JP2000263731A - Corrugated panel made of polycarbonate resin - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a corrugated panel good in weatherability and excellent not only in lighting properties but also in barrier properties. SOLUTION: A polycarbonate resin corrugated panel constituted by laminating a weatherable resin layer to at least the single surface of a polycarbonate resin substrate layer is employed and at least the single surface of the corrugated panel is characterized by that arithmetic mean roughness (Ra) is 5-20 μm, the max. height (Ry) is 25-100 μm and haze measured according to JIS K7105 is 60% or more.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION The present invention relates to a method for improving weather resistance,
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a polycarbonate resin corrugated sheet excellent in daylighting properties and useful as a corrugated sheet having an effect of blinding.

[0002]

2. Description of the Related Art Conventionally, as a corrugated sheet for blindfold use, a sheet made of a resin material such as a vinyl chloride resin or an acrylic resin has been used. Corrugated sheets made of vinyl chloride resin have good workability and can be arbitrarily colored, and corrugated sheets made of acrylic resin are widely used as building materials because of their excellent weather resistance. Became.

[0003] In recent years, from the viewpoint of privacy protection, there is a strong demand for attaching a blind plate to a terrace or a veranda of a residential building, and a corrugated sheet excellent in blindness and weather resistance has been demanded.

[0004] However, corrugated sheets made of vinyl chloride resin have low light transmittance and excellent blinding properties, but have poor weather resistance, and discolor in a relatively short time when exposed to ultraviolet rays outdoors or the like, and deteriorate. There was a drawback of doing it. For this reason, a corrugated sheet made of acrylic resin, which is excellent in weather resistance, lightweight and relatively inexpensive, has been used.

However, recently, in the event of a fire accident, a problem has been pointed out that combustible materials placed on a veranda or the like contribute to hasten the spread of fire, and attention has been paid to the burning performance of the blindfold corrugated sheet itself. Have been. Specifically, it is to change the corrugated sheet to a non-combustible or self-extinguishing material, but unfortunately the acrylic resin corrugated sheet itself is self-combustible, and it will continue to burn once it is lit There are disadvantages, and the impact resistance is also poor.

Therefore, polycarbonate resin has received the most attention as a self-extinguishing material replacing acrylic resin.
The corrugated sheet made of polycarbonate resin itself is not particularly novel, and has been used instead of an acrylic resin corrugated sheet in applications required for impact resistance, heat resistance, flame resistance, and the like.

[0007]

However, since the polycarbonate resin is inferior in weather resistance to the acrylic resin,
When exposed to ultraviolet rays outdoors or the like, there is a problem that discoloration and reduction in strength are caused in a relatively short time. Therefore, there is a disadvantage that it can be used only in a place where the influence of ultraviolet rays is small. As a technique for improving the weather resistance of the polycarbonate resin corrugated sheet, a method of coating the surface of the polycarbonate resin corrugated sheet with an acrylic resin has been developed. In particular, by adding an ultraviolet absorber to the acrylic resin to be coated, the weather resistance is further improved. With these technologies, the weather resistance of the polycarbonate resin corrugated sheet,
It can be sufficiently improved to a practical level, and greatly contributes to expanding the use of polycarbonate resin corrugated sheets in outdoor use.

However, when the acrylic resin is laminated on the polycarbonate resin, the impact resistance of the polycarbonate resin is remarkably reduced, and the refractive index of the two resins is different, so that the transparency is lost when the laminated product is recycled. There was a problem. As described above, at present, a corrugated sheet as a blindfold application that can achieve a desired purpose has not yet been obtained.

Accordingly, an object of the present invention is to provide a polycarbonate resin corrugated sheet which has good weather resistance and excellent daylighting properties and also has excellent shielding properties.

[0010]

Means for Solving the Problems The present inventor has made extensive studies in view of the above-mentioned problems, and as a result, a polycarbonate resin is used as a base layer, and a weather-resistant resin layer is laminated on at least one side of the base layer. At least one side of the corrugated sheet has an arithmetic average roughness (Ra) of 5 to 20 μm and a maximum height (R
y) is 25 to 100 μm and JIS K 710
By providing a haze of 60% or more as measured in accordance with No. 5, a polycarbonate resin corrugated sheet having excellent weather resistance and excellent shielding properties while maintaining impact resistance and heat resistance is provided. They found what they could do and arrived at the present invention. In particular, in the present invention, the thickness of the polycarbonate resin base material layer is 0.5 to 1.5 mm, and the thickness of the weather-resistant resin layer is 5 to 1.5 mm.
To 100 μm, wherein the weather-resistant resin layer is an ultraviolet absorber 1 to 20 with respect to 100 parts by weight of the polycarbonate resin.
The above-mentioned subject can be more effectively solved by the polycarbonate resin corrugated sheet by weight and blended.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the polycarbonate resin corrugated sheet of the present invention will be described in detail. The polycarbonate resin used as the base material layer constituting the present invention is obtained by a phosgene method of reacting various dihydroxydiaryl compounds with phosgene, or a transesterification method of reacting a dihydroxydiaryl compound with a carbonate ester such as diphenyl carbonate. A typical example is a polycarbonate resin produced from 2,2-bis (4-hydroxyphenyl) propane (bisphenol A).

