Translucent building materials and structures

Abstract

To provide a translucent housing material which is excellent in both impact resistance and weather resistance and contains a polycarbonate-based resin, and a building which has the translucent housing material and is excellent in reliability.SOLUTION: A translucent housing material 1 of the present invention has a base material 2 containing a polycarbonate-based resin as a main material, and resin layers 3 which are provided on both surface sides of the base material 2, and are formed using a resin composition containing a resin material having no aromatic ring and an ultraviolet absorber. The degree of yellowing of the translucent housing material measured according to JIS K 7373 after the resin layer 3 is irradiated with ultraviolet light according to JIS K 7350-4 using a sunshine weatherometer for 3,000 hours is less than 2.0 [ΔYI], and the translucent housing material 1 has a peak energy of 120 J or more in a high-speed surface impact test according to ASTM D3763.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a light-transmitting building material and a building. [Background technology]

[0002] Light-transmitting resin substrates are used in roads such as expressways, soundproof walls installed in outdoor stadiums, etc., roofing materials installed in carports, garages, storerooms, etc., and window materials installed in sunrooms, balconies, terraces, gates, doors, fences, etc. In other words, light-transmitting resin substrates are used as light-transmitting building materials and arranged in positions in buildings where light transmittance is required.

[0003] In recent years, polycarbonate plates containing polycarbonate resins have been proposed as such translucent building materials (see, for example, Patent Document 1).

[0004] However, although this carbonate plate has excellent impact resistance and flame resistance, it has the drawback of being poor in weather resistance for the following reasons.

[0005] In other words, when polycarbonate sheets are used as translucent building materials exposed to sunlight, the polycarbonate resin changes and deteriorates due to the long-term exposure of the polycarbonate sheets to ultraviolet rays, which results in yellowing of the polycarbonate sheets and an increase in their haze value, resulting in problems such as reduced visibility of the polycarbonate sheets.

[0006] Various studies have been conducted with the aim of improving the poor weather resistance of polycarbonate sheets. However, as described above, the reality is that polycarbonate sheets have not been sufficiently improved to be used as translucent building materials for buildings. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] International Publication No. 2014 / 088105 Summary of the Invention [Problem to be solved by the invention]

[0008] An object of the present invention is to provide a translucent building material containing a polycarbonate resin that is excellent in both impact resistance and weather resistance, and a highly reliable building that includes such a translucent building material. [Means for solving the problem]

[0009] Such objectives are as follows: (1) 8 This is achieved by the present invention described in (1) a substrate primarily made of polycarbonate resin; a translucent building material having resin layers provided on both surfaces of the substrate and formed using a resin composition containing a resin material having no aromatic ring and an ultraviolet absorber; The resin composition contains a rubber component, The content of the rubber component in the resin layer is 2.0% by weight or more and 10.0% by weight or less, the content of the ultraviolet absorber in the resin layer is 2.0% by weight or more and 9.0% by weight or less, the ultraviolet absorber is a triazine-based ultraviolet absorber, The resin layer has an average thickness B of 10 μm or more and 60 μm or less, the resin layer is irradiated with ultraviolet light for 3000 hours using a sunshine weatherometer in accordance with JIS K 7350-4, and the yellowing index of the translucent building material measured in accordance with JIS K 7373 is less than 2.0 [ΔYI]; and The translucent building material is characterized by having a peak energy of 120 J or more in a high-speed surface impact test in accordance with ASTM D3763.

[0012] ( 2 2. The light-transmitting building material according to (1) above, wherein the resin material having no aromatic ring is an aliphatic resin.

[0013] ( 3The aliphatic resin is a (meth)acrylic resin. 2 ) The light-transmitting building material according to claim 1.

[0015] ( 4 The relationship B / A between the average thickness A [μm] of the base material and the average thickness B [μm] of both resin layers is 0.0017 3 2. The light-transmitting building material according to any one of claims 1 to 11.

[0016] ( 5 ) The translucent building material is any of the above (1) to (2) whose average thickness C is 3.0 mm or more and 18.0 mm or less. 4 2. The light-transmitting building material according to any one of claims 1 to 11.

[0017] ( 6 The resin layer is selected from the group consisting of (1) to (3) above, and has a flexural modulus of elasticity at 25°C of 1500 MPa or more. 5 2. The light-transmitting building material according to any one of claims 1 to 11.

[0018] ( 7 The resin layer has a Charpy impact strength of 5.0 kJ / m as measured in accordance with ISO 179-1. 2 More than 20.0kJ / m 2 The above (1) to ( 6 2. The light-transmitting building material according to any one of claims 1 to 11.

[0019] ( 8 ) (1) above or ( 7 10. A building comprising the light-transmitting building material according to any one of claims 1 to 9. [Effects of the Invention]

[0020] According to the present invention, a light-transmitting building material can be provided that is excellent in both impact resistance and weather resistance. Therefore, by using such a light-transmitting building material as a component in a building that requires light transmission, the building can be made to have excellent reliability. [Brief explanation of the drawings] ​

[0021] [Figure 1] 1 is a longitudinal cross-sectional view showing an embodiment of a light-transmitting building material of the present invention. [Figure 2] FIG. 2 is a side view of a building material manufacturing apparatus that uses a co-extrusion method to manufacture the light-transmitting building material shown in FIG. DETAILED DESCRIPTION OF THE INVENTION

[0022] The light-transmitting building material and building of the present invention will be described in detail below with reference to preferred embodiments shown in the accompanying drawings.

