RESIN SHEET FOR MOLDING AND MOLDED ARTICLE USING SAME

Abstract

A resin sheet for molding includes a substrate layer that contains polycarbonate resin (a1), a high-hardness resin layer that contains high-hardness resin and that is provided on at least one surface of the substrate layer, a hard coat layer or a hard coat antiglare layer that is provided on at least one surface of the high-hardness resin layer, and a wet antireflection layer that is laminated on a surface of the hard coat layer or the hard coat antiglare layer on the side opposite from the high-hardness resin layer, wherein the glass transition temperatures of the polycarbonate resin (a1) and the high-hardness resin satisfy the following relationship: −10° C.≤(glass transition temperature of high-hardness resin)−(glass transition temperature of polycarbonate resin (a1))≤40° C.

Claims

1. A resin sheet for molding comprising: a substrate layer including a polycarbonate resin (a1); a high-hardness resin layer including a high-hardness resin, wherein the high-hardness resin layer is provided on at least one surface of the substrate layer; a hard coat layer or a hard coat anti-glare layer that is provided on at least one surface of the high-hardness resin layer; and a wet anti-reflection layer that is laminated on a surface of the hard coat layer or hard coat anti-glare layer on an opposite side to the high-hardness resin layer side, wherein the polycarbonate resin (a1) and the high-hardness resin each have a glass transition point that satisfies the following relationship.
−10° C.≤(glass transition point of high-hardness resin)−(glass transition point of polycarbonate resin (a1))≤40° C.

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

3. The resin sheet for molding according to claim 2, wherein the aromatic polycarbonate resin includes a structural unit represented by the following formula (3a). ##STR00017##

4. The resin sheet for molding according to claim 1, wherein a content of the polycarbonate resin (a1) is 75 to 100% by mass based on a total mass of the substrate layer.

5. The resin sheet for molding according to claim 1, wherein the high-hardness resin includes at least one selected from the group consisting of: a resin (B1), which is a copolymer including a (meth)acrylate structural unit (a) represented by the following general formula (1): ##STR00018## wherein R.sup.1 is a hydrogen atom or a methyl group, R.sup.2 is an alkyl group having 1 to 18 carbon atoms; and an aliphatic vinyl structural unit (b) represented by the following general formula (2): ##STR00019## wherein R.sup.3 is a hydrogen atom or a methyl group, and R.sup.4 is a cyclohexyl group which may be substituted with a hydrocarbon group having 1 to 4 carbon atoms, a resin (B2), which is a copolymer including 6 to 77% by mass of a (meth)acrylate 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, a resin (B3), which is a copolymer including a structural unit (c) represented by the following general formula (5): ##STR00020## a resin (B4), which is a copolymer including 5 to 20% by mass of a styrene structural unit, 60 to 90% by mass of a (meth)acrylate structural unit, and 5 to 20% by mass of an N-substituted maleimide structural unit, a resin (B5), which is a polymer including a structural unit (e) represented by the following general formula (7): ##STR00021## and a resin (B6), which is a copolymer including 50 to 95% by mass of a styrene structural unit and 5 to 50% by mass of an unsaturated dicarboxylic acid unit.

6. The resin sheet for molding according to claim 5, wherein the resin (B3) is a copolymer further including a structural unit (d) represented by the following formula (6). ##STR00022##

7. A resin molded article produced by molding the resin sheet for molding according to claim 1.

Description

EXAMPLES

[0235] Hereinafter, working examples of the present invention will be described, but the present invention is not limited to embodiments of the working examples.

<Measurement of Glass Transition Point (Tg)>

[0236] The glass transition point of the polycarbonate resins and high-hardness resins used in the examples and comparative examples was measured using a differential scanning calorimeter DSC7020 manufactured by Hitachi High-Tech Science on a sample of 10 mg at a heating rate of 10° C./min, and calculating based on the midpoint method.

<Measurement of Reflectance>

[0237] The opposite side of the anti-reflection layer of the resin sheet for molding was painted black with a black marker pen, and the visual reflectance was measured with a SD-7000 manufactured by Nippon Denshoku. For the visual reflectance, a value including specular reflection (SCI) was adopted.

<Measurement of Pencil Hardness of Resin Sheet>

[0238] Each of the resin sheets produced in the Examples and Comparative Examples was evaluated by the pencil scratch hardness test in accordance with JIS K 5600-5-4. The highest hardness of the pencil, with which the surface of the hard coat anti-glare layer was not damaged when the pencil was pressed against the surface at an angle of 45° with respect to the surface with a load of 750 g, while increasing the hardness thereof, was evaluated as the pencil hardness. The hardness of 2H or harder was evaluated as acceptable.

<Production of Molded Article Having Curved Shape and Evaluation of Crack of Hard Coat after Molding>

[0239] The resin sheets produced in the Examples and Comparative Examples were subjected to thermoforming. Regarding Examples 1-3 and 5-15 and Comparative Examples 1-6 and 8-11, molds for hot pressing with a clearance (gap between an upper mold and a lower mold for sandwiching a sheet for molding) of 2 mm and a molding R of 50 mm were used, and regarding Example 4 and Comparative Example 7, molds for hot pressing with a clearance of 3.5 mm and a molding R of 100 mm were used. The pressure applied to the molds for hot pressing was 0.6 MPa. The material of the molds was aluminum. The mold temperature at the time of thermoforming was 124° C. in Examples 1-5, 7-11 and 13-15 and Comparative Examples 1-4, 9 and 10, and 143° C. in Examples 6 and 12 and Comparative Examples 5-8 and 11.

