CN104520102B - 多层膜、装饰成型用膜及成型体 - Google Patents
多层膜、装饰成型用膜及成型体 Download PDFInfo
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- CN104520102B CN104520102B CN201380041505.6A CN201380041505A CN104520102B CN 104520102 B CN104520102 B CN 104520102B CN 201380041505 A CN201380041505 A CN 201380041505A CN 104520102 B CN104520102 B CN 104520102B
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- layer
- film
- thickness
- multilayer film
- resin
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Classifications
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- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B11/00—Making preforms
- B29B11/14—Making preforms characterised by structure or composition
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/001—Combinations of extrusion moulding with other shaping operations
- B29C48/002—Combinations of extrusion moulding with other shaping operations combined with surface shaping
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/07—Flat, e.g. panels
- B29C48/08—Flat, e.g. panels flexible, e.g. films
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
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- B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
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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
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
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- B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
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- B29C2949/00—Indexing scheme relating to blow-moulding
- B29C2949/07—Preforms or parisons characterised by their configuration
- B29C2949/0715—Preforms or parisons characterised by their configuration the preform having one end closed
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- B—PERFORMING OPERATIONS; TRANSPORTING
- 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
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
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- B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
- B29C48/21—Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- 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
- B29K2069/00—Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/03—3 layers
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- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/24—All layers being polymeric
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Abstract
本发明提供一种表面硬度、透明性优异、热收缩率小、脆性高且装饰成型加工后的修整性容易的多层膜。本发明的多层膜包含:包含粘度平均分子量为13000以上且小于20000的聚碳酸酯树脂的层(A层)、以及层叠于A层的两面的包含丙烯酸系树脂的层(B‐1层和B‐2层),该多层膜整体的厚度为50~200μm,且A层的厚度为整体厚度的5%~30%。
Description
技术领域
本发明涉及用于成型物的表面装饰用途的多层膜及其成型体。
背景技术
模内转印、模内层叠、真空压空成型层叠等装饰成型法从以往就是以家电制品、汽车内饰部件、杂货类等为对象使用的方法,但近年来环境意识提高、技术也持续革新,应用范围大幅地扩展。装饰成型使用对膜施以印刷、赋形或金属蒸镀等而得的装饰成型用膜。作为其基材膜,目前为止使用丙烯酸膜、PET膜、聚碳酸酯膜等。
作为该基材膜所需的特性,可以举出可正确地转印为目标形状的热成型性、在印刷等对膜表面进行装饰时所需的耐溶剂性、表面硬度、耐热性、透明性、耐候性等。然而,没有全部满足这些特性的基材,目前为止的现状是根据用途一边面对问题一边使用。
例如丙烯酸膜的特征在于,其优异的透明性、耐候性优异、且膜的脆性高而容易切割,因此特定的装饰成型加工方法的装饰性优异,大多用于装饰用途。然而,丙烯酸膜在向要求耐热性的用途的展开方面有限,难以在维持装饰时的切割容易性的同时要求高耐热性的领域应用。
此外,在聚碳酸酯膜的情况下,虽然耐热性高,但与丙烯酸膜相比韧性高而难以切割,因此装饰性差。
作为该基材特性的改善方法的一种,提出有在聚碳酸酯树脂层的至少一面层叠丙烯酸树脂层而得的层叠膜(参照专利文献1~10)。
该层叠膜是改善丙烯酸膜的耐热性,另一方面,从聚碳酸酯膜的方面来看改善了其表面硬度、耐溶剂性和耐候性,进行所谓的“取优”而成为具有平衡的特性的层叠膜。然而,修整性、表面硬度与丙烯酸单层膜相比无法令人满意,且热成型性、成型后的外观、透明性常成为问题。
作为如此的装饰成型用膜的基材,目前为止,从原料方面的改良或制成层叠体这样的构成方面出发,也对其特性改善进行了各种各样的研究,但仍并不充分,需要进一步的改良。