[0023] The light-transmitting building material 1 of the present invention comprises a substrate 2 primarily made of a polycarbonate resin, and resin layers 3 provided on both sides of the substrate 2 and formed using a resin composition containing a resin material having no aromatic ring and an ultraviolet absorber. After irradiating the resin layer 3 with ultraviolet light for 3000 hours using a sunshine weatherometer in accordance with JIS K 7350-4, the light-transmitting building material 1 exhibits a yellowing index of less than 2.0 [ΔYI] as measured in accordance with JIS K 7373, and the light-transmitting building material 1 exhibits a peak energy of 120 J or greater in a high-speed surface impact test in accordance with ASTM D3763. Thus, if the yellowing index of the light-transmitting building material 1 after ultraviolet light irradiation is less than 2.0 [ΔYI], it can be said that the light-transmitting building material 1 has excellent durability, i.e., excellent weather resistance, even when exposed to ultraviolet light for a long period of time. Furthermore, in a high-speed surface impact test, the peak energy of the light-transmitting building material 1 is 120 J or more, so it can be said that the light-transmitting building material 1 has excellent impact resistance. Therefore, it can be said that the light-transmitting building material 1 is a resin substrate (resin laminate) that is excellent in both impact resistance and weather resistance.

[0024] This light-transmitting building material 1 is used, for example, as soundproof walls installed on roads such as expressways and outdoor stadiums, roofing materials for carports, garages, storerooms, etc., and window materials for sunrooms, balconies, terraces, gates, doors, fences, etc., in other words, as materials to be placed in positions in buildings where light translucency is required. Therefore, by using the light-transmitting building material 1 as such materials, buildings equipped with the light-transmitting building material 1 can be made highly reliable.

[0025] <<Translucent building materials>> The light-transmitting building material 1 will be described in detail below.

[0026] As described above, the light-transmitting building material 1 of the present invention is composed of a laminated substrate including the base material 2 and the resin layers 3 provided on both sides of the base material 2.

[0027] Fig. 1 is a vertical cross-sectional view showing an embodiment of a light-transmitting building material of the present invention. Hereinafter, for convenience of explanation, the upper side of Fig. 1 will be referred to as "top" and the lower side as "bottom." Furthermore, in Fig. 1, the thickness direction of the light-transmitting building material is exaggerated, and therefore the actual dimensions are significantly different.

[0028] <Base material> As shown in FIG. 1, the base material 2 is positioned as an intermediate layer of the light-transmitting building material 1, which is a laminated substrate, and constitutes the main layer of the light-transmitting building material 1. The base material 2 contains polycarbonate resin as its main material, which gives the light-transmitting building material 1 excellent impact resistance and flame resistance.

[0029] The polycarbonate resin is not particularly limited and various types can be used, but aromatic polycarbonate resins are preferred. Aromatic polycarbonate resins have aromatic rings in their main chains, which can improve the strength (impact resistance) of the substrate 2. Therefore, it is relatively easy to achieve a peak energy of 120 J or more.

[0030] The aromatic polycarbonate resin is synthesized, for example, by an interfacial polycondensation reaction between bisphenol and phosgene, or an ester exchange reaction between bisphenol and diphenyl carbonate.

[0031] Examples of bisphenols include bisphenol A and bisphenol (modified bisphenol) which is the origin of the repeating unit of polycarbonate represented by the following formula (1A).

[0032] [ka] (In formula (1A), X represents an alkyl group, aromatic group, or cycloaliphatic group having 1 to 18 carbon atoms; Ra and Rb each independently represent an alkyl group having 1 to 12 carbon atoms; m and n each represent an integer of 0 to 4; and p represents the number of repeating units.)

[0033] Specific examples of bisphenols that are the source of the repeating units of the polycarbonate represented by formula (1A) include 4,4'-(pentane-2,2-diyl)diphenol, 4,4'-(pentane-3,3-diyl)diphenol, 4,4'-(butane-2,2-diyl)diphenol, 1,1'-(cyclohexanediyl)diphenol, 2-cyclohexyl-1,4-bis(4-hydroxyphenyl)benzene, 2,3-biscyclohexyl-1,4-bis(4-hydroxyphenyl)benzene, 1,1'-bis(4-hydroxy-3-methylphenyl)cyclohexane, and 2,2'-bis(4-hydroxy-3-methylphenyl)propane, and these can be used alone or in combination of two or more.

[0034] In particular, it is preferable that the polycarbonate resin be primarily composed of a bisphenol-type polycarbonate resin having a skeleton derived from bisphenol. By using such a bisphenol-type polycarbonate resin, the base material 2 exhibits even greater strength. Therefore, the effects obtained by including a polycarbonate resin in the base material 2 can be more significantly exhibited.

[0035] The content of the polycarbonate resin in the substrate 2 is not particularly limited, but is preferably 75 parts by mass or more, and more preferably 85 parts by mass or more, per 100 parts by mass of the substrate. By setting the content of the polycarbonate resin within the above range, the substrate 2 can exhibit excellent strength.

[0036] Furthermore, the base material 2 may contain, in addition to the polycarbonate resin described above, various additives such as an ultraviolet absorber, a heat ray absorber, a plasticizer, an antioxidant, a lubricant, a colorant, and a filler, as needed.

[0037] The ultraviolet absorber and the heat ray absorber may be the same as those contained in the resin layer 3, which will be described later.

[0038] Furthermore, examples of plasticizers include polyethylene glycol, polyamide oligomer, ethylene bisstearamide, phthalate ester, polystyrene oligomer, polyethylene wax, silicone oil, etc., and one or more of these can be used in combination.