[0240] Regarding the obtained molded articles, the presence or absence of a crack in the 50 mm R portion or 100 mm R portion was confirmed. Note that when a resin sheet in which the total thickness of the substrate layer and the high-hardness resin layer is 0.5 mm, 1.2 mm or 1.5 mm was formed using the molds for hot pressing with the clearance of 2 mm, a single-layer polycarbonate sheet of 1.5 mm, 0.8 mm or 0.5 mm was laid under it to adjust the total thickness to be 2 mm, thereby performing hot press molding.

<Flow Mark>

[0241] Regarding each layered body of the high-hardness resin layer and the polycarbonate resin layer before hard-coated produced in the Examples and Comparative Examples, outer appearance thereof was visually examined under a three-wavelength fluorescent lamp to confirm the presence or absence of a scaly pattern and white turbidity. The case where none of scaly pattern and white turbidity was observed was evaluated as “flow mark is absent”, and the case where a scaly pattern or white turbidity was observed was evaluated as “flow mark is present”.

Example 1: R100 (Tg: 124° C.)/Low Tg PC (Tg: 125° C.)/1.2 mmt

[0242] A layered body consisting of a substrate layer and a high-hardness resin layer was formed using a multilayer extrusion apparatus having a single screw extruder with a screw diameter of 35 mm, a single screw extruder with a screw diameter of 65 mm, a feed block connected to the respective extruders and a T-die connected to the feed block. Specifically, a high-hardness resin (B2) (copolymer containing 21% by mass of a methyl methacrylate structural unit, 64% by mass of a styrene structural unit and 15% by mass of a maleic anhydride structural unit; RESISFY R100 (manufactured by Denka)) was continuously introduced into the single screw extruder with the screw diameter of 35 mm and extruded at a cylinder temperature of 230° C. and a discharge rate of 2.6 kg/hour. Further, a polycarbonate resin (Iupizeta T-1380; manufactured by Mitsubishi Gas Chemical Company, Inc.) was continuously introduced into the single screw extruder with the screw diameter of 65 mm and extruded at a cylinder temperature of 240° C. and a discharge rate of 50.0 kg/hour.

[0243] The extruded high-hardness resin and the extruded polycarbonate resin were introduced into the feed block having a distribution pin for two types of two layers, and the high-hardness resin and the polycarbonate resin were layered at 240° C. It was further introduced into the T-die at 240° C. to be extruded into a sheet shape, and using 3 mirror-finished rolls each at 120° C., 130° C. and 190° C. from the upstream side, it was transferred on the mirror surfaces and cooled and stretched, thereby obtaining the layered body consisting of the high-hardness resin layer and the polycarbonate resin layer (substrate layer). The stretching magnification was 1.3 times. The thickness of the obtained layered body was 1.2 mm, and the thickness of the high-hardness resin layer near the center thereof was 60 μm.

[0244] A hard coat anti-glare layer was formed on the high-hardness resin layer side of the layered body obtained above. The material of the hard coat anti-glare layer is as described below.

Relative to 100 parts by mass of a mixture containing:

[0245] U6HA: hexafunctional urethane acrylate oligomer (manufactured by Shin-Nakamura Chemical Co., Ltd.), 60% by mass;

[0246] 4EG-A: PEG200 #diacrylate (manufactured by Kyoeisha Chemical Co., Ltd.), 35% by mass; and

[0247] RS-90: fluorine-containing group/hydrophilic group/lipophilic group/UV reactive group-containing oligomer (manufactured by DIC), 5% by mass,

[0248] Photopolymerization initiator: 1-184 (manufactured by BASF [compound name: 1-hydroxy-cyclohexyl phenyl ketone]), 1 part by mass

[0249] The above-described material was applied to the layered body using a bar coater, the concave-convex surface of a frosted glass plate having a haze of 10% and a thickness of 2 mm was attached thereon, and it was irradiated with a metal halide lamp (20 mW/cm.sup.2) from above the glass plate for 5 seconds to cure the hard coat. After the hard coat anti-glare layer was bonded, the frosted glass plate was removed, thereby preparing a resin sheet. The thickness of the hard coat anti-glare layer was 6 μm.

<Wet Anti-Reflection Layer>

[0250] A wet anti-reflection layer was formed on the obtained resin sheet with the following high refractive index paint and low refractive index paint.

<High Refractive Index Paint>

[0251] The high refractive index paint for forming the high refractive index layer was obtained by adding 12 parts by mass of a urethane acrylate oligomer (UN-3320HC, manufactured by Negami Chemical Industrial), 11 parts by mass of an acrylate monomer (4EG-A, manufactured by Kyoeisha Chemical), 5 parts by mass of a photopolymerization initiator (Irgacure-184), and 900 parts by mass of organic solvent MEK (methyl ethyl ketone) to 110 parts by mass of Zircoster ZP-153 (zirconium oxide, manufactured by Nippon Shokubai Co., Ltd.) as zirconia.