Examples of the dihydroxydiaryl compound include bis (4-hydroxyphenyl) methane, 1,1-bis (4-hydroxyphenyl) ethane, and 2,2-bis (4-hydroxyphenyl) in addition to bisphenol A.
Butane, 2,2-bis (4-hydroxyphenyl) octane, bis (4-hydroxyphenyl) phenylmethane, 2,2-bis (4-hydroxyphenyl-3-methylphenyl) propane, 1,1-bis (4 -Hydroxy-3-tert-butylphenyl) propane, 2,2-bis (4-hydroxy-3-bromophenyl) propane,
2,2-bis (4-hydroxy-3,5-dibromophenyl) propane, 2,2-bis (4-hydroxy-3,
Bis (hydroxyaryl) alkanes such as 5-dichlorophenyl) propane, bis (hydroxyaryl) such as 1,1-bis (4-hydroxyphenyl) cyclopentane and 1,1-bis (4-hydroxyphenyl) cyclohexane Cycloalkanes, 4,4'-dihydroxydiphenyl ether, 4,4'-dihydroxy-
Dihydroxydiaryl ethers such as 3,3'-dimethyldiphenylether, dihydroxydiarylsulfides such as 4,4'-dihydroxydiphenylsulfide, 4,4'-dihydroxydiphenylsulfoxide, 4,4'-dihydroxy-3,3 Dihydroxydiarylsulfoxides such as'-dimethyldiphenylsulfoxide; and dihydroxydiarylsulfones such as 4,4'-dihydroxydiphenylsulfone and 4,4'-dihydroxy-3,3'-dimethyldiphenylsulfone. These can be used alone or 2
More than one kind is used as a mixture, but in addition to these, piperazine, dipiperidyl hydroquinone, resorcinol, 4,
4′-dihydroxydiphenyl or the like may be used as a mixture.

Further, the above dihydroxyaryl compound and a phenol compound having three or more valences as shown below may be mixed and used. That is, it includes phloroglucin, 4,6-dimethyl-2,4,6-tri- (4-hydroxyphenyl) -heptene, 2,4,6-dimethyl-
2,4,6-tri- (4-hydroxyphenyl) -heptane, 1,3,5-tri- (4-hydroxyphenyl)
-Benzol, 1,1,1-tri- (4-hydroxyphenyl) -ethane and 2,2-bis- [4,4-
(4,4′-dihydroxydiphenyl) -cyclohexyl] -propane.

The viscosity average molecular weight of the polycarbonate resin is usually from 10,000 to 100,000, preferably from 1 to 100,000.
It is in the range of 5,000 to 35,000. In producing such a polycarbonate resin, a molecular weight regulator, a catalyst and the like can be used as required.

[0015] In addition, within a range that does not impair the effects of the present invention,
Various additives such as a heat stabilizer, a colorant, a fluorescent whitening agent, a flame retardant, a filler, a release agent, a softener, an antistatic agent and an antibacterial agent, which are commonly used, are added to the polycarbonate resin as required. May be appropriately selected and added.

A weather-resistant resin layer having an affinity for a polycarbonate resin is provided on at least one surface of the base material layer constituting the present invention. As such a weather-resistant resin layer, the polycarbonate resins exemplified above can be used, and an ultraviolet absorber is added and blended with the polycarbonate resin. Benzotriazole-based compounds,
Examples thereof include those composed of a benzophenone-based compound, a hydroxyphenyltriazine-based compound, a salicylic acid phenylester-based compound, and among others, a benzotriazole-based compound and a hydroxyphenyltriazine-based compound are more preferable. The proportion of the ultraviolet absorber incorporated in the weather-resistant resin layer is preferably in the range of 1 to 20 parts by weight with respect to 100 parts by weight of the polycarbonate resin.
More preferably, it is in the range of 15 to 15 parts by weight. If the compounding ratio is less than 1 part by weight, the weather resistance tends to be insufficient, and
Exceeding 0 parts by weight is not preferred because the viscosity of the polycarbonate resin composition itself is reduced and smoke generated due to evaporation of the ultraviolet absorbent is remarkable.