[0039] Furthermore, in order to improve adhesion to the resin layer 3, the substrate 2 may be subjected to a surface roughening treatment such as sandblasting or solvent treatment, or a surface oxidation treatment such as corona discharge treatment, chromic acid treatment, flame treatment, hot air treatment, ozone / ultraviolet irradiation treatment, or electron beam irradiation treatment.

[0040] The average thickness A of the substrate 2 is preferably 3.0 mm or more and 18.0 mm or less, and more preferably 6.0 mm or more and 18.0 mm or less. If the average thickness A of the substrate 2 is less than the lower limit, depending on the type of polycarbonate resin, the impact resistance of the translucent building material 1 may be reduced. If the average thickness A of the substrate 2 exceeds the upper limit, depending on the type of polycarbonate resin, molding the translucent building material 1 into a curved shape may become difficult.

[0041] The substrate 2 may have a single layer structure made of a material containing a polycarbonate-based resin, or a multilayer structure in which two or more single layer films made of a material containing a polycarbonate-based resin are laminated together.

[0042] In the case of a multi-layer structure, the layers may be made of the same material or different materials, and may have different thicknesses or the same thickness.

[0043] For example, the multilayer substrate 2 may have a first impact-resistant layer with excellent impact resistance, a combustion-resistant layer with excellent combustion resistance, and a second impact-resistant layer with excellent impact resistance stacked in this order. That is, one combustion-resistant layer may be sandwiched between two impact-resistant layers. This further improves the impact resistance and combustion resistance of the substrate 2.

[0044] <Resin layer> As shown in FIG. 1, the resin layer 3 (coating layer) is laminated so as to cover both the upper surface (one surface) and the lower surface (the other surface) of the base material 2, and is formed using a resin composition containing a resin material having no aromatic ring and an ultraviolet absorber, and is provided to impart excellent weather resistance to the light-transmitting building material 1 while maintaining the excellent impact resistance of the light-transmitting building material 1 derived from the base material 2.

[0045] In this way, the resin layer 3 contains a resin material that does not have an aromatic ring and an ultraviolet absorber, which imparts excellent weather resistance to the resin layer 3 and the substrate 2. Therefore, the translucent building material 1 exhibits excellent weather resistance. Furthermore, by including a resin material that does not have an aromatic ring in the resin layer 3, it is relatively easy to set the resin layer 3 to satisfy the mechanical properties described below.

[0046] The resin material having no aromatic ring is contained in the resin layer 3 so that, by not having an aromatic ring, even if the resin layer 3 is exposed to ultraviolet rays, the resin material having no aromatic ring in the resin layer 3 can be appropriately suppressed or prevented from changing or deteriorating, thereby improving the weather resistance of the resin layer 3.

[0047] The resin material without an aromatic ring is not particularly limited as long as it does not have an aromatic ring in its structure, and examples thereof include aliphatic resins whose main chains are composed of an aliphatic structure. The aliphatic resin may have a side chain, and the side chain may be composed of an aliphatic structure. The aliphatic structure may be linear, branched, or cyclic. The aliphatic resin may be linear, branched, or cyclic, with cyclic aliphatic resins being preferred. This allows the resin layer 3 to be configured to satisfy the mechanical properties described below with relative ease. The aliphatic structure may contain heteroatoms such as oxygen, sulfur, nitrogen, or phosphorus, or may have at least a portion of the carbon atoms substituted with fluorine atoms.

[0048] Furthermore, this resin material (aliphatic resin whose main chain is composed of an aliphatic structure) is not particularly limited and may be, for example, any of those classified into (meth)acrylic resins, polycarbonate resins, epoxy resins, polyamide resins, polyimide resins, polyolefin resins, etc., but among these, (meth)acrylic resins or polycarbonate resins are preferred. (Meth)acrylic resins or polycarbonate resins whose main chain is composed of an aliphatic structure are relatively easy or inexpensive to obtain, and the resin layer 3 can be relatively easily configured to satisfy the mechanical properties described below, so they are preferably used as resin materials without aromatic rings.

[0049] The ultraviolet absorber is contained in the resin layer 3 to absorb ultraviolet rays in the resin layer 3 and suppress or prevent the ultraviolet rays from reaching the base material 2, thereby suppressing the alteration and deterioration of the polycarbonate resin contained in the base material 2, and as a result, improving the weather resistance of the base material 2 and ultimately the translucent building material 1.

[0050] The ultraviolet absorber is not particularly limited, but examples thereof include triazine-based, benzophenone-based, benzotriazole-based, and cyanoacrylate-based ultraviolet absorbers, and one or two of these may be used in combination.

[0051] Furthermore, the content of the UV absorber in the resin layer 3 is not particularly limited, but is preferably 2.0% by weight to 9.0% by weight, and more preferably 3.0% by weight to 7.0% by weight. If the content of the UV absorber in the resin layer 3 is less than the lower limit, the weather resistance of the substrate 2 may be reduced depending on the type of UV absorber. If the content of the UV absorber in the resin layer 3 exceeds the upper limit, no further improvement in the weather resistance of the substrate 2 is observed, and depending on the type of UV absorber, it may be difficult to set the resin layer 3 to satisfy the mechanical properties described below.

[0052] Furthermore, it is preferable that a rubber component is contained in the resin layer 3, i.e., the resin composition used to form the resin layer 3. In this way, by containing a rubber component in the resin layer 3 in addition to the resin material having no aromatic ring and the ultraviolet absorber, the resin layer 3 can be set to satisfy the mechanical properties described below relatively easily.

