Acrylic sheet, acrylic adhesive sheet and processes for preparing the sheets

• US 5,753,362 A
• Filed: 08/11/1995
• Issued: 05/19/1998
• Est. Priority Date: 08/12/1994
• Status: Expired due to Term

• Current Assignee: Soken Chemical & Engineering Co., Ltd.
• Original Assignee: Soken Chemical & Engineering Co., Ltd.
• Inventors: Kawase, Susumu, Imai, Tatsuhiro
• Primary Examiner(s): LE, HOA T
• Application Number:
  US08/514,114
• Time in Patent Office: 1,012 Days
• Field of Search: 428/327, 428/523, 428/340, 428/143, 428/147
• US Class Current: 428/327
• CPC Class Codes: C08J 2333/08 Homopolymers or copolymers of acrylic acid esters
• CPC Class Codes: C08J 5/18 Manufacture of films or sheets
• CPC Class Codes: C08K 7/16 Solid spheres
• CPC Class Codes: C08K 7/22 Expanded, porous or hollow particles
• CPC Class Codes: C08L 2205/20 Hollow spheres
• CPC Class Codes: C08L 2666/04 Macromolecular compounds according to groups C08L7/00 - C08L49/00, or C08L55/00 - C08L57/00; Derivatives thereof
• CPC Class Codes: C08L 33/08 Homopolymers or copolymers of acrylic acid esters
• CPC Class Codes: C08L 33/12 Homopolymers or copolymers of methyl methacrylate
• CPC Class Codes: Y10T 428/254 Polymeric or resinous material
• CPC Class Codes: Y10T 428/31938 Polymer of monoethylenically unsaturated hydrocarbon

Abstract

The acrylic sheet of the invention is an acrylic sheet containing particles homogeneously dispersed in a resin matrix which does not substantially contain air bubbles and has an air bubble content of not more than 10% by volume; in which the resin matrix for constituting the acrylic sheet is a crosslinked (meth)acrylic copolymer obtained by forming a crosslinked structure among the molecules of a (meth)acrylic copolymer, which is a copolymer of 0.1-15% by weight of a polymerizable monomer having a functional group, 60-99.9% by weight of a (meth)acrylic acid alkyl ester and 0-39.9% by weight of other monomer and has a weight-average molecular weight of 150,000 to 1,200,000, by means of a polyfunctional compound having reactivity to the functional group of the polymerizable monomer for preparing the (meth)acrylic copolymer; and the particles dispersed in the resin matrix formed from the crosslinked (meth)acrylic copolymer have a mean particle diameter of 1 to 100 μm and a true specific gravity of 0.2 to 3.0. This acrylic sheet can be prepared by synthesizing a specific (meth)acrylic copolymer in an aqueous medium or an organic solvent, mixing a reaction solution of the copolymer with the polyfunctional compound and particles, casting the deformed mixture and drying it. The acrylic adhesive sheet of the invention is an adhesive sheet having an adhesive layer provided on at least one surface of the acrylic sheet, and can be prepared by forming the adhesive layer on the surface of the acrylic sheet.

Claims

1. An acrylic sheet containing particles homogeneously dispersed in a resin matrix which does not substantially contain air bubbles and has an air bubble content of not more than 10% by volume, comprising:

a resin matrix for constituting the acrylic sheet which includes a crosslinked (meth)acrylic copolymer obtained by forming a crosslinked structure among the molecules of a (meth)acrylic copolymer, which is a copolymer of 0.1-15% by weight of a polymerizable monomer having a functional group, 60-99.9% by weight of a (meth)acrylic acid alkyl ester and 0-39.9% by weight of other monomer and has a weight-average molecular weight of 150,000 to 1,200,000, by means of a polyfunctional compound having reactivity to the functional group of the polymerizable monomer for preparing the (meth)acrylic copolymer; and

particles dispersed in the resin matrix formed from the crosslinked (meth)acrylic copolymer having a mean particle diameter of 1 to 100 μ

m and a true specific gravity of 0.2 to 3.0.

2. The acrylic sheet as claimed in claim 1, wherein the polymerizable monomer having a functional group is an α

,β

-unsaturated carboxylic acid.

3. The acrylic sheet as claimed in claim 1, wherein the polyfunctional compound having reactivity to the functional group is at least one compound selected from the group consisting of polyglycidylamine, metallic chelate compounds and polyisocyanate.

4. The acrylic sheet as claimed in claim 3, wherein the crosslinked structure formed among the molecules of the (meth)acrylic copolymer is a crosslinked structure having been formed by 0.001-1.0 part by weight of a polyfunctional compound having reactivity to the functional group, based on 100 parts by weight of the (meth)acrylic copolymer.

5. The acrylic sheet as claimed in claim 1, wherein the polyfunctional compound having reactivity to the functional group is polyglycidylamine.

6. The acrylic sheet as claimed in claim 5, wherein the crosslinked structure formed among the molecules of the (meth)acrylic copolymer is a crosslinked structure having been formed by 0.001-1.0 part by weight of a polyfunctional compound having reactivity to the functional group, based on 100 parts by weight of the (meth)acrylic copolymer.

7. The acrylic sheet as claimed in claim 1, wherein the crosslinked structure formed among the molecules of the (meth)acrylic copolymer is a crosslinked structure having been formed by 0.001-1.0 part by weight of a polyfunctional compound having reactivity to the functional group, based on 100 parts by weight of the (meth)acrylic copolymer.

8. The acrylic sheet as claimed in claim 1, wherein the particles dispersed in the resin matrix are at least one kind of particles selected from the group consisting of solid particles, porous particles and hollow particles.

9. The acrylic sheet as claimed in claim 8, wherein the particles are contained in amounts of 15 to 55% by volume based on the amount of the crosslinked (meth)acrylic copolymer for forming the matrix.

10. The acrylic sheet as claimed in claim 1 wherein the particles are contained in amounts of 15 to 55% by volume based on the amount of the crosslinked (meth)acrylic copolymer for forming the matrix.