The polycarbonate resin corrugated sheet of the present invention comprises:
On at least one surface of the base material layer, a weather-resistant resin layer is formed, and on at least one surface of the corrugated sheet,
Embossing is applied. This embossing is usually
At least one surface of a polycarbonate resin or a weather-resistant resin in a melt-softened state is transferred to an embossed uneven surface by an embossing roll or the like. In the present invention, it is important to define the arithmetic average roughness, maximum height, and haze due to the surface irregularities. First, the arithmetic average roughness (Ra) is in the range of 5 to 20 μm, and this value is 5 μm.
If it is less than m, the shielding property cannot be obtained. Conversely, if it exceeds 20 μm, the shielding property will be good, but the transparency will be poor and the lighting will not be good. The maximum height (Ry) is 25 to 100.
If the value is less than 25 μm, the transfer state of the surface will not be uniform, and if it exceeds 100 μm, it will be difficult to produce an embossing roll to be transferred. Furthermore, Haze is based on JIS K 710
5, which is at least 60%, preferably in the range of 70% to 90%. If this value is less than 60%, the shielding property is deteriorated, which is not preferable.

The polycarbonate resin corrugated sheet of the present invention comprises:
For example, when used for a roof material such as a terrace, it is preferable to provide a weather-resistant resin layer on one surface that is exposed to sunlight and provide an embossed surface in the numerical range defined above on the other surface. In this case, by providing the weather-resistant resin layer on the surface that is exposed to sunlight, it is possible to absorb and reflect ultraviolet rays and secure lighting for a long period of time. In addition, it is not preferable to provide the embossed surface on the surface that is exposed to sunlight, because the surface is easily stained by dust, and it is difficult to secure the daylighting property.

The method for producing the polycarbonate resin corrugated sheet of the present invention includes a method by coextrusion and a method by lamination. In the method by coextrusion, a film, a sheet or a plate is extruded from an extruder for a polycarbonate resin to be a base material layer, and is coextruded from an extruder for a polycarbonate resin to be a weather resistant resin layer to form a pair of rolls. In the middle,
After one side is formed into a laminate by a flat roll and the other is formed by an embossing roll having an embossed shape, it is formed into a corrugated sheet by a molding process. In the method using lamination, a film, sheet or plate is extruded from a polycarbonate resin extruder to be used as a base material layer, passed between a pair of rolls, and one side is a flat roll, and the other is an embossed After embossing with a roll, a film to be a weather resistant resin layer is laminated, and then formed into a corrugated sheet by a molding process.

The thickness of the base material layer of the polycarbonate resin corrugated sheet thus obtained is 0.5 to 1.5 mm.
Is more preferable, and more preferably 0.6 to 1.0.
mm. When the thickness is less than 0.5 mm, the moldability of the molding is poor and the physical properties are deteriorated, and it is difficult to use it outdoors. On the other hand, when the thickness exceeds 1.5 mm, the cost is high and the economy is uneconomical. The thickness of the weather-resistant resin layer is 5 to 10
If the thickness is less than 5 μm, the weather resistance effect is not sufficient and the lighting becomes poor. If the thickness exceeds 100 μm, the weather resistance effect does not change and is uneconomical.

[0021]

EXAMPLES Examples and comparative examples of the present invention will be described below.
The evaluation and test methods used in the examples and comparative examples are as follows.

[Arithmetic average roughness, maximum height] JIS B-
A test piece of 10 cm square was taken out from the polycarbonate resin corrugated sheet in accordance with 0601 (surface roughness), and the arithmetic average roughness and the maximum height on the peak side and the valley side of the embossed surface were measured. The measuring instrument used for the measurement was Softtest
-211 (manufactured by Mitutoyo Corporation, trade name).

[Haze] A 10 cm square test piece was cut out of a polycarbonate resin corrugated sheet in accordance with JIS K 7105, and the light diffusivity was measured with the peak or valley fixed at the center. The measuring machine used for the measurement is SM Color Computer SM-3 (trade name, manufactured by Suga Test Instruments Co., Ltd.). The haze was calculated by the following equation. Haze = (Td / Tt) × 100 (%) Td = light diffusivity Tt = total light transmittance

[Weather Resistance] According to ASTM D-1925, a 10 cm square test piece cut out from a polycarbonate resin corrugated sheet was measured for the degree of yellowing. The test piece is sunshine weatherometer WEL
-SUN-DC type (manufactured by Suga Test Instruments Co., Ltd., trade name) 2,0
After irradiation for 00 hours, the degree of yellowing was measured in the same manner as above, and the increase (ΔYI) was calculated. The smaller the ΔYI, the better the weather resistance.

[Shielding Property] Evaluation was made in relation to haze. ○: Great shielding effect. ×: The shielding effect is small.

