Isosorbide Polycarbonate Multilayer Body Adhesion
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Solution Overview
Problem
Current multilayer bodies made from polycarbonate resins lack excellent heat resistance, impact resistance, surface hardness, chemical resistance, and adhesion, particularly when combining isosorbide polycarbonates with bisphenol A polycarbonates, leading to poor laminate performance.
Innovation Solution
A polycarbonate resin composition containing isosorbide and a monomer with an aromatic structure, along with an aliphatic or alicyclic diol monomer, is used to create a laminate with improved heat resistance, impact resistance, surface hardness, and chemical resistance, and enhanced adhesion to aromatic polycarbonates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an acrylic resin containing a weather-proofing agent is used to cover a polycarbonate substrate, then weather resistance is improved, but impact resistance, heat resistance, and chemical resistance are not fully exerted
Solution Approach 1:
The patent uses a composite structure consisting of a polycarbonate resin layer and an isosorbide polycarbonate layer. The polycarbonate resin provides impact resistance and chemical resistance, while the isosorbide polycarbonate layer provides weather resistance and surface hardness, creating a multi-functional composite material that overcomes the limitations of single-material solutions
2Temperature
If isosorbide polycarbonate is used to improve heat resistance, weather resistance, and surface hardness, then adhesion to general bisphenol A polycarbonates is significantly low
Solution Approach 1:
The patent changes the chemical composition parameters of the polycarbonate layer by incorporating specific copolymerization components (cyclic carbonates and chain carbonates) in controlled ratios. This parameter adjustment creates a polycarbonate resin with both high heat resistance and improved adhesion to bisphenol A polycarbonate substrates
3Temperature
If a copolymer composition having isosorbide and a spiro ring is used, then heat resistance and adhesion are considered, but chemical resistance is not considered
Solution Approach 1:
The patent creates a composite polycarbonate system combining isosorbide-based cyclic carbonate units with chain carbonate units derived from specific diols. This composite structure provides comprehensive performance including heat resistance, chemical resistance, and adhesion, addressing the limitations of previous single-component copolymer compositions
4Strength
If a copolymer composition having isosorbide and an aromatic ring is used, then molecular weight and mechanical properties are improved, but adhesion to aromatic polycarbonate resin is not described
Solution Approach 1:
The patent precisely controls the compositional parameters of the copolymer, specifying that cyclic carbonate units (from isosorbide) constitute 5-50 mol% and chain carbonate units constitute 50-95 mol% of the total. This parameter optimization ensures both improved mechanical properties and adequate adhesion to aromatic polycarbonate substrates
Data Source
AI summary
A multilayer body includes at least one layer (A) made of a polycarbonate resin (A) whose main repeating units include a unit (a-1) composed of an ether diol residue represented by the following formula (1) and a unit (a-2) composed of a diol residue represented by the following formula (2), and at least one layer (B) containing an aromatic polycarbonate resin (B), wherein the molar ratio of the unit (a-1) is 50 to 96 mol% and the molar ratio of the unit (a-2) is 4 to 50 mol%, with respect to 100 mol% of the total repeating units of the polycarbonate resin (A) and the proportion of the aromatic polycarbonate resin (B) in the layer (B) containing an aromatic polycarbonate resin (B) is 30% by weight or more, and the multilayer body is excellent in heat resistance, impact resistance, surface hardness, adhesion, and chemical resistance. In the formula (2), R1 and R2 each independently represent at least one group selected from the group consisting of a hydrogen atom, a halogen atom, an alkyl group having 1 to 10 carbon atoms, an alkoxy group having 1 to 10 carbon atoms, a cycloalkyl having 6 to 20 carbon atoms, a cycloalkoxy group having 6 to 20 carbon atoms, an alkenyl group having 2 to 10 carbon atoms, an aryl group having 6 to 10 carbon atoms, an aryloxy group having 6 to 10 carbon atoms, an aralkyl group having 7 to 20 carbon atoms, an aralkyloxy group having 7 to 20 carbon atoms, a nitro group, an aldehyde group, a cyano group, and a carboxyl group, and when a plurality of R1 and R2 are present, they may be the same or different; a and b each represent an integer of 1 to 4; and W represents at least one bonding group selected from the group consisting of a single bond and a bonding group represented by the following formula (3). In the formula (3), R3, R4, R5, R6, R7, R8, R9, and R10 each independently represent at least one group selected from the group consisting of a hydrogen atom, an alkyl group having 1 to 10 carbon atoms, an aryl group having 6 to 10 carbon atoms, and an aralkyl group having 7 to 20 carbon atoms, and when a plurality of R3, R4, R5, R6, R7, R8, R9, and R10 are present, they may be the same or different; R11, R12, R13, and R14 each independently represent at least one group selected from the group consisting of an alkyl group having 1 to 10 carbon atoms, a cycloalkenyl group having 6 to 20 carbon atoms, an alkenyl group having 2 to 10 carbon atoms, an aryl group having 6 to 10 atoms, and an aralkyl group having 7 to 20 carbon atoms, and when a plurality of R11, R12, R13, and R14 are present, they may be the same or different; A represents a single bond, an oxygen atom or a sulfur atom; c represents an integer of 1 to 10; d represents an integer of 4 to 7; e represents an integer of 1 to 10; and f represents an integer of 1 to 100.