<Low Refractive Index Paint>

[0252] The low refractive index paint for forming the low refractive index layer was obtained by adding 10 parts by mass of an aliphatic urethane acrylate oligomer, 10 parts by mass of an acrylate monomer (4EG-A, Kyoeisha Chemical), 2 parts by mass of a photopolymerization initiator (Irgacure-184), and 378 parts by mass of organic solvent MEK (methyl ethyl ketone) to 100 parts by mass of Thrulya 4320 (manufactured by JGC C&C) as hollow silica.

[0253] The high refractive index paint was coated on the hard coat anti-glare layer side of the resin sheet with a bar coater and dried at 100° C. for 2 minutes. After that, the paint was irradiated with UV (300 mJ/cm.sup.2) and cured to obtain a high refractive index layer. The coating thickness of the high refractive index layer was 180 nm, and the refractive index was 1.7.

[0254] Next, the low refractive index paint was coated on the high refractive index layer with a bar coater and dried at 100° C. for 2 minutes. After that, the paint was irradiated with UV (300 mJ/cm.sup.2) and cured to obtain a low refractive index layer. The coating thickness of the low refractive index layer was 150 nm, and the refractive index was 1.38.

[0255] A resin sheet for molding was produced as described above. The visual reflectance of the resin sheet for molding was 1.0%.

Example 2: R100 (Tg 124° C.)/Low Tg PC (Tg 125° C.)/2 mmt

[0256] The discharge rate during extrusion of the polycarbonate resin with a single screw extruder was set to 83.0 kg/h, and the thickness of the laminate of the high-hardness resin layer and the polycarbonate resin layer (substrate layer) was 2 mm (the thickness of the high-hardness resin layer near the center was 60 μm). The stretch ratio was 1.17 times. A hard coat anti-glare layer was formed in the same manner as in Example 1 to form a resin sheet. The method for forming the wet anti-reflection layer on the resin sheet was carried out in the same manner as in Example 1 to produce a resin sheet for molding.

Example 3: R100 (Tg 124° C.)/Low Tg PC (Tg 125° C.)/0.5 mmt

[0257] The discharge rate during extrusion of the high-hardness resin (B2) and the polycarbonate resin with a single screw extruder was set to 4.8 kg/h and 35.0 kg/h, respectively, and the thickness of the laminate of the high-hardness resin layer and the polycarbonate resin layer (substrate layer) was 0.5 mm (the thickness of the high-hardness resin layer near the center was 60 μm). The stretch ratio was 1.5 times. A hard coat anti-glare layer was formed in the same manner as in Example 1 to form a resin sheet. The method for forming the wet anti-reflection layer on the resin sheet was carried out in the same manner as in Example 1 to produce a resin sheet for molding.

Example 4: R100 (Tg 124° C.)/Low Tg PC (Tg 125° C.)/3.5 mmt

[0258] The discharge rate during extrusion of the high-hardness resin (B2) and the polycarbonate resin with a single screw extruder was set to 1.3 kg/h and 72.0 kg/h, respectively, and the thickness of the laminate of the high-hardness resin layer and the polycarbonate resin layer (substrate layer) was 3.5 mm (the thickness of the high-hardness resin layer near the center was 60 μm). The stretch ratio was 1.1 times. A hard coat anti-glare layer was formed in the same manner as in Example 1 to form a resin sheet. The method for forming the wet anti-reflection layer on the resin sheet was carried out in the same manner as in Example 1 to produce a resin sheet for molding.

Example 5: R310 (Tg 141° C.)/Low Tg PC (Tg 125° C.)/2 mmt

[0259] Using the same multi-layer extrusion apparatus as in Example 1, a laminate composed of a substrate layer and a high-hardness resin layer was molded. Specifically, the high-hardness resin (B2) (a copolymer of 6% by mass of a methyl methacrylate structural unit, 71% by mass of a styrene structural unit, and 23% by mass of a maleic anhydride structural unit; Resisfy R310 (manufactured by Denka)) was continuously introduced into the single-screw extruder having a screw diameter of 35 mm, and extruded under conditions of a cylinder temperature of 240° C. and a discharge rate of 2.6 kg/h. Further, a polycarbonate resin (Iupizeta T-1380; manufactured by Mitsubishi Gas Chemical) was continuously introduced into the single-screw extruder having a screw diameter of 65 mm, and extruded under conditions of a cylinder temperature of 240° C. and a discharge rate of 83.0 kg/h.

[0260] Then, extrusion with a T-die was carried out in the same manner as in Example 1 to obtain a laminate of a high-hardness resin layer and a polycarbonate resin layer (substrate layer). The thickness of the obtained laminate was 2 mm, and the thickness of the high-hardness resin layer near the center was 60 μm. The stretch ratio was 1.17 times.

[0261] A hard coat anti-glare layer was formed in the same manner as in Example 1. The method for forming the wet anti-reflection layer on the resin sheet was carried out in the same manner as in Example 1 to produce a resin sheet for molding.

Example 6: R310 (Tg 141° C.)/S-1000 (Tg 147° C.)/2 mmt

[0262] Using the same multi-layer extrusion apparatus as in Example 1, a laminate composed of a substrate layer and a high-hardness resin layer was molded. Specifically, the high-hardness resin (B2) (a copolymer of 6% by mass of a methyl methacrylate structural unit, 71% by mass of a styrene structural unit, and 23% by mass of a maleic anhydride structural unit; Resisfy R310 (manufactured by Denka)) was continuously introduced into the single-screw extruder having a screw diameter of 35 mm, and extruded under conditions of a cylinder temperature of 240° C. and a discharge rate of 2.6 kg/h. Further, a polycarbonate resin (Iupilon S-1000; manufactured by Mitsubishi Engineering-Plastics) was continuously introduced into the single-screw extruder having a screw diameter of 65 mm, and extruded under conditions of a cylinder temperature of 280° C. and a discharge rate of 83.0 kg/h.