现有技术文献
专利文献
专利文献1:日本特许第3457514号公报
专利文献2:日本特许第3489972号公报
专利文献3:日本特许第3904262号公报
专利文献4:日本特开2005-231257号公报
专利文献5:日本特开2005-219330号公报
专利文献6:日本特开2007-160892号公报
专利文献7:日本特开2009-172953号公报
专利文献8:日本特开2009-234183号公报
专利文献9:日本特开2009-234184号公报
专利文献10:日本特开2009-248363号公报
发明内容
本发明的目的是提供一种耐热性、表面硬度、透明性优异、热收缩率小、脆性高的装饰成型加工后的修整性容易的多层膜。此外,本发明的目的是提供使用该多层膜的装饰成型用膜和装饰成型体。此外,本发明的目的是提供该多层膜的制造方法。
本发明的发明人等对于具有聚碳酸酯树脂层和丙烯酸树脂层的多层膜,针对聚碳酸酯树脂层的原料方面以及聚碳酸酯树脂层与丙烯酸树脂层的厚度构成进行了深入研究。其结果发现,通过在由粘度平均分子量为13000以上且小于20000的聚碳酸酯树脂构成的层(A层)的两面层叠由丙烯酸系树脂构成的层(B-1层和B-2层),且将A层厚度调整为整体的厚度的5%~30%,可以得到耐热性、透明性、表面硬度、修整性优异、低热收缩率的多层膜,完成了本发明。
即,本发明如下所述。
1.一种多层膜,其中,包含:包含粘度平均分子量为13000以上且小于20000的聚碳酸酯树脂的层(A层)、以及层叠于A层的两面的包含丙烯酸系树脂的层(B-1层和B-2层),该多层膜的整体的厚度为50~200μm,且A层的厚度为整体厚度的5%~30%。
2.如前项1所述的多层膜,其中,雾度为4%以下。
3.一种装饰成型用膜,对前项1或2所述的多层膜的一面施以装饰而成。
4.一种装饰成型体,其包含基材及形成于该基材表面的前项3所述的装饰成型用膜。
5.一种在A层的两面分别层叠有B-1层和B-2层的前项1所述的多层膜的制造方法,其中包含:将构成A层的包含粘度平均分子量为13000以上且小于20000的聚碳酸酯树脂的成型材料A、构成B-1层的包含丙烯酸系树脂的成型材料B-1、以及构成B-2层的包含丙烯酸系树脂的成型材料B-2进行共挤出。
具体实施方式
以下,对本发明进行详述。
[多层膜]
本发明的多层膜具有包含聚碳酸酯树脂的层(A层)以及包含丙烯酸系树脂的层(B-1层和B-2层)。即,是在A层的两面分别层叠B-1层和B-2层而成的多层膜。
<聚碳酸酯树脂>
聚碳酸酯树脂是二羟基化合物通过碳酸酯键结合的聚合物,通常是使二羟基成分和碳酸酯前体通过界面聚合法或熔融聚合法反应而得到的聚合物。
作为二羟基成分的代表例,可以举出2,2-双(4-羟基苯基)丙烷(通称双酚A)、2,2-双{(4-羟基-3-甲基)苯基}丙烷、2,2-双(4-羟基苯基)丁烷、2,2-双(4-羟基苯基)-3-甲基丁烷、2,2-双(4-羟基苯基)-3,3-二甲基丁烷、2,2-双(4-羟基苯基)-4-甲基戊烷、1,1-双(4-羟基苯基)环己烷、1,1-双(4-羟基苯基)-3,3,5-三甲基环己烷、1,1-双(4-羟基苯基)辛烷、1,1-双(4-羟基苯基)癸烷、9,9-双{(4-羟基-3-甲基)苯基}芴、9,9-双(4-羟基苯基)芴、α,α’-双(4-羟基苯基)-间二异丙基苯、异山梨醇、1,3-丙二醇、1,4-丁二醇、1,6-己二醇等。可以是将它们单独使用而得的均聚物,也可以是共聚2种以上而得的共聚物。从物性方面、成本方面出发,优选为双酚A。本发明中,优选为双酚成分的50摩尔%以上为双酚A的聚碳酸酯,更优选为60摩尔%以上,进一步优选为90摩尔%以上。
作为具体的聚碳酸酯,可以举出双酚A的均聚物、双酚A与1,1-双(4-羟基苯基)-3,3,5-三甲基环己烷的2元共聚物、双酚A与9,9-双{(4-羟基-3-甲基)苯基}芴的2元共聚物等。最优选为双酚A的均聚物。