[0053] The rubber component is not particularly limited, but examples thereof include copolymer rubbers mainly composed of acrylic esters, diene rubbers such as polybutadiene, poly(styrene-butadiene), and poly(acrylonitrile-butadiene), saturated rubbers obtained by hydrogenating the diene rubbers, acrylic rubbers such as isoprene rubber, chloroprene rubber, and polybutyl acrylate, and crosslinked or non-crosslinked rubbers such as ethylene-propylene copolymer rubber, ethylene-propylene-diene monomer terpolymer rubber (EPDM), and ethylene-octene copolymer rubber, and one or more of these may be used in combination.

[0054] The content of the rubber component is set appropriately depending on the type of rubber component, but is preferably 2.0% by weight to 10.0% by weight, and more preferably 3.0% by weight to 7.0% by weight. By setting the content of the rubber component in the resin layer 3 within this range, it becomes possible to improve the weather resistance of the base material 2 and relatively easily set the resin layer 3 to satisfy the mechanical properties described below.

[0055] Furthermore, the resin layer 3, that is, the resin composition used to form the resin layer 3, preferably contains a heat ray absorbing agent, which can improve the heat resistance of the resin layer 3.

[0056] Examples of the heat ray absorbing agent include carbon black, carbon powder, tin oxide, indium oxide, zinc oxide, ITO, ATO, etc., and one or more of these can be used in combination.

[0057] The resin layer 3, that is, the resin composition used to form the resin layer 3, may further contain other materials in addition to the various constituent materials described above.

[0058] The other materials are not particularly limited, but examples thereof include plasticizers, colorants, sensitizers, stabilizers, surfactants, antioxidants, anti-reducing agents, antistatic agents, surface conditioners, and hydrophilizing additives, and one or more of these may be used in combination.

[0059] The average thickness B of the resin layer 3 is not particularly limited, but is preferably 10 μm or more and 60 μm or less, and more preferably 15 μm or more and 40 μm or less. By setting the average thickness B of the resin layer 3 within this range, the effect obtained by adding an ultraviolet absorber to the resin layer 3 can be optimally exhibited, and a decrease in the weather resistance of the substrate 2 and, in turn, the translucent building material 1 can be reliably suppressed or prevented. Furthermore, even if the resin layer 3 has a small average thickness B set within this range, by using a resin composition formed from the above-mentioned constituent materials, the resin layer 3 can be relatively easily set to satisfy the mechanical properties described below.

[0060] Furthermore, the relationship B / A, which represents the relationship between the average thickness A [mm] of the base material 2 and the average thickness B [mm] of the resin layer 3, is 0.0017

[0061] The two resin layers 3 formed on both the upper and lower surfaces of the substrate 2 are not particularly limited as long as they each contain a resin material without an aromatic ring and an ultraviolet absorber as described above, and may be the same or different. The two resin layers 3 may have the same or different average thicknesses B. When the two resin layers 3 have different average thicknesses, the average value thereof is taken as the thickness B of the resin layer 3.

[0062] ​Furthermore, it is preferable that the mechanical properties of the resin layer 3 having the above-mentioned structure are set as follows.

[0063] That is, the resin layer 3 preferably has a flexural modulus at 25° C. of 1500 MPa or more, and more preferably 1700 MPa or more and 2500 MPa or less.

[0064] Furthermore, the resin layer 3 preferably has a tensile strain at break at 25° C. of 40% or more and 200% or less, and more preferably 80% or more and 160% or less.

[0065] Furthermore, the resin layer 3 has a Charpy impact strength of 5.0 kJ / m as measured in accordance with ISO179-1. 2 More than 20.0kJ / m 2 Preferably it is 6.5 kJ / m or less. 2 More than 20.0kJ / m 2 More preferably, it is:

[0066] Setting at least one of the flexural modulus, tensile strain at break, and Charpy impact strength of the resin layer 3 within the above ranges enables the resin layer 3 to have excellent mechanical properties. Therefore, the translucent building material 1 including the resin layer 3 as a coating layer for the substrate 2 can satisfy the requirement of a peak energy of 120 J or more in a high-speed surface impact test in accordance with ASTM D3763.

[0067] By providing the translucent building material 1 with the base material 2 and resin layer 3 configured as described above, it is possible to achieve both excellent impact resistance and weather resistance, and in the present invention, the following two criteria are satisfied.

[0068] That is, in the light-transmitting building material 1, the yellowing index of the substrate 2 measured in accordance with JIS K 7373 after irradiating the resin layer 3 with ultraviolet light for 3000 hours using a sunshine weatherometer in accordance with JIS K 7350-4 is less than 2.0 [ΔYI], and preferably 1.0 [ΔYI] or less. This provides the light-transmitting building material 1 with superior weather resistance, which in turn more effectively suppresses or prevents deterioration in the appearance of the light-transmitting building material 1, making the light-transmitting building material 1 suitable for use as a component in a building where light transmissivity is required.

[0069] Furthermore, the light-transmitting building material 1 satisfies the requirement that the peak energy be 120 J or more, preferably 220 J or more, in a high-speed surface impact test in accordance with ASTM D3763. This means that the light-transmitting building material 1 has sufficient impact resistance, and as a result, the light-transmitting building material 1 can be suitably used as a component that requires light transmissivity in a building that needs to have impact resistance.

[0070] In addition to satisfying the above two indices, it is preferable that the following indices indicating weather resistance and impact resistance are also satisfied.

[0071] That is, as an indicator of weather resistance, the change in haze value of the substrate 2 of the light-transmitting building material 1 after irradiation with ultraviolet light, as measured in accordance with ASTM D1003, is preferably 7.0% or less, and more preferably 4.0% or less. Furthermore, the total light transmittance of the substrate 2 is preferably 75.0% or more, and more preferably 85.0% or more. By setting the change in haze value and the total light transmittance of the substrate 2 as described above, it can be said that the light-transmitting building material 1 has even better weather resistance.