[0263] The extruded high-hardness resin and the polycarbonate resin were introduced into a feed block equipped with two types of two-layer distribution pins, and the high-hardness resin and the polycarbonate resin were laminated at a temperature of 280° C. Further, the laminated product was introduced into a T-die having a temperature of 280° C., extruded into a sheet, and cooled and stretched while transferring a mirror surface with three mirror-finishing rolls having temperatures of 120° C., 130° C., and 190° C. from the upstream side to obtain a laminate of a high-hardness resin layer and a polycarbonate resin layer (substrate layer). The thickness of the obtained laminate was 2 mm, and the thickness of the high-hardness resin layer near the center was 60 μm. The stretch ratio was 1.17 times.

[0264] A hard coat anti-glare layer was formed in the same manner as in Example 1. The method for forming the wet anti-reflection layer on the resin sheet was carried out in the same manner as in Example 1 to produce a resin sheet for molding.

Example 7: PM120N (Tg 120° C.)/Low Tg PC (Tg 125° C.)/1.5 mmt

[0265] Using the same multi-layer extrusion apparatus as in Example 1, a laminate composed of a substrate layer and a high-hardness resin layer was molded. Specifically, the high-hardness resin (B4) (a copolymer of 7% by mass of a styrene structural unit, 86% by mass of a methyl methacrylate structural unit, and 7% by mass of a N-phenylmaleimide structural unit; Delpet PM120N (manufactured by Asahi Kasei Chemicals Co., Ltd.)) was continuously introduced into the single-screw extruder having a screw diameter of 35 mm, and extruded under conditions of a cylinder temperature of 230° C. and a discharge rate of 2.6 kg/h. Further, a polycarbonate resin (Iupizeta T-1380; manufactured by Mitsubishi Gas Chemical) was continuously introduced into the single-screw extruder having a screw diameter of 65 mm, and extruded under conditions of a cylinder temperature of 240° C. and a discharge rate of 62.0 kg/h.

[0266] Then, extrusion with a T-die was carried out in the same manner as in Example 1 to obtain a laminate of a high-hardness resin layer and a polycarbonate resin layer (substrate layer). The thickness of the obtained laminate was 1.5 mm, and the thickness of the high-hardness resin layer near the center was 60 μm. The stretch ratio was 1.23 times.

[0267] A hard coat anti-glare layer was formed in the same manner as in Example 1. The method for forming the wet anti-reflection layer on the resin sheet was carried out in the same manner as in Example 1 to produce a resin sheet for molding.

Example 8: R200 (Tg 126° C.)/Low Tg PC (Tg 125° C.)/2 mmt

[0268] Using the same multi-layer extrusion apparatus as in Example 1, a laminate composed of a substrate layer and a high-hardness resin layer was molded. Specifically, the high-hardness resin (B2) (a copolymer of 26% by mass of a methyl methacrylate structural unit, 55% by mass of a styrene structural unit, and 19% by mass of a maleic anhydride structural unit; Resisfy R200 (manufactured by Denka)) was continuously introduced into the single-screw extruder having a screw diameter of 35 mm, and extruded under conditions of a cylinder temperature of 230° C. and a discharge rate of 2.6 kg/h. Further, a polycarbonate resin (Iupizeta T-1380; manufactured by Mitsubishi Gas Chemical) was continuously introduced into the single-screw extruder having a screw diameter of 65 mm, and extruded under conditions of a cylinder temperature of 240° C. and a discharge rate of 83.0 kg/h.

[0269] Then, extrusion with a T-die was carried out in the same manner as in Example 1 to obtain a laminate of a high-hardness resin layer and a polycarbonate resin layer (substrate layer). The thickness of the obtained laminate was 2 mm, and the thickness of the high-hardness resin layer near the center was 60 μm. The stretch ratio was 1.17 times.

[0270] The material of the hard coat anti-glare layer was the same as in Example 1. The material was applied on the laminate with a bar coater, and the mirror surface of 2 mm-thick mirror glass having a haze of less than 1% was arranged on the laminate. A metal halide lamp (20 mW/cm.sup.2) was irradiated for 5 seconds from above the glass to cure the hard coat, and after the hard coat layer was attached, the mirrored glass plate was peeled off to produce a resin sheet. The thickness of the hard coat layer was 6 μm. The method for forming the wet anti-reflection layer on the resin sheet was carried out in the same manner as in Example 1 to produce a resin sheet for molding, except that the anti-reflection layer was formed on the surface of the hard coat layer.

Example 9: C-PC (KH3410UR) (Tg 118° C.)/Low Tg PC (Tg 125° C.)/2 mmt

[0271] Using the same multi-layer extrusion apparatus as in Example 1, a laminate composed of a substrate layer and a high-hardness resin layer was molded. Specifically, the high-hardness resin (B3) (polycarbonate resin; Iupilon KH3410UR (manufactured by Mitsubishi Engineering-Plastics)) was continuously introduced, and extruded under conditions of a cylinder temperature of 270° C. and a discharge rate of 2.6 kg/h. Further, a polycarbonate resin (Iupizeta T-1380; manufactured by Mitsubishi Gas Chemical) was continuously introduced into the single-screw extruder having a screw diameter of 65 mm, and extruded under conditions of a cylinder temperature of 240° C. and a discharge rate of 83.0 kg/h.