该聚碳酸酯树脂的玻璃化转变温度优选为100~200℃的范围,更优选为120~180℃的范围,进一步优选为135~150℃的范围。若玻璃化转变温度过高,则其熔融粘度变得过高而熔融制膜变得困难,因此不优选,此外,若玻璃化转变温度过低,则多层膜的耐热性不足,因此不适合本发明用途。
作为碳酸酯前体,使用羰基卤化物、碳酸酯或卤代甲酸酯等,具体而言,可以举出光气、碳酸二苯酯或二元酚的二卤代甲酸酯等。
使上述二价二羟基化合物与碳酸酯前体通过界面聚合法或熔融聚合法反应而制造聚碳酸酯树脂时,也可以根据需要使用催化剂、末端终止剂、二元酚的抗氧化剂等。此外,聚碳酸酯树脂可以是将三官能以上的多官能性芳香族化合物共聚而得的分支聚碳酸酯树脂,也可以是将芳香族或脂肪族的二官能性羧酸共聚而得的聚酯碳酸酯树脂,此外,也可以是将得到的聚碳酸酯树脂混合2种以上而得的混合物。
聚碳酸酯树脂的分子量以粘度平均分子量表示为13000以上且小于20000的范围。若该分子量低于13000,则熔融粘度过低,熔融制膜变得困难,此外,若为20000以上,则作为多层膜的韧性变强,装饰成型后的装饰变得困难。优选为14000~19000的范围,更优选为15000~18500的范围。聚碳酸酯树脂为2种以上的混合物时表示混合物整体的分子量。这里,粘度平均分子量是指测定将聚碳酸酯0.7g溶解于二氯甲烷100mL而得的溶液在20℃的比粘度(ηsp),由下述式算出粘度平均分子量(Mv)。
ηsp/c=[η]+0.45×[η]2c
[η]=1.23×10-4M0.83
(其中c=0.7g/dL,[η]为特性粘度)
进而,该聚碳酸酯树脂中也可以添加一般的热稳定剂、紫外线吸收剂、耐光稳定剂、着色剂、脱模剂、润滑剂、防静电剂等各种添加剂。
<丙烯酸系树脂>
本发明中B-1层和B-2层用的丙烯酸系树脂是以甲基丙烯酸酯或丙烯酸酯的聚合物为主体的树脂。作为丙烯酸系树脂,可以举出甲基丙烯酸甲酯的均聚物、或优选含有50重量%以上、更优选含有70重量%以上、进一步优选含有80重量%以上甲基丙烯酸甲酯的共聚物。
作为其它共聚成分,可以举出甲基丙烯酸乙酯、甲基丙烯酸丁酯、甲基丙烯酸2-乙基己酯、丙烯酸甲酯、丙烯酸乙酯、丙烯酸丁酯、丙烯酸2-乙基己酯等。
此外,作为其它共聚成分,可以举出其它烯键式不饱和单体。具体而言,可以举出苯乙烯、α-甲基苯乙烯、乙烯基甲苯等乙烯基芳香族化合物、1,3-丁二烯、异戊二烯等二烯系化合物、丙烯腈、甲基丙烯腈等烯基氰化合物、丙烯酸、甲基丙烯酸、马来酸酐、N-取代马来酰亚胺等。它们可以单独使用,也可以组合使用2种以上。共聚成分的含量优选为0~50重量%,更优选为0~30重量%,进一步优选为0~20重量%。
丙烯酸树脂的制造方法一般大致分为乳液聚合法、悬浮聚合法、连续聚合法,本发明所使用的丙烯酸树脂可以通过任意聚合方法制造。
本发明中,在不损害发明效果的范围内,为了改善多层膜的热成型时的毛边、裂纹,也可以在丙烯酸树脂中添加橡胶粒子。通过在丙烯酸树脂中添加橡胶粒子而改善韧性为公知的技术,已被广泛地应用,也可以在本发明中使用。一般若添加橡胶粒子,则有透明性下降的趋势,在本发明中优选使用透明性尽可能高的橡胶粒子。作为优选的橡胶粒子,可以举出:形成核壳结构的橡胶粒子,该核壳结构的橡胶粒子是将由丙烯酸系的交联弹性聚合物构成的核层用甲基丙烯酸酯树脂包覆而得的;以及形成3层结构的橡胶粒子等,该3层结构的橡胶粒子是将中心部的甲基丙烯酸酯树脂用丙烯酸系的交联弹性聚合物包覆,进一步将其外侧用甲基丙烯酸酯树脂被覆而得的。该多层结构的橡胶粒子在丙烯酸树脂中的分散性良好,能够得到透明性高的多层膜。本发明中,装饰成型时,可以综合考虑基材膜所需的韧性、透明性而决定橡胶粒子的有无、以及含有橡胶粒子时该橡胶粒子的种类、量、大小等。
进而,该丙烯酸系树脂中也可以添加一般的热稳定剂、紫外线吸收剂、耐光稳定剂、着色剂、脱模剂、润滑剂、防静电剂、消光剂等各种添加剂。
<层构成>