[0072] Furthermore, as an indicator of impact resistance, the translucent building material 1 preferably exhibits ductile fracture, out of ductile fracture and brittle fracture, in a high-speed surface impact test in accordance with ASTM D3763. When the translucent building material 1 exhibits ductile fracture, scattering of fragments of the substrate 2 and resin layer 3 constituting the translucent building material 1 can be appropriately suppressed or prevented when the translucent building material 1 is impacted, thereby improving safety in the event of breakage of the translucent building material 1. In this specification, ductile fracture in a high-speed surface impact test refers to a state in which, after a punch penetrates the translucent building material 1 in the high-speed surface impact test, the substrate 2 and resin layer 3 constituting the translucent building material 1 remain unbroken, and further, the deformed portion around the through hole remains uniformly protruding.

[0073] Furthermore, the average thickness C of this light-transmitting building material 1 is not particularly limited, but is preferably 3.0 mm or more and 18.0 mm or less, and more preferably 6.0 mm or more and 18.0 mm or less. By applying the present invention to a light-transmitting building material 1 whose average thickness C is set within this range, it is possible to reliably make the light-transmitting building material 1 excellent in both impact resistance and weather resistance.

[0074] The light-transmitting building material 10 may be a flat laminate as shown in FIG. 1, or may be, for example, a thermoformed body having at least a curved configuration depending on the intended use.

[0075] <Method for manufacturing light-transmitting building materials> The translucent building material 1 having the above-described configuration can be manufactured using, for example, a co-extrusion method, a pressing method, a casting method, an injection method, etc., but the following describes an example of manufacturing the translucent building material 1 using a co-extrusion method.

[0076] First, a building material manufacturing apparatus to which the co-extrusion method is applied will be described. Fig. 2 is a side view of a building material manufacturing apparatus that uses a co-extrusion method to manufacture the light-transmitting building material shown in Fig. 1. In the following description, the upper side in Fig. 2 will be referred to as "upper" and the lower side as "lower."

[0077] The building material manufacturing apparatus 500 shown in FIG. 2 has a sheet supply unit 700 and a sheet forming unit 800.

[0078] The sheet supply section 700 includes an extruder 210, an extruder 220, a T-die 600, and a two-type, three-layer distribution type distributor 230, and the distributor 230 is connected to a pipe 212 connected to the molten resin discharge section 211 of the extruder 210 and to a pipe 212 connected to the molten resin discharge section 221 of the extruder 220, and the T-die 600 is further connected to the distributor 230 via the pipe 212.

[0079] In the sheet supply section 700 configured as described above, the resin composition (constituent material) constituting the substrate 2 is stored in the extruder 210, and the resin composition (constituent material) constituting the resin layer 3 is stored in the extruder 220. Then, the resin composition (A) constituting the substrate 2 in a molten or softened state and the resin composition (B) constituting the resin layer 3 in a molten or softened state are supplied to a two-kind, three-layer distributor 230. The distributor 230 operates to produce a molten sheet (sheet) 150 in a molten or softened state, in which the resin composition (B), the resin composition (A), and the resin composition (B) are laminated in this order. The molten sheet 150 is then supplied to the sheet forming section 800 via the distributor 230, the piping 212, and the T-die 600 (opening 601). By using this configuration to obtain the molten sheet 150 by co-extrusion, the thickness of the formed molten sheet 150 can be stabilized.

[0080] The sheet forming unit 800 has a touch roll 110, a cooling roll 120, and a rear-stage cooling roll 130. These rolls are configured to rotate independently by motors (drive means) not shown, and the rotation of these rolls cools the molten sheet 150, thereby continuously feeding out the translucent building material 1. By continuously feeding the molten or softened molten sheet 150 into this sheet forming unit 800, the first surface 15 and the second surface 13 of the molten sheet 150 are flattened, and the molten sheet 150 is set to a desired thickness.

[0081] Furthermore, the molten sheet 150 that has passed between the cooling roll 120 and the touch roll 110 is further supplied between the cooling roll 120 and the subsequent cooling roll 130, whereby the molten sheet 150 is cooled, and as a result, a translucent building material 1 is formed in which the resin layer 3, the base material 2, and the resin layer 3 are laminated in this order.

[0082] Chilled roll 120 is a roll having a smooth outer peripheral surface, and includes a cooling means for cooling molten sheet 150 that has been supplied from T-die 600 and is in a molten state. By pressing molten sheet 150 against chilled roll 120, first surface 15 is flattened and molten sheet 150 is cooled.

[0083] Touch roll 110 is a roll having a smooth outer peripheral surface, and is disposed opposite cooling roll 120. By supplying molten sheet 150 between touch roll 110 and cooling roll 120, second surface 13 of molten sheet 150 is flattened.

[0084] The rear-stage cooling roll 130 is a roll having a smooth outer peripheral surface, is equipped with a cooling means for cooling the molten sheet 150, and is disposed after the touch roll 110 and the cooling roll 120. By supplying the molten sheet 150 to such a rear-stage cooling roll 130, the molten sheet 150 can be cooled more reliably, and the translucent building material 1 can be obtained.

[0085] In this embodiment, a case has been described in which the cooling roll 120 has a cooling means and the touch roll 110 does not have a cooling means, but the present invention is not limited to such a case, and it is sufficient that at least one of the cooling roll 120 and the touch roll 110 has a cooling means, and the touch roll 110 may have a cooling means and the cooling roll 120 may not have a cooling means, or both the cooling roll 120 and the touch roll 110 may have a cooling means.