[0272] Then, extrusion with a T-die was carried out in the same manner as in Example 1 to obtain a laminate of a high-hardness resin layer and a polycarbonate resin layer (substrate layer). The thickness of the obtained laminate was 2 mm, and the thickness of the high-hardness resin layer near the center was 60 μm. The stretch ratio was 1.17 times.

[0273] A hard coat layer was formed in the same manner as in Example 8. The method for forming the wet anti-reflection layer on the resin sheet was carried out in the same manner as in Example 1 to produce a resin sheet for molding, except that the anti-reflection layer was formed on the hard coat layer surface.

Example 10: Alloy of R100 and PM120N (Tg 123° C.)/low Tg PC (Tg 125° C.)/1.2 mmt

[0274] 75% by mass of a copolymer of 21% by mass of a methyl methacrylate structural unit, 64% by mass of a styrene structural unit, and 15% by mass of a maleic anhydride structural unit (Resisfy R100 (manufactured by Denka)) and 25% by mass of a copolymer of 7% by mass of a styrene structural unit, 86% by mass of a methyl methacrylate structural unit, and 7% by mass of a N-phenylmaleimide structural unit (Delpet PM120N (manufactured by Asahi Kasei Chemicals Co., Ltd.) were introduced into an extruder (TEM-26SS, L/D of about 40; manufactured by Toshiba Machine Co., Ltd.) having a screw diameter of 26 mm, and melt-kneaded at 240° C. to obtain a high-hardness resin including the resin (B2) and the resin (B4).

[0275] Using the same multi-layer extrusion apparatus as in Example 1, a laminate composed of a substrate layer and a high-hardness resin layer was molded. Specifically, the above high-hardness resin was continuously introduced into the single-screw extruder having a screw diameter of 35 mm, and extruded under conditions of a cylinder temperature of 230° C. and a discharge rate of 2.6 kg/h. Further, a polycarbonate resin (Iupizeta T-1380; manufactured by Mitsubishi Gas Chemical) was continuously introduced into the single-screw extruder having a screw diameter of 65 mm, and extruded under conditions of a cylinder temperature of 240° C. and a discharge rate of 50.0 kg/h.

[0276] Then, extrusion with a T-die was carried out in the same manner as in Example 1 to obtain a laminate of a high-hardness resin layer and a polycarbonate resin layer (substrate layer). The thickness of the obtained laminate was 1.2 mm, and the thickness of the high-hardness resin layer near the center was 60 μm. The stretch ratio was 1.3 times.

[0277] A hard coat layer was formed in the same manner as in Example 8. The method for forming the wet anti-reflection layer on the resin sheet was carried out in the same manner as in Example 1 to produce a resin sheet for molding, except that the anti-reflection layer was formed on the hard coat layer surface.

Example 11: R310 (Tg 141° C.)/Low Tg PC (Tg 125° C.)/0.5 mmt

[0278] Using the same multi-layer extrusion apparatus as in Example 1, a laminate composed of a substrate layer and a high-hardness resin layer was molded. Specifically, the high-hardness resin (B2) (a copolymer of 6% by mass of a methyl methacrylate structural unit, 71% by mass of a styrene structural unit, and 23% by mass of a maleic anhydride structural unit; Resisfy R310 (manufactured by Denka)) was continuously introduced into the single-screw extruder having a screw diameter of 35 mm, and extruded under conditions of a cylinder temperature of 230° C. and a discharge rate of 8 kg/h. Further, a polycarbonate resin (Iupizeta T-1380; manufactured by Mitsubishi Gas Chemical) was continuously introduced into the single-screw extruder having a screw diameter of 65 mm, and extruded under conditions of a cylinder temperature of 240° C. and a discharge rate of 35.0 kg/h.

[0279] Then, extrusion with a T-die was carried out in the same manner as in Example 1 to obtain a laminate of a high-hardness resin layer and a polycarbonate resin layer (substrate layer). The thickness of the obtained laminate was 0.5 mm, and the thickness of the high-hardness resin layer near the center was 100 μm. The stretch ratio was 1.5 times.

[0280] The material of the hard coat anti-glare layer was the same as in Example 1. The material was applied on the laminate with a bar coater, and the uneven surface of 2 mm-thick frosted glass having a haze of 4% was arranged on the laminate. A metal halide lamp (20 mW/cm.sup.2) was irradiated for 5 seconds to cure the hard coat, and after the hard coat anti-glare layer was attached, the frosted glass plate was peeled off to produce a resin sheet. The thickness of the hard coat anti-glare layer was 6 μm.

[0281] The method for forming the wet anti-reflection layer on the resin sheet was carried out in the same manner as in Example 1 to produce a resin sheet for molding.