本发明的多层膜的总厚度为50~200μm的范围,优选为50~150μm的范围,更优选为60~130μm的范围。若总厚度过薄,则操作变得困难而不适合用作装饰膜用途,此外,在生产上也变得困难。另一方面,总厚度过厚时,热成型时的膜加热花费时间,或热成型性下降,因此不优选。
此外,就本发明中优选的多层膜的厚度组成而言,A层的厚度为总厚度的5~30%。A层的厚度更优选为总厚度的10~25%。A层的厚度小于5%时,耐热性、热收缩率差,若大于30%,则修整性差,不优选。
B-1层和B-2层的厚度优选为20μm以上。若B-1层或B-2层的厚度薄于20μm,则表面硬度、耐溶剂性的特性变得不充分,因此不优选。更优选B-1层或B-2层的厚度为30μm以上,进一步优选为40μm以上。B-1层或B-2层的厚度的上限取决于总厚度和A层的厚度,但优选为90μm以下,更优选为70μm以下。
作为装饰成型用膜的基材膜,优选为透明性高的膜。就本发明的多层膜而言,其总光线透射率优选为90%以上,更优选为91%以上。此外,雾度优选为4%以下,更优选为3%以下,进一步优选为2%以下,特别优选为1%以下。
<多层膜的制造方法>
本发明的多层膜可以通过以往公知的方法制造。可以举出例如预先将各层分别制膜并进行层叠、或热压加压的方法;将预先制膜得到的一层的膜作为基材,在其两面涂布而形成另一层的方法;通过共挤出法将各个树脂层层叠制膜的方法等。其中,从经济性、生产稳定性等出发,最优选为使用共挤出法的制造方法。
即,本发明的多层膜可以将A层用的成型材料A、B-1层用的成型材料B-1和B-2层用的成型材料B-2共挤出而制造。
共挤出法是使用各自的挤出机将成型材料A、成型材料B-1和成型材料B-2熔融挤出,使用供料头或多岐管模头进行层叠,从而得到多层膜的方法,通过调整各挤出机的挤出量、制膜速度、模头狭缝间隔等,能够控制所得到的多层膜的总厚度和厚度组成。
采用共挤出法的情况下,一般以冷却辊将从模具挤出的熔融树脂冷却后,通过缠绕成卷状而制膜,本发明中在这种情况下也可以对多层膜附加保护膜后缠绕。尤其是丙烯酸系树脂不含橡胶粒子时,有时表面的润滑性不足而难以直接缠绕,在这种情况下,优选附加保护膜后缠绕。在这种情况下,可以使用聚乙烯系、聚丙烯系等公知的保护膜。此外,丙烯酸系树脂包含橡胶粒子,且得到的多层膜的表面的润滑性良好的情况下,也能够不使用保护膜而直接缠绕。
[装饰成型用膜]
本发明的装饰成型用膜是对上述多层膜的一面施以装饰而得的膜。
作为装饰方法,可以举出利用印刷形成图案层、形成金属或金属氧化物的薄膜层等,也可以将它们进行组合。
作为用于形成图案层的印刷方法,可以根据制品形状、印刷用途而使用凹版印刷、平板印刷、柔版印刷、干式胶版印刷、移印、丝网印刷等公知的印刷方法。此外,作为形成金属或金属氧化物的薄膜层的方法,可以举出蒸镀、喷镀法、镀覆法等。作为蒸镀法,具体而言,可以举出真空蒸镀法、溅射法、离子镀、热CVD法、等离子CVD法、光CVD法等方法。此外,作为喷镀法,可以举出大气压等离子喷镀法、减压等离子喷镀法等。作为镀覆法,可以举出无电解镀覆法、熔融镀覆法、电镀法等。这些之中,蒸镀法能够容易地形成金属层,此外,从品质方面、环境对应的方面出发也优选使用。
也可以在如此对多层膜的一面施以装饰而得的膜上进一步形成粘合层或胶粘层。该粘合层或胶粘层是在热成型时使装饰对象体与装饰成型用膜的胶粘性提高的层。通常,真空成型、压空成型的情况下,装饰的面大多成为装饰对象体侧,因此该粘合层和胶粘层优选形成于基材膜的装饰面上。作为材料,可以应用适合基材膜和装饰对象体的材质的热敏性或压敏性的粘合剂、胶粘剂。具有粘合层或胶粘层时,通常以在其上附加脱模膜的形式提供。
此外,本发明的装饰成型用膜也可以对与装饰对象体为相反侧的表面进行硬涂、防水·防油涂布、紫外线吸收涂布、红外线吸收涂布、金属蒸镀涂布等各种表面处理。
[装饰成型体]
本发明的装饰成型体包含基材及形成于其表面的上述装饰成型用膜。基材为后述的具有各种部件的形状的成型体。基材由热可塑性树脂、热固化树脂等各种树脂构成。
