃、C4=210℃、C5=220℃、D=230℃で混練押出し、ペレット化した。なお、アクリル系樹脂(A1)は、住友化学社製 スミペックスLG(重量平均分子量8.3万)を使用した。
上記で得られたペレット15gに塩化メチレン60gを加え、30分間静置し、その後、手振りで1分間攪拌し、6時間静置し、手振りで1分間攪拌し、12時間静置し、手振りで1分間攪拌し、20分間静置し、スターラーチップで5時間攪拌することで、アクリル系樹脂、グラフト共重合体及び塩化メチレン(δH=7.1)を含むドープ(ドープ中の固形分濃度は20重量%、樹脂成分中のグラフト共重合体濃度は10重量%)を調製した。
<グラフト共重合体(B)のドープ準備液の作製>
表3に記載のグラフト共重合体(B)6gを塩化メチレン114gに投入し、14時間静置し、その後、手振りで1分間攪拌し、20分間静置し、スターラーチップで5時間攪拌することで、グラフト共重合体のドープ準備液(グラフト共重合体濃度は5重量%)を調製した。
アクリル系樹脂(A1)30gを塩化メチレン70gに投入し、14時間静置し、その後、手振りで1分間攪拌し、20分間静置することで、アクリル系樹脂のドープ準備液(アクリル系樹脂濃度は30重量%)を調製した。
上記で得られたグラフト共重合体のドープ準備液30gとアクリル系樹脂のドープ準備液45gを混ぜて、30分間静置し、その後、手振りで1分間攪拌し、6時間静置し、手振りで1分間攪拌し、12時間静置し、手振りで1分間攪拌し、20分間静置し、スターラーチップで5時間攪拌することで、アクリル系樹脂、グラフト共重合体及び塩化メチレンを含むドープ(ドープ中の固形分濃度は20重量%、樹脂成分中のグラフト共重合体濃度は10重量%)を調製した。
<ペレットの作製>
製造例14で得たグルタルイミドアクリル系樹脂(A2)60重量部と、グラフト共重合体(B13)40重量部とを、ベント付単軸押出機(HW-40-28:40m/m、L/D=28、田端機械(株)製)を用い、設定温度C1~C3=200℃、C4=210℃、C5=220℃、D=230℃で混練押出し、ペレット化した。
上記で得られたペレット15gに塩化メチレン60gを加え、30分間静置し、その後、手振りで1分間攪拌し、6時間静置し、手振りで1分間攪拌し、12時間静置し、手振りで1分間攪拌し、20分間静置し、スターラーチップで5時間攪拌することで、アクリル系樹脂(A2)、グラフト共重合体(B13)及び塩化メチレンを含むドープ(ドープ中の固形分濃度は20重量%、樹脂成分中のグラフト共重合体濃度は40重量%)を調製した。
<グラフト共重合体(B13)のドープ準備液の作製>
グラフト共重合体(B13)24gを塩化メチレン96gに投入し、14時間静置し、その後、手振りで1分間攪拌し、20分間静置し、スターラーチップで5時間攪拌することで、グラフト共重合体のドープ準備液(グラフト共重合体濃度は20重量%)を調製した。
アクリル系樹脂(A2)30gを塩化メチレン70gに投入し、14時間静置し、その後、手振りで1分間攪拌し、20分間静置することで、アクリル系樹脂(A2)のドープ準備液(アクリル系樹脂濃度は30重量%)を調製した。
上記で得られたグラフト共重合体(B13)のドープ準備液30gとアクリル系樹脂(A2)のドープ準備液30g、塩化メチレン15gを混ぜて、30分間静置し、その後、手振りで1分間攪拌し、6時間静置し、手振りで1分間攪拌し、12時間静置し、手振りで1分間攪拌し、20分間静置し、スターラーチップで5時間攪拌することで、アクリル系樹脂(A2)、グラフト共重合体(B13)及び塩化メチレンを含むドープ(ドープ中の固形分濃度は20重量%、樹脂成分中のグラフト共重合体濃度は40重量%)を調製した。