Example 12: FPC0220 (Tg 184° C.)/E2000 (Tg 147° C.)/1.2 mmt

[0282] Using the same multi-layer extrusion apparatus as in Example 1, a laminate composed of a substrate layer and a high-hardness resin layer was molded. Specifically, the high-hardness resin (B5) (a polycarbonate resin including a structural unit represented by formula (7); Iupizeta FPC0220 (manufactured by Mitsubishi Gas Chemical)) was continuously introduced into the single-screw extruder having a screw diameter of 35 mm, and extruded under conditions of a cylinder temperature of 300° C. and a discharge rate of 2.6 kg/h. Further, a polycarbonate resin (Iupilon E2000; manufactured by Mitsubishi Gas Chemical) was continuously introduced into the single-screw extruder having a screw diameter of 65 mm, and extruded under conditions of a cylinder temperature of 280° C. and a discharge rate of 50.0 kg/h.

[0283] The extruded high-hardness resin and the polycarbonate resin were introduced into a feed block equipped with two types of two-layer distribution pins, and the high-hardness resin and the polycarbonate resin were laminated at a temperature of 280° C. Further, the laminated product was extruded into a sheet with a T-die having a temperature of 280° C., and cooled and stretched while transferring a mirror surface with three mirror-finishing rolls having temperatures of 120° C., 130° C., and 190° C. from the upstream side to obtain a laminate of a high-hardness resin layer and a polycarbonate resin layer (substrate layer). The thickness of the obtained laminate was 1.2 mm, and the thickness of the high-hardness resin layer near the center was 60 μm. The stretch ratio was 1.3 times.

[0284] A hard coat anti-glare layer was formed in the same manner as in Example 11. The method for forming the wet anti-reflection layer on the resin sheet was carried out in the same manner as in Example 1 to produce a resin sheet for molding.

Example 13: MS-H (Tg 115° C.)/Low Tg PC (Tg 125° C.)/1.2 mmt

[0285] Using the same multi-layer extrusion apparatus as in Example 1, a laminate composed of a substrate layer and a high-hardness resin layer was molded. The high-hardness resin (B1) (a resin in which both R.sup.1 and R.sup.2 in general formula (1) are methyl groups, R.sup.3 in general formula (2) is a hydrogen atom, and R.sup.4 is a cyclohexyl group; composed of 75 mol % of a (meth)acrylate structural unit and 25 mol % of an aliphatic vinyl structural unit and has a weight average molecular weight of 120,000) was continuously introduced into the single-screw extruder having a screw diameter of 35 mm, and extruded under conditions of a cylinder temperature of 240° C. and a discharge rate of 2.6 kg/h. Further, a polycarbonate resin (Iupizeta T-1380; manufactured by Mitsubishi Gas Chemical) was continuously introduced into the single-screw extruder having a screw diameter of 65 mm, and extruded under conditions of a cylinder temperature of 240° C. and a discharge rate of 50.0 kg/h.

[0286] Then, extrusion with a T-die was carried out in the same manner as in Example 1 to obtain a laminate of a high-hardness resin layer and a polycarbonate resin layer (substrate layer). The thickness of the obtained laminate was 1.2 mm, and the thickness of the high-hardness resin layer near the center was 60 μm. The stretch ratio was 1.3 times.

[0287] A hard coat anti-glare layer was formed in the same manner as in Example 11. The method for forming the wet anti-reflection layer on the resin sheet was carried out in the same manner as in Example 1 to produce a resin sheet for molding.

Example 14: Alloy of V020 and St-MAH Resin (Tg 132° C.)/Low Tg PC (Tg 125° C.)/1.2 mmt

[0288] 75% by mass of a copolymer of 78% by mass of a styrene structural unit and 22% by mass of a maleic anhydride structural unit (XIBOND 160 (manufactured by Polyscope) and 25% by mass of an acrylic resin (Altuglas (manufactured by Arkema Asahi Kasei Chemicals Co., Ltd.)) were extruded with an extruder (TEM-26SS, L/D of about 40; manufactured by Toshiba Machine Co., Ltd.) having a screw diameter of 26 mm, and melt-kneaded at 240° C. to obtain a high-hardness resin including the resin (B6).

[0289] Using the same multi-layer extrusion apparatus as in Example 1, a laminate composed of a substrate layer and a high-hardness resin layer was molded. Specifically, the above high-hardness resin was continuously introduced into the single-screw extruder having a screw diameter of 35 mm, and extruded under conditions of a cylinder temperature of 230° C. and a discharge rate of 2.6 kg/h. Further, a polycarbonate resin (Iupizeta T-1380; manufactured by Mitsubishi Gas Chemical) was continuously introduced into the single-screw extruder having a screw diameter of 65 mm, and extruded under conditions of a cylinder temperature of 240° C. and a discharge rate of 50.0 kg/h.

[0290] Then, extrusion with a T-die was carried out in the same manner as in Example 1 to obtain a laminate of a high-hardness resin layer and a polycarbonate resin layer (substrate layer). The thickness of the obtained laminate was 1.2 mm, and the thickness of the high-hardness resin layer near the center was 60 μm. The stretch ratio was 1.3 times.

[0291] A hard coat layer was formed in the same manner as in Example 8. The method for forming the wet anti-reflection layer on the resin sheet was carried out in the same manner as in Example 1 to produce a resin sheet for molding, except that the anti-reflection layer was formed on the hard coat layer surface.