作为装饰成型体,可以举出汽车内饰件、汽车的指示器面板、电化制品、化妆品盒、建材内饰和外饰品、各种设备或制品和杂货类的盒、开关、钥匙、键盘、方向盘、杠杆、按钮、作为家电·AV设备的电脑或手机和移动设备的外壳或外装部件等。装饰成型体的装饰层的转印性优异、表面硬度高,此外,耐候性、耐热性优异,可用作各种电子·电气设备,车辆部件、机械部件、其它建材、农业·渔业用材料、运输容器、包装容器、杂货等各种制品。
装饰成型体可以通过使用装饰成型用膜进行以往公知的各种成型,在表面得到装饰成型体。
作为成型法,可以举出属于注射成型中的模具内装饰施工方法的嵌入成型法,该方法是将预先沿着注射成型模具进行真空成型而得的装饰成型用膜安装于模具内,在其中注射熔融树脂,进行注射成型的同时使膜熔敷于制品。
此外,还可以举出如下方法:虽然是注射成型模具内的装饰,但将装饰成型用膜以真空压贴附于模具内腔侧,在注射成型时同时成型而施加热和压力,从而使膜贴合于成型体的方法。此外,可以举出以真空成型或压空成型进行层叠的方法。此外,也优选使用以注射成型模具内的装饰方法将装饰成型用膜注射成型时同时成型时,仅将装饰层转印于成型体的模内转印成型法。
作为热成型时的装饰成型用膜的加热方法,可以使用红外线加热器、电加热器、高频感应、卤素灯、微波、高温衍生物(蒸气等)、激光等各种的方法。
实施例
以下,通过实施例更具体地说明本发明,但本发明不仅限定于这些实施例。实施例、比较例中进行的物性测定以下述方法进行。
(1)聚碳酸酯的粘度平均分子量
聚碳酸酯的粘度平均分子量(M)是由浓度0.7g/dL的二氯甲烷溶液在20℃的粘度测定求出特性粘度[η],由下述式算出。
ηSP/c=[η]+0.45×[η]2c(其中[η]为特性粘度)
[η]=1.23×10-4M0.83
c=0.7
(2)玻璃化转变温度(Tg)
使用TA Instruments制2920型DSC,以升温速度20℃/分钟测定,求出下降点。
(3)多层膜的总厚度
以Anritsu株式会社制的电子微膜厚计测定,为在膜宽度方向的中央部的值。
(4)多层膜的厚度组成
使用株式会社KEYENCE制的激光显微镜VA-9710,通过观测膜截面进行测定。为膜宽方向的中央部的值。
(5)膜的总光线透射率、雾度
使用日本电色工业株式会社制的雾度仪NDH-5000型测定。
(6)膜的表面硬度
按照JIS K 5600测定铅笔硬度。
(7)热收缩率
将膜剪切为200mm×50mm大小,使用精密规尺(最小刻度0.5mm)在中央部标记100.0mm标线。(但是读取至0.25mm单位。)将以140℃烤箱加热90秒后的标线的变化率作为热收缩率。
热收缩率(%)=(100.0-加热后的标线长度)/100.0×100
(8)修整性
通过嵌入成型法制成在成型体外周从端面突出30mm左右多余的膜的装饰成型体。对该多余部分的膜进行修整的工序时,以是否可以用手弯曲而容易地除去,且可以在成型体端面无残留地除去毛边来判断好坏。
○:可以将多余部分的膜用手弯曲而容易地除去,且在基材侧未残留毛边。
×:即使将多余部分的膜用手弯曲也无法容易地除去,基材侧也残留毛边。
实施例1
(成型材料A)
准备聚碳酸酯树脂颗粒(帝人化成株式会社制PANLITE AD5503,粘度平均分子量15200)。
(成型材料B-1和B-2)
准备丙烯酸树脂(Dugassa制PLEXIGLAS8N(8N);标准等级)作为B-1层用的成型材料B-1和B-2层用的成型材料B-2。
(共挤出)
将成型材料A以及成型材料B-1、B-2分别使用螺杆直径40mm的单轴挤出机在料筒温度240℃(成型材料A)、250℃(成型材料B-1、B-2)的条件下,以供料头方式从650mm宽的T型模头挤出,使熔融树脂的一面接触冷却辊而冷却后,进行修边而制成具有B-1层/A层/B-2层的3层结构的膜宽400mm的多层膜。应予说明,缠绕时使用聚乙烯系的弱粘合性的保护膜。