(Example 1) Polycarbonate resin as a polycarbonate resin base layer: Caliber 302-4 (average molecular weight: 28,000, manufactured by Sumitomo Dow, trade name)
Polycarbonate resin as weather resistant resin layer: Caliber 3
02-4 (described above), 100 parts by weight of an ultraviolet absorber:
A composition obtained by mixing 10 parts by weight of Tinuvin 1577 (trade name, manufactured by Ciba Geigy) is melt-kneaded at a mold temperature of 280 ° C. by each extruder, and the melts are combined with an adapter in front of an extrusion die to form a base layer. The discharge amount and the die were adjusted so that the thickness was 0.7 mm and the thickness of the weather-resistant resin layer was 50 μm. The weather resistant resin layer was laminated on one side of the base material layer. Extruded into a sheet from an extrusion die, passed between a pair of rolls assembled by embossing roll and flat roll,
Asperities were transferred to the other side of the weather-resistant resin layer by embossing rolls, and a corrugated polycarbonate resin sheet was obtained through a molding step. With respect to the polycarbonate resin corrugated sheet thus obtained, the yellowing degree of weather resistance, arithmetic average roughness, maximum height, haze, and the shielding property were evaluated by the above-described evaluation and test methods. Table 1 shows the results.

(Comparative Example 1) A polycarbonate resin as a polycarbonate resin base layer without a weather-resistant resin layer was used.
Only the caliber 302-4 (described above) was melt-kneaded at a mold temperature of 280 ° C. using an extruder, and the die was adjusted so that the thickness of the base material layer was 0.7 mm. The sheet was extruded into a sheet form from an extrusion die, passed between a pair of rolls composed of an embossing roll and a flat roll, and the irregularities were transferred to one surface by the embossing roll, followed by a molding step to obtain a polycarbonate resin corrugated sheet. For the polycarbonate resin corrugated sheet thus obtained, the weather resistance yellowing degree as described above,
The arithmetic average roughness, the maximum height, and the haze were measured, and the shielding properties were evaluated. The results are shown in Table 1.

Comparative Example 2 An embossed roll and a flat roll manufactured with an arithmetic average roughness of 5 μm and a maximum roughness of 20 μm out of a pair of rolls were used as in Example 1.
In the same manner as described above, a polycarbonate resin corrugated sheet was obtained. However, the unevenness of the embossing roll could not be completely transferred. For the polycarbonate resin corrugated sheet thus obtained, by the above evaluation method, while measuring the yellowing degree of weather resistance, arithmetic average roughness, maximum height, haze, and evaluated the shielding properties, The results are shown in Table 1.

[0029]

[Table 1]

[Evaluation Results] In Example 1, good results were obtained for weather resistance, arithmetic average roughness, maximum height, haze, and shielding property. Comparative Example 2 was inferior in shielding properties and inferior in shielding properties, and had a defect in any of the above evaluations, and was not desirable.

[0031]

According to the present invention, it is possible to provide a polycarbonate resin corrugated sheet having excellent weather resistance, excellent light-receiving properties, and excellent shielding properties. Therefore, it can be suitably used as a building material.

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) // C08J 5/00 CFD C08J 5/00 CFD C08K 5/07 C08K 5/07 5/105 5/105 5 / 3492 5/3492 C08L 69/00 C08L 69/00 F-term (reference) 2E105 BB05 FF02 FF32 2E108 GG17 4F071 AA50 AA81 AC10 AC19 AE05 AF29 AF30Y AH03 BA01 BB06 BC01 BC03 BC08 BC09 BC16 4F100 AK01 BA03BA AK01 BA10BAKBABAA CA07B CA07C DD07B DD07C EH17 EJ40 GB07 JA20A JA20B JA20C JL09B JL09C JN08 YY00A YY00B YY00C 4J002 CG011 CG021 CG031 EE036 EH146 EU176 EU186 FD056 GF00 GL00

Claims (2)

[Claims] 1. A polycarbonate resin corrugated sheet obtained by laminating a weather-resistant resin layer on at least one side of a polycarbonate resin substrate layer, wherein at least one side of the corrugated sheet has an arithmetic average roughness (Ra) of 5 to 5. 20 μm, maximum height (Ry) 25-100 μm, and JIS
A polycarbonate resin corrugated sheet characterized by having a haze measured according to K 7105 of 60% or more. 2. The polycarbonate resin base material layer has a thickness of 0.5 to 1.5 mm, and the weather resistant resin layer has a thickness of 5 to 10 mm.
2. The polycarbonate resin corrugated sheet according to claim 1, wherein the weatherable resin layer is 0 μm, and 1 to 20 parts by weight of an ultraviolet absorber is blended with respect to 100 parts by weight of the polycarbonate resin.