Example 15: Alloy of V020 and St-MAH Resin (Tg 132° C.)/Low Tg PC (Tg 125° C.)/1.2 mmt

[0292] 75% by mass of a copolymer of 78% by mass of a styrene structural unit and 22% by mass of a maleic anhydride structural unit (XIBOND 160 (manufactured by Polyscope) and 25% by mass of an acrylic resin (Altuglas (manufactured by Arkema Asahi Kasei Chemicals Co., Ltd.)) were extruded with an extruder (TEM-26SS, L/D of about 40; manufactured by Toshiba Machine Co., Ltd.) having a screw diameter of 26 mm, and melt-kneaded at 240° C. to obtain a high-hardness resin including the resin (B6).

[0293] Using the same multi-layer extrusion apparatus as in Example 1, a laminate composed of a substrate layer and a high-hardness resin layer was molded. Specifically, the above high-hardness resin was continuously introduced into the single-screw extruder having a screw diameter of 35 mm, and extruded under conditions of a cylinder temperature of 230° C. and a discharge rate of 2.6 kg/h. Further, a polycarbonate resin (Iupizeta T-1380; manufactured by Mitsubishi Gas Chemical) was continuously introduced into the single-screw extruder having a screw diameter of 65 mm, and extruded under conditions of a cylinder temperature of 240° C. and a discharge rate of 50.0 kg/h.

[0294] Then, extrusion with a T-die was carried out in the same manner as in Example 1 to obtain a laminate of a high-hardness resin layer and a polycarbonate resin layer (substrate layer). The thickness of the obtained laminate was 1.2 mm, and the thickness of the high-hardness resin layer near the center was 60 μm. The stretch ratio was 1.3 times.

[0295] A hard coat layer was formed in the same manner as in Example 8. The method for forming the wet anti-reflection layer on the resin sheet was carried out in the same manner as in Example 1 to produce a resin sheet for molding, except that the anti-reflection layer was formed on the hard coat layer surface.

Comparative Example 1: MS-H (Tg 115° C.)/Low Tg PC (125° C.)/0.5 mmt

[0296] The conditions when extruding the high-hardness resin (B1) with a single-screw extruder were a cylinder temperature of 230° C. and a discharge rate of 8.0 kg/h. The discharge rate during extrusion of the polycarbonate resin with a single-screw extruder was set to 35.0 kg/h, and the thickness of the laminate of the high-hardness resin layer and the polycarbonate resin layer (substrate layer) was 0.5 mm (the thickness of the high-hardness resin layer near the center was 60 μm). The stretch ratio was 1.5 times.

[0297] A hard coat anti-glare layer was formed in the same manner as in Example 1. In order from the hard coat anti-glare layer side of the resin sheet as the first layer, each layer was formed by vacuum deposition in which the high refractive index layer was TiO.sub.2 (refractive index 2.49) and the low refractive index layer was SiO.sub.2 (refractive index 1.46) to form an inorganic anti-reflection layer (not a wet anti-reflection layer obtained by a wet film forming method) to obtain a resin sheet for molding.

[0298] The types and thicknesses of each layer were as follows.

First layer: TiO.sub.2 10 nm
Second layer: SiO.sub.2 50 nm
Third layer: TiO.sub.2 20 nm
Fourth layer: SiO.sub.2 40 nm
Fifth layer: TiO.sub.2 20 nm
Sixth layer: SiO.sub.2 110 nm

[0299] The visual reflectance of the obtained resin sheet for molding was 0.6%.

Comparative Example 2: Alloy of R100 and PMMA (Tg 115° C.)/Low Tg PC (Tg 125° C.)/1.2 mmt

[0300] 75% by mass of a copolymer composed of 21% by mass of a methyl methacrylate structural unit, 64% by mass of a styrene structural unit, and 15% by mass of a maleic anhydride structural unit (Resisfy R100; manufactured by Denka) and 25% by mass of an acrylic resin (Parapet HR-1000L (PMMA); manufactured by Kuraray Co., Ltd.) were extruded with an extruder (TEM-26SS, L/D of about 40; manufactured by Toshiba Machine Co., Ltd.) having a screw diameter of 26 mm, and melt-kneaded at 240° C. to obtain a high-hardness resin including the resin (B2).

[0301] Using the same multi-layer extrusion apparatus as in Example 1, a laminate composed of a substrate layer and a high-hardness resin layer was molded. Specifically, the above high-hardness resin was continuously introduced into the single-screw extruder having a screw diameter of 35 mm, and extruded under conditions of a cylinder temperature of 230° C. and a discharge rate of 2.6 kg/h. Further, a polycarbonate resin (Iupizeta T-1380; manufactured by Mitsubishi Gas Chemical) was continuously introduced into the single-screw extruder having a screw diameter of 65 mm, and extruded under conditions of a cylinder temperature of 240° C. and a discharge rate of 50.0 kg/h.

[0302] Then, extrusion with a T-die was carried out in the same manner as in Example 1 to obtain a laminate of a high-hardness resin layer and a polycarbonate resin layer (substrate layer). The thickness of the obtained laminate was 1.2 mm, and the thickness of the high-hardness resin layer near the center was 60 μm. The stretch ratio was 1.3 times.

[0303] A hard coat anti-glare layer was formed in the same manner as in Example 1. An inorganic anti-reflection layer was formed on the resin sheet in the same manner as in Comparative Example 1 to produce a resin sheet for molding.