[0086] The light-transmitting building material 1 is manufactured by the manufacturing method of the light-transmitting building material using the building material manufacturing apparatus 500 as described above.

[0087] The method for manufacturing a translucent building material includes an extrusion process in which a molten sheet 150 in a molten or softened state is extruded into a strip-shaped sheet, a molding process in which the first surface 15 and the second surface 13 of the molten sheet 150 are flattened to form a translucent building material 1, and a cooling process in which the molded molten sheet 150 in a molten or softened state is cooled.If at least a portion of the translucent building material 1 is to have a curved shape, the method further includes a curved surface molding process.

[0088] Each step for producing the light-transmitting building material 1 will be described in detail below. (Extrusion process) First, a molten sheet 150 in a molten or softened state is extruded into a strip-shaped sheet.

[0089] In this extrusion process, the resin composition (constituent material) that constitutes the base material 2 is stored in extruder 210, and the resin composition (constituent material) that constitutes the resin layer 3 is stored in extruder 220. Then, the resin composition (A) that constitutes the base material 2 in a molten or softened state and the resin composition (B) that constitutes the resin layer 3 in a molten or softened state are supplied to a two-kind, three-layer distributor 230. When this distributor 230 is operated, a molten sheet (sheet) 150 in a molten or softened state, in which the resin composition (B), the resin composition (A), and the resin composition (B) are layered in this order, is extruded through the distributor 230 and piping 212 and from an opening 601 of a T-die 600. As a result, the molten sheet 150 in a molten or softened state that has been made into a strip-shaped sheet is continuously fed out.

[0090] In other words, the molten sheet 150 in a molten or softened state is extruded from the opening 601 to form a film by a co-extrusion method.

[0091] (molding process) Next, the first surface 15 and the second surface 13 of the molten sheet 150 are flattened, and the molten sheet 150 is set to a predetermined thickness, thereby forming a translucent building material 1 in which a molten or softened resin layer 3, a base material 2, and a resin layer 3 are laminated in this order.

[0092] This forming step is carried out by supplying the molten sheet 150 between the touch roll 110 and the cooling roll 120 .

[0093] At this time, the outer peripheral surface of cooling roll 120 and the outer peripheral surface of touch roll 110 each have a smooth roll shape, so that first surface 15 and second surface 13 of molten sheet 150 are pressed against the smooth outer peripheral surfaces, thereby being flattened.

[0094] Furthermore, the distance between the outer peripheral surface of the cooling roll 120 and the outer peripheral surface of the touch roll 110 is set to the thickness of the translucent building material 1 to be formed, and by appropriately setting this distance to a predetermined size, a molten sheet 150 of the desired thickness can be obtained.

[0095] Thus, in this process, the cooling roll 120 and the touch roll 110 are used to flatten the first surface 15 and the second surface 13, respectively, and to set the thickness of the molten sheet 150.

[0096] (cooling process) Next, molten sheet 150 in a molten or softened state, in which first surface 15 and second surface 13 have been flattened and made porous, is cooled.

[0097] As a result, the translucent building material 1 is formed, which is made of a laminate 4 in which the resin layer 3, the base material 2 and the resin layer 3 are laminated in this order.

[0098] This cooling step is carried out by feeding the molten sheet 150 between the cooling roll 120 and the rear cooling roll 130 .

[0099] As a result, the first surface 15 of the molten sheet 150 abuts against the cooling roll 120 until the cooling roll 120 rotates 180 degrees, and the second surface 13 of the molten sheet 150 abuts against the subsequent cooling roll 130 until the subsequent cooling roll 130 rotates 90 degrees.

[0100] In this embodiment, both the cooling roll 120 and the rear-stage cooling roll 130 are equipped with cooling means, and therefore the molten sheet 150, whose first surface 15 and second surface 13 have been flattened, is cooled by the contact of the molten sheet 150 with the respective rolls 120, 130. As a result, the first surface 15 and second surface 13 are flattened, and a translucent building material 1 is obtained.

[0101] In this embodiment, molten sheet 150 is cooled with first surface 15 and second surface 13 of molten sheet 150 alternately abutting against cooling rolls 120, 130. This reliably prevents molten sheet 150 from being cooled with warping occurring on the first surface 15 or second surface 13 side.

[0102] As described above, in this process, the cooling rolls 120 and 130 equipped with cooling means are used to cool the molten sheet 150. By going through the steps described above, a flat plate-shaped translucent building material 1 can be obtained.

[0103] (Curved surface forming process) Furthermore, if part or all of the flat plate-shaped translucent building material 1 is to be formed into a curved shape, a forming process is carried out after the flat plate forming process to form part or all of the flat plate into a curved shape.

[0104] A method for forming part or all of the translucent building material 1 into a curved shape includes, for example, heating the flat translucent building material 1 and pressing it against a mold immediately after the resin softens to form a curved shape.

[0105] The method for heating the light-transmitting building material 1 is not particularly limited, and examples thereof include known methods such as an infrared drying oven, a gas-type hot air drying oven, a hot air circulation drying oven, etc. Examples of thermoforming methods include vacuum molding, pressure molding, press molding, and free blow molding.

[0106] The curved shape is a shape having a curved surface, and includes, for example, a shape in which the cross section of the molded article is an arc shape.

[0107] In this manner, the light-transmitting building material 1 is formed in which part or all of the flat plate is formed into a curved shape.