得到的多层膜的总厚度为125μm,厚度组成为B-1层/A层/B-2层=48/27/50(μm),A层的厚度为整体厚度的22%。它们均为膜宽方向中央部的值,但宽度方向的厚度不均为±3μm,此外,测定厚度组成的宽度方向分布,其结果,是在各层为±2μm以内且均匀性高的膜。将总光线透射率、雾度、表面硬度示于表1。热收缩率为0.50%,非常低,且脆性高,因此修整性也容易。
实施例2
除了改变A层的厚度比率、缠绕速度以外,与实施例1同样地制膜,得到总厚度129μm、A层的厚度调整为整体厚度的11%的多层膜。将膜物性示于表1。热收缩率、修整性与实施例1同样良好。
实施例3
除了改变A层的厚度比率、缠绕速度以外,与实施例1同样地制膜,得到总厚度73μm、A层的厚度调整为整体厚度的10%的多层膜。将膜物性示于表1。热收缩率、修整性与实施例1同样良好。
实施例4
除了将成型材料A变更为帝人化成株式会社制PANLITE L1225JM(粘度平均分子量18500),改变A层的厚度比率、缠绕速度以外,与实施例1同样地制膜,得到厚度123μm、A层的厚度调整为整体厚度的15%的多层膜。将膜物性示于表1。热收缩率、修整性与实施例1同样良好。
实施例5
除了将成型材料B-1和B-2变更为丙烯酸树脂(三菱丽阳株式会社制ACRYPETVH001),改变A层的厚度比率、缠绕速度以外,与实施例4同样地制膜,得到厚度75μm、A层的厚度调整为整体厚度的16%的多层膜。将膜物性示于表1。热收缩率、修整性与实施例1同样良好。比较例1
除了将成型材料A变更为帝人化成株式会社PANLITE L-1250(粘度平均分子量23700),改变A层的厚度比率、缠绕速度以外,与实施例1同样地制膜,得到厚度128μm、A层的厚度调整为整体厚度的20%的多层膜。将膜物性示于表1。粘度平均分子量高、韧性高而难以切割,因此修整性困难。
比较例2
除了改变A层的厚度比率、缠绕速度以外,与实施例1同样地制膜,得到厚度125μm的多层膜。厚度组成为B-1层/A层/B-2层=40/45/40(μm),A层的厚度为整体厚度的36%。将膜物性示于表1。韧性高而难以切割,因此修整性困难。
比较例3
除了将成型材料B-1和B-2变更为丙烯酸树脂(三菱丽阳株式会社制ACRYPETVH001),改变A层的厚度比率、缠绕速度以外,与实施例1同样地制膜,得到厚度113μm的多层膜。厚度组成为B-1层/A层/B-2层=26/63/24(μm),A层的厚度为整体厚度的56%。将膜物性示于表1。韧性高而难以切割,因此修整性困难。
比较例4
将丙烯酸树脂(三菱丽阳株式会社制ACRYPET VH001)不以供料头方式而以单层方式,通过螺杆直径40mm的单轴挤出机在料筒温度250℃下从650mm宽的T型模头挤出,其后与实施例1同样地得到宽度400mm的丙烯酸膜。将得到的膜的物性示于表1。是雾度和热收缩率高且耐热性低的膜。
本发明的多层膜的耐热性、修整性、表面硬度、热收缩率等优异。根据本发明的制造方法,可以制造具有上述优异特性的多层膜。
产业上的可利用性
本发明的多层膜可用作装饰成型的材料。
Claims (5)
1.一种多层膜,包含:包含粘度平均分子量为13000以上且小于20000的聚碳酸酯树脂的层即A层、以及层叠于A层的一面的包含丙烯酸系树脂的层即B-1层和层叠于A层的另一面的包含丙烯酸系树脂的层即B-2层,该多层膜的整体的厚度为50~200μm,且A层的厚度为整体厚度的5%~25%。
2.如权利要求1所述的多层膜,其中,雾度为4%以下。
3.一种装饰成型用膜,对权利要求1或2所述的多层膜的一面施以装饰而成。
4.一种装饰成型体,其包含基材及形成于该基材表面的权利要求3所述的装饰成型用膜。
5.一种在A层的两面分别层叠有B-1层和B-2层的权利要求1所述的多层膜的制造方法,其中包含:将构成A层的包含粘度平均分子量为13000以上且小于20000的聚碳酸酯树脂的成型材料A、构成B-1层的包含丙烯酸系树脂的成型材料B-1、以及构成B-2层的包含丙烯酸系树脂的成型材料B-2进行共挤出。
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