ペレット化を経ずに、グラフト共重合体(B13)6g、アクリル系樹脂(A2)9g、及び塩化メチレン60gを混ぜて、30分間静置し、その後、手振りで1分間攪拌し、6時間静置し、手振りで1分間攪拌し、12時間静置し、手振りで1分間攪拌し、20分間静置し、スターラーチップで5時間攪拌することで、アクリル系樹脂(A2)、グラフト共重合体(B13)及び塩化メチレンを含むドープ(ドープ中の固形分濃度は20重量%、樹脂成分中のグラフト共重合体濃度は40重量%)を調製した。
グラフト共重合体(B13)の代わりにグラフト共重合体(B2)を使用したこと以外は、実施例12と同様にしてアクリル系樹脂(A2)、グラフト共重合体(B2)及び塩化メチレンを含むドープ(ドープ中の固形分濃度は20重量%、樹脂成分中のグラフト共重合体濃度は40重量%)を調製した。
濁度計(日本電色工業社製、NDH 4000)を用いて、JIS K7136に準拠し、光路長10mmの石英セルを用いて、各実施例及び比較例で得られたドープのヘイズを測定した。得られた各ドープのヘイズ値を以下の基準で評価した。
A:ヘイズ値が20%未満
B:ヘイズ値が20%以上23%未満
C:ヘイズ値が23%以上30%未満
D:ヘイズ値が30%以上40%未満
E:ヘイズ値が40%以上
ガラス板(30cm×30cm)の上に、各実施例1~13で得られたドープを約20mL垂らし、200μm厚みのアプリケーターを用いてドープ膜を形成し、その後、90℃で10分間1次乾燥し、さらに120℃で5分間2次乾燥することで、キャストフィルムを作製した。
実施例1と比較例1についてドープを調製する際の溶解速度を次の手順で測定した。容器にスターラーチップ、及び8gの溶剤と2gのペレットを入れ、マグネチックスターラーで200rpmの回転数で攪拌し、目視で完全に溶解するまでの時間を計測して、これを溶解速度とした。結果を表5に示す。
溶剤として塩化メチレンの代わりに、メチルエチルケトン(δH=5.1)を使用した以外は実施例1と同様にしてドープを調製した。ドープのヘイズを上記方法により測定した。また、ドープを調製する際の溶解速度を上記方法により測定した。結果を表5に示す。
溶剤として塩化メチレンの代わりに、メチルエチルケトンを使用した以外は比較例1と同様にしてドープを調製した。ドープのヘイズを上記方法により測定した。また、ドープを調製する際の溶解速度を上記方法により測定した。結果を表5に示す。
溶剤として塩化メチレンの代わりに、N,N-ジメチルホルムアミド(δH=11.3)を使用した以外は実施例1と同様にしてドープを調製した。ドープのヘイズを上記方法により測定した。また、ドープを調製する際の溶解速度を上記方法により測定した。結果を表5に示す。
溶剤として塩化メチレンの代わりに、N,N-ジメチルホルムアミドを使用した以外は比較例1と同様にしてドープを調製した。ドープのヘイズを上記方法により測定した。また、ドープを調製する際の溶解速度を上記方法により測定した。結果を表5に示す。
Claims (22)
- 熱可塑性アクリル系樹脂、グラフト共重合体、及び、溶剤、を含む、溶液流延法によるフィルム製造用ドープであって、
前記グラフト共重合体は、コア層とシェル層を有し、前記コア層の平均粒子径が125~400nmであり、
前記グラフト共重合体は、メチルエチルケトンによる膨潤度が3.5以上であり、
前記溶剤は、ハンセン溶解度パラメーターにおける水素結合項δHが6.0以上8.0以下である、ドープ。 - 前記グラフト共重合体は、メチルエチルケトンによる膨潤度が3.6以上5.0以下である、請求項1に記載のドープ。
- 前記グラフト共重合体は、(メチルエチルケトンによる膨潤度/グラフト共重合体中の軟質重合体比率)/(コア層中の軟質重合体比率)で表される膨潤性係数Sが10.5~18.0である、請求項1又は2に記載のドープ。
- コア層は、アルキルチオ基からなるポリマー末端構造を有する、請求項1~3のいずれかに記載のドープ。