[0108] While the light-transmitting building material and building of the present invention have been described above with reference to the illustrated embodiments, the present invention is not limited to these, and each component of the light-transmitting building material and building may be replaced with any component that can exhibit the same function. In addition, any component may be added.

[0109] Furthermore, the translucent building material may have at least one other layer, such as a bonding layer (adhesive layer), interposed between the base material and the resin layer. [Example]

[0110] The present invention will be described in more detail below with reference to examples, although the present invention is not limited to these examples in any way.

[0111] 1. Formation of translucent building materials [Example 1] [1] First, a resin layer forming material (resin composition) was prepared by stirring and mixing a composite material in which an acrylic rubber component was dispersed in polymethyl methacrylate (PMMA) (Kuraray Co., Ltd.'s "Parapet GR00100") and a triazine-based ultraviolet absorber so that the respective contents were 95.0% by weight and 5.0% by weight.

[0112] Also, bisphenol A polycarbonate (manufactured by Mitsubishi Engineering Plastics Corporation, "Iupilon E2000") was prepared as a material for forming a substrate.

[0113] [2] Next, the prepared base material and resin layer forming material were respectively stored in the single-screw extruder 210 and the single-screw extruder 220 provided in the building material manufacturing apparatus 500 shown in Fig. 2, and then supplied from the single-screw extruder 210 and the single-screw extruder 220 to the distributor 230 under the condition that the rotation speed of the single-screw extruder 210 was 50 rpm. Then, the distributor 230 distributed the resin layer forming material, base material forming material, and resin layer forming material in this order in layers, and supplied the distributed material to the T-die 600, and then extruded from the opening 601 of the T-die 600 into the sheet molding unit 800 as a molten sheet.

[0114] The sheet-like distribution material extruded from the opening 601 was then sandwiched between the touch roll 110 and the cooling roll 120, and between the cooling roll 120 and the subsequent cooling roll 130, thereby flattening and cooling the material, thereby obtaining the translucent building material 1 of Example 1, which is composed of a laminate including a base material 2 and a resin layer 3 covering both the upper and lower surfaces of the base material 2.

[0115] The average thickness A of the base material 2 and the average thickness B of the resin layer 3 in the obtained translucent building material 1 were 3.0 mm and 20.0 μm, respectively.

[0116] The flexural modulus of the resin layer 3 measured in accordance with ISO 178 was 1800 MPa, and the tensile strain at break of the resin layer 3 measured in accordance with ISO 527 was 60%. Furthermore, the Charpy impact strength (notched) of the resin layer 3 measured in accordance with ISO 179-1 was 6.5 kJ / m 2 It was.

[0117] [Examples 2 to 3] In step [2], the distribution ratio of the base material forming material and the resin layer forming material in the distributed product formed by the distributor 230 was adjusted to form the base material 2 and the resin layer 3 having average thicknesses A and B as shown in Table 1. The translucent building materials 1 of Examples 2 and 3 were obtained in the same manner as in Example 1, except that the base material 2 and the resin layer 3 had average thicknesses A and B as shown in Table 1.

[0118] [Examples 4 to 5, Comparative Example 3] In step [1], the contents of the composite and triazine-based ultraviolet absorber contained in the resin layer-forming material were changed as shown in Table 1, and further, in step [2], the distribution ratio of the base material-forming material and the resin layer-forming material in the distributed product formed by the distributor 230 was adjusted to form the base material 2 and the resin layer 3 having average thicknesses A and B as shown in Table 1. Except for this, the translucent building materials 1 of Examples 4 to 5 and Comparative Example 3 were obtained in the same manner as in Example 1.

[0119] [Example 6] In step [1], polyvinylidene fluoride (KF Polymer #850, manufactured by Kureha Corporation) was used instead of the composite material contained in the resin layer-forming material, and in step [2], the distribution ratio of the base material-forming material and the resin layer-forming material in the distributed product formed by the distributor 230 was adjusted to form a base material 2 and a resin layer 3 with average thicknesses A and B as shown in Table 1. The translucent building material 1 of Example 6 was obtained in the same manner as in Example 1, except that:

[0120] [Comparative Example 1] A translucent building material 1 of Comparative Example 1 was obtained in the same manner as in Example 1, except that in step [1], bisphenol A polycarbonate (manufactured by Mitsubishi Engineering Plastics Corporation, "Iupilon E2000") was used instead of the composite material contained in the resin layer forming material.

[0121] Comparative Example 2 In step [1], bisphenol A polycarbonate (manufactured by Mitsubishi Engineering-Plastics Corporation, "Iupilon E2000") was used instead of the composite material contained in the resin layer-forming material, and in step [2], the distribution ratio of the base material-forming material and the resin layer-forming material in the distributed product formed by the distributor 230 was adjusted to form a base material 2 and a resin layer 3 with average thicknesses A and B as shown in Table 1. Except for this, a translucent building material 1 of Comparative Example 2 was obtained in the same manner as in Example 1.

[0122] 2. Evaluation The light-transmitting building materials 1 of the examples and comparative examples were evaluated by the following methods.

[0123] <Weather resistance test> For each of the translucent building materials 1 in the examples and comparative examples, a sample (width 60 mm, length 120 mm, thickness 4 mm) was heated in a hot air circulating oven set at 170°C for 10 minutes to soften it, and immediately after removing it, it was attached to a wooden cylinder with a radius of 30 mm via a flannel cloth, with the coating surface facing outwards, and kept in this state until the sample cooled to near room temperature, thereby forming a single curved surface to obtain a molded product.

