# US 11,897,980 B2 · Laminated resin sheet for molding, and molded article using same

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- Number: US 11,897,980 B2
- Document ID: US11897980B2
- Status: Granted
- Kind: B2
- Application number: 17/793,729
- Filed: 2021-02-03
- Published: 2023-05-11
- Granted: 2024-02-13
- Earliest claimed: 2020-02-18
- Assignees: Mitsubishi Gas Chemical Company, Inc.; Mgc Filsheet Co., Ltd.
- Applicants: Mitsubishi Gas Chemical Company, Inc.; Mgc Filsheet Co., Ltd.
- Inventors: Masato Takasaki; Atsuhiro Tokita
- Web page: https://patentgrep.com/patent/US11897980B2

## CPC

- C08F 220/14: Methyl esters {, e.g. methyl (meth)acrylate}
- B32B 1/00: Layered products having a non-planar shape
- B32B 7/02: Physical, chemical or physicochemical properties
- B32B 7/022: Mechanical properties
- B32B 7/027: Thermal properties
- B32B 27/08: of synthetic resin
- B32B 27/30: comprising vinyl {(co)polymers; comprising acrylic (co)polymers}
- B32B 27/302: {comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers}
- B32B 27/308: {comprising acrylic (co)polymers}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/36: comprising polyesters
- B32B 27/365: {comprising polycarbonates}
- C08L 25/14: with unsaturated esters
- C09D 5/006: {Anti-reflective coatings}
- B32B 2250/02: 2 layers
- B32B 2250/05: 5 or more layers
- B32B 2250/24: All layers being polymeric
- B32B 2255/10: on synthetic resin layer or on natural or synthetic rubber layer
- B32B 2255/26: Polymeric coating
- B32B 2270/00: Resin or rubber layer containing a blend of at least two different polymers
- B32B 2307/40: having particular optical properties
- B32B 2307/414: Translucent
- B32B 2307/536: Hardness
- B32B 2307/584: Scratch resistance
- B32B 2307/732: Dimensional properties
- B32B 2307/7376: Thickness
- B32B 2307/738: Thermoformability
- B32B 2457/00: Electrical equipment
- B32B 2605/003: Interior finishings
- B32B 2605/08: Cars
- C08F 212/08: Styrene
- C08F: MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- 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 (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)

## Abstract

Provided are: a laminated resin sheet for molding, which is less likely to cause an abnormal appearance during molding, and has an anti-glare layer but has excellent transparency; and a molded article using the same. This laminated resin sheet for molding comprises: a high-hardness resin layer containing a high-hardness resin; a base material layer which contains a polycarbonate resin (a1) and is disposed on one surface side of the high-hardness resin layer; and a hard coat anti-glare layer disposed on the other surface side of the high-hardness resin layer, wherein the glass transition point (Tg1) of the high-hardness resin and the glass transition point (Tg2) of the polycarbonate resin (a1) satisfy the following relationship, and the maximum valley depth (Rv) of the recesses and protrusions of the hard coat anti-glare layer is at most 0.9 μm −10° C.≤(Tg1−Tg2)≤40° C.

## Claims

### Claim 1

A laminated resin sheet for molding, which comprises:
a high hardness resin layer containing a high hardness resin;
a base material layer which contains a polycarbonate resin (a1) and is disposed on one surface side of the high hardness resin layer; and
a hard coat anti-glare layer disposed on the other surface side of the high hardness resin layer,
wherein the high hardness resin comprises at least one selected from the group consisting of:
Resin (B2), which is a copolymer (D) containing 6 to 77% by mass of a (meth)acrylic acid ester structural unit, 15 to 71% by mass of a styrene structural unit, and 8 to 23% by mass of an unsaturated dicarboxylic acid structural unit;
Resin (B3), which is a polymer containing a structural unit (c) represented by general formula (5) below:
Resin (B4), which is a copolymer (G) containing 5 to 20% by mass of a styrene structural unit, 60 to 90% by mass of a (meth)acrylic acid ester structural unit, and 5 to 20% by mass of an N-substituted maleimide structural unit;
Resin (B5), which is a polymer containing a structural unit (e) represented by general formula (7) below:
and
Resin (B6), which is a copolymer (H) containing 50 to 95% by mass of a styrene structural unit and 5 to 50% by mass of an unsaturated dicarboxylic acid structural unit;
wherein the glass transition point (Tg1) of the high hardness resin and the glass transition point (Tg2) of the polycarbonate resin (a1) satisfy the following relationship:
−10° C.≤(Tg1−Tg2)≤40° C.,
wherein the maximum valley depth (Rv) of the recesses and protrusions of the hard coat anti-glare layer is 0.9 μm or less; and
wherein the laminated resin sheet for molding has a haze of 12% or less.

### Claim 2 (depends on 1)

The laminated resin sheet for molding according to claim 1, wherein the polycarbonate resin (a1) is an aromatic polycarbonate resin.

### Claim 3 (depends on 2)

The laminated resin sheet for molding according to claim 2, wherein the aromatic polycarbonate resin contains a structural unit represented by general formula (3a):

### Claim 4 (depends on 1)

The laminated resin sheet for molding according to claim 1, wherein the content of the polycarbonate resin (a1) is 75 to 100% by mass relative to the total mass of the base material layer.

### Claim 5 (depends on 1)

The laminated resin sheet for molding according to claim 1, wherein the Resin (B3) is a copolymer further containing a structural unit (d) represented by general formula (6) below:

### Claim 6 (depends on 1)

The laminated resin sheet for molding according to claim 1, wherein the content of the high hardness resin is 70 to 100% by mass relative to the total mass of the high hardness resin layer.

### Claim 7 (depends on 1)

The laminated resin sheet for molding according to claim 1, wherein the total thickness of the base material layer and the high hardness resin layer is 0.5 to 3.5 mm.

### Claim 8 (depends on 1)

The laminated resin sheet for molding according to claim 1, wherein the ratio of the thickness of the base material layer in the total thickness of the base material layer and the high hardness resin layer is 75% to 99%.

### Claim 9 (depends on 1)

The laminated resin sheet for molding according to claim 1, wherein the pencil hardness of the surface of the hard coat anti-glare layer is 2H or harder.

### Claim 10 (depends on 1)

The laminated resin sheet for molding according to claim 1, wherein:
a laminated protective film, in which a first protective film and a second protective film are layered, is disposed on both the outermost surfaces of the laminated resin sheet for molding; and
the second protective film is disposed at the outer side.

### Claim 11 (depends on 10)

The laminated resin sheet for molding according to claim 10, which has the laminated protective film, wherein:
the first protective film is a polyolefin-based film having a melting point of 100 to 130° C.; and
the second protective film is a polyolefin-based film having a melting point of 140° C. or higher.

### Claim 12 (depends on 10)

The laminated resin sheet for molding according to claim 10, which has the laminated protective film, wherein:
the first protective film is a polyolefin-based film having a melting point of 100 to 130° C.; and
the second protective film is a PET-based film.

### Claim 13 (depends on 1)

A molded article obtained by molding with use of the laminated resin sheet for molding according to claim 1.