- シェル層は、単層又は多層であり、前記単層を構成する重合体、又は、前記多層のうち最もガラス転移温度の高い層を構成する重合体は、ガラス転移温度が92℃以下である、請求項1~4のいずれかに記載のドープ。
- グラフト共重合体は、ゲル分率が90%以下である、請求項1~5のいずれかに記載のドープ。
- コア層は、メタクリル酸エステル単位(a-1)40~100重量%、これと共重合可能な二重結合を有する他の単量体単位(a-2)60~0重量%、及び、前記(a-1)および(a-2)の合計100重量部に対して多官能性単量体単位0.01~10重量部を構成単位として含む硬質重合体(I)と、
アクリル酸エステル単位(b-1)60~100重量%、これと共重合可能な二重結合を有する他の単量体単位(b-2)0~40重量%、及び、前記(b-1)および(b-2)の合計100重量部に対して多官能性単量体単位0.1~5重量部を構成単位として含む軟質重合体(II)とを有し、
軟質重合体(II)は、硬質重合体(I)に結合しており、
シェル層は、メタクリル酸エステル単位(c-1)60~100重量%、これと共重合可能な二重結合を有する他の単量体単位(c-2)40~0重量%、及び、前記(c-1)および(c-2)の合計100重量部に対して多官能性単量体単位0~10重量部を構成単位として含む硬質重合体(III)を含み、
硬質重合体(III)は、硬質重合体(I)および/または軟質重合体(II)にグラフト結合している、請求項1~6のいずれかに記載のドープ。 - 硬質重合体(I)が、アルキルチオ基からなるポリマー末端構造を有する、請求項7に記載のドープ。
- 熱可塑性アクリル系樹脂は、重量平均分子量が30万以上である、請求項1~8のいずれかに記載のドープ。
- 熱可塑性アクリル系樹脂は、重量平均分子量が17万以下である、請求項1~9のいずれかに記載のドープ。
- 熱可塑性アクリル系樹脂は、メタクリル酸メチル単位30~100重量%、及び、これと共重合可能な他のビニル系単量体単位0~70重量%を構成単位として含む重合体である、請求項1~10のいずれかに記載のドープ。
- 熱可塑性アクリル系樹脂は、主鎖に環構造を有し、
前記環構造は、グルタルイミド環構造、ラクトン環構造、無水マレイン酸由来環構造、マレイミド由来環構造、及び無水グルタル酸環構造からなる群より選択される少なくとも1種である、請求項1~11のいずれかに記載のドープ。 - 熱可塑性アクリル系樹脂の配合量とグラフト共重合体の配合量の合計100重量部に対して、前記熱可塑性アクリル系樹脂の配合量が30~98重量部であり、前記グラフト共重合体の配合量が70~2重量部である、請求項1~12のいずれかに記載のドープ。
- 溶液流延法によるアクリル系樹脂フィルムの製造方法であって、
請求項1~13のいずれかに記載のドープを支持体表面に流延した後、溶剤を蒸発させる工程を含む、フィルムの製造方法。 - 前記ドープは、熱可塑性アクリル系樹脂とグラフト共重合体を含むペレットを作製した後、該ペレットを前記溶剤に溶解分散させることで調製される、請求項14に記載のフィルムの製造方法。
- 請求項1~14のいずれかに記載のドープから形成されてなるアクリル系樹脂フィルム。
- アクリル系樹脂フィルムは、厚みが10~500μmである、請求項16に記載のアクリル系樹脂フィルム。
- アクリル系樹脂フィルムは、他基材表面への積層保護用フィルムである、請求項16又は17に記載のアクリル系樹脂フィルム。
- アクリル系樹脂フィルムは、光学用フィルムである、請求項16又は17に記載のアクリル系樹脂フィルム。
- 光学用フィルムは、偏光子保護フィルムである、請求項19に記載のアクリル系樹脂フィルム。
- 偏光子と、請求項20に記載のアクリル系樹脂フィルムを積層してなる、偏光板。
- 請求項21に記載の偏光板を含む、ディスプレイ装置。
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