[0124] Next, the molded articles obtained from the light-transmitting building materials 1 of each Example and Comparative Example were subjected to an accelerated test using a carbon arc sunshine weatherometer in accordance with JIS K 7350-4. The appearance after 3000 hours of ultraviolet irradiation was evaluated as follows: yellowing index (ΔYI) in accordance with JIS K 7373; and the change in haze value (ΔHAZE) and total light transmittance (TT) in accordance with ASTM D1003.

[0125] <<Yellowing index (ΔYI)>> ◎: ΔYI is 1.0 or less and there is no change in appearance. Good: ΔYI is greater than 1.0 and less than 2.0, There is little or no change in appearance. △: ΔYI is 2.0 or more and less than 3.0, There is a noticeable or slight change in appearance. ×: ΔYI exceeds 3.0 and a clear change in appearance is observed.

[0126] <<Change in haze value (ΔHAZE)>> ⊚: ΔHAZE is 4.0 or less. Good: ΔHAZE is greater than 4.0 and equal to or less than 7.0. ×: ΔHAZE is greater than 7.0.

[0127] <<Total light transmittance (TT)>> ◎: TT is 85.0 or more and there is no change in appearance. ○: TT is 75.0 or more and less than 85.0, and there is no change in appearance. △: TT is 75.0 or more and less than 85.0, and there is a change in appearance. ×: TT is less than 75.0 and there is a change in appearance.

[0128] <Return evaluation> The light-transmitting building material 1 of each example and comparative example was crushed using a crusher or the like, and the resulting powder was mixed with polycarbonate resin powder in a ratio of 3:7 to prepare a mixture. This mixture was then supplied to a T-die 600 provided in a building material manufacturing apparatus 500, and extruded from an opening 601 of the T-die 600 into a sheet molding section 800 as a molten sheet. The total luminous transmittance (TT) of the resulting molded body was then evaluated as follows.

[0129] <<Total light transmittance (TT)>> ◎: TT is 85.0 or higher. ○: TT is 75.0 or more and less than 85.0. ×: TT is less than 75.0.

[0130] <High-speed surface impact test> The light-transmitting building material 1 of each example and comparative example was cut into a square lumber, and then the peak energy was measured and the failure mode was observed using a high-speed surface impact tester (Instron's "DynaTap CEAST9350") conforming to ASTM D3763 at room temperature (23°C), with a punch tip diameter of 1 / 2 inch (12.7 mm), and an impact speed of 8.257 m / s.

[0131] The evaluation results of the light-transmitting building materials 1 of the respective Examples and Comparative Examples obtained as described above are shown in Table 1 below.

[0132] [Table 1]

[0133] As shown in Table 1, in each example, the translucent building material 1 was constructed as a laminate having a substrate 2 primarily made of polycarbonate resin and two resin layers 3 formed on both sides of the substrate 2 using a resin composition containing a resin material having no aromatic ring and an ultraviolet absorber, respectively. This enabled the translucent building material 1 of each example to have a yellowing index of less than 2.0 [ΔYI] and a peak energy of 120 J or more in the high-speed surface impact test. Therefore, each example showed results that indicated that a translucent building material 1 superior in both impact resistance and weather resistance was obtained compared to each comparative example. [Explanation of symbols]

[0134] 1 Translucent building materials 2 Base material 3 Resin layer 4 Laminate 13 Side 2 15 Page 1 110 Touch Roll 120 cooling roll 130 Rear cooling roll 150 Melting Sheet 210 Extruder 211 Molten resin discharge section 212 Piping 220 Extruder 221 Molten resin discharge section 230 Distributor 500 Building material manufacturing equipment 600 T-die 601 Opening 700 Sheet Supply Unit 800 Sheet forming section

Claims

1. a base material primarily made of polycarbonate resin; a translucent building material having resin layers provided on both surfaces of the substrate and formed using a resin composition containing a resin material having no aromatic ring and an ultraviolet absorber; The resin composition contains a rubber component, the content of the rubber component in the resin layer is 2.0% by weight or more and 10.0% by weight or less, the content of the ultraviolet absorber in the resin layer is 2.0% by weight or more and 9.0% by weight or less, the ultraviolet absorber is a triazine-based ultraviolet absorber, The resin layer has an average thickness B of 10 μm or more and 60 μm or less, the resin layer is irradiated with ultraviolet light for 3000 hours using a sunshine weatherometer in accordance with JIS K 7350-4, and then the yellowing index of the translucent building material measured in accordance with JIS K 7373 is less than 2.0 [ΔYI]; and The light-transmitting building material is characterized in that the peak energy in a high-speed surface impact test in accordance with ASTM D3763 is 120 J or more.

2. 2. The light-transmitting building material according to claim 1, wherein the resin material having no aromatic ring is an aliphatic resin.

3. 3. The light-transmitting building material according to claim 2, wherein the aliphatic resin is a (meth)acrylic resin.

4. 4. The light-transmitting building material according to claim 1, wherein a relationship B / A between an average thickness A [μm] of the base material and an average thickness B [μm] of both of the resin layers satisfies the relationship 0.0017<B / A<0.

01.

5. 5. The light-transmitting building material according to claim 1, wherein the light-transmitting building material has an average thickness C of 3.0 mm or more and 18.0 mm or less.

6. 6. The light-transmitting building material according to claim 1, wherein the resin layer has a flexural modulus at 25[deg.] C. of 1500 MPa or more.

7. The resin layer has a Charpy impact strength of 5.0 kJ / m as measured in accordance with ISO 179-1. ２ 20.0kJ / m or more ２ 7. The light-transmitting building material according to claim 1, wherein:

8. A building comprising the light-transmitting building material according to any one of claims 1 to 7.

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