Comparative Example 3: R100 (Tg 124° C.)/Low Tg PC (Tg 125° C.)/1.2 mmt

[0304] Using a multi-screw extruder having a single-screw extruder with a screw diameter of 35 mm, a single-screw extruder with a screw diameter of 65 mm, a feed block connected to each extruder, and a T-die connected to the feed block, a laminate composed of a substrate layer and a high-hardness resin layer was molded. Specifically, the high-hardness resin (B2) (a copolymer of 21% by mass of a methyl methacrylate structural unit, 64% by mass of a styrene structural unit, and 15% by mass of a maleic anhydride structural unit; Resisfy R100 (manufactured by Denka)) was continuously introduced into the single-screw extruder having a screw diameter of 35 mm, and extruded under conditions of a cylinder temperature of 230° C. and a discharge rate of 2.6 kg/h. Further, a polycarbonate resin (Iupizeta T-1380; manufactured by Mitsubishi Gas Chemical) was continuously introduced into the single-screw extruder having a screw diameter of 65 mm, and extruded under conditions of a cylinder temperature of 240° C. and a discharge rate of 50.0 kg/h.

[0305] The extruded high-hardness resin and the polycarbonate resin were introduced into a feed block equipped with two types of two-layer distribution pins, and the high-hardness resin and the polycarbonate resin were laminated at a temperature of 240° C. Further, the laminated product was introduced into a T-die having a temperature of 240° C., extruded into a sheet, and cooled and stretched while transferring a mirror surface with three mirror-finishing rolls having temperatures of 120° C., 130° C., and 190° C. from the upstream side to obtain a laminate of a high-hardness resin layer and a polycarbonate resin layer (substrate layer). The stretch ratio was 1.3 times. The thickness of the obtained laminate was 1.2 mm, and the thickness of the high-hardness resin layer near the center was 60 μm.

[0306] A hard coat anti-glare layer was formed in the same manner as in Example 1. An inorganic anti-reflection layer was formed on the resin sheet in the same manner as in Comparative Example 1 to produce a resin sheet for molding.

Comparative Example 4

[0307] A laminate of a high-hardness resin layer and a polycarbonate resin layer (substrate layer) was obtained in the same manner as in Example 1.

[0308] A hard coat anti-glare layer was formed in the same manner as in Example 1. An inorganic anti-reflection layer was formed on the resin sheet in the same manner as in Comparative Example 1 to produce a resin sheet for molding.

Comparative Example 5: MS-H (Tg 115° C.)/S1000 (Tg 147° C.)/1.2 mmt

[0309] Using the same multi-layer extrusion apparatus as in Example 1, a laminate composed of a substrate layer and a high-hardness resin layer was molded. Specifically, the high-hardness resin (B1) (a resin in which both R.sup.1 and R.sup.2 in general formula (1) are methyl groups, R.sup.3 in general formula (2) is a hydrogen atom, and R.sup.4 is a cyclohexyl group; composed of 75 mol % of a (meth)acrylate structural unit and 25 mol % of an aliphatic vinyl structural unit and has a weight average molecular weight of 120,000) was continuously introduced into the single-screw extruder having a screw diameter of 35 mm, and extruded under conditions of a cylinder temperature of 240° C. and a discharge rate of 2.6 kg/h. Further, a polycarbonate resin (Iupilon S-1000; manufactured by Mitsubishi Engineering-Plastics) was continuously introduced into the single-screw extruder having a screw diameter of 65 mm, and extruded under conditions of a cylinder temperature of 280° C. and a discharge rate of 50.0 kg/h.

[0310] The extruded high-hardness resin and the polycarbonate resin were introduced into a feed block equipped with two types of two-layer distribution pins, and the high-hardness resin and the polycarbonate resin were laminated at a temperature of 270° C. Further, the laminated product was extruded into a sheet with a T-die having a temperature of 270° C., and cooled while transferring a mirror surface with three mirror-finishing rolls having temperatures of 120° C., 130° C., and 190° C. from the upstream side to obtain a laminate of a high-hardness resin layer and a polycarbonate resin layer (substrate layer). The stretch ratio was 1.3 times. The thickness of the obtained laminate was 1.2 mm, and the thickness of the high-hardness resin layer near the center was 60 μm.

[0311] A hard coat anti-glare layer was formed in the same manner as in Example 1. The method for forming the wet anti-reflection layer on the resin sheet was carried out in the same manner as in Example 1 to produce a resin sheet for molding.

Comparative Example 6: MS-H (Tg 115° C.)/S1000 (Tg 147° C.)/2 mmt

[0312] In Comparative Example 5, the discharge rate during extrusion of the polycarbonate resin with a single-screw extruder was set to 83.0 kg/h, and the thickness of the laminate of the high-hardness resin layer and the polycarbonate resin layer (substrate layer) was set to 2 mm (the thickness of the high-hardness resin layer near the center was 60 μm). The stretch ratio was 1.17 times.

[0313] A hard coat anti-glare layer was formed in the same manner as in Example 1. The method for forming the wet anti-reflection layer on the resin sheet was carried out in the same manner as in Example 1 to produce a resin sheet for molding.

Comparative Example 7: MS-H (Tg 115° C.)/S1000 (Tg 147° C.)/3.5 mmt

[0314] In Comparative Example 5, the discharge rate during extrusion of the high-hardness resin (B1) and the polycarbonate resin with a single screw extruder was set to 1.3 kg/h and 72.0 kg/h, respectively, and the thickness of the laminate of the high-hardness resin layer and the polycarbonate resin layer (substrate layer) was 3.5 mm (the thickness of the high-hardness resin layer near the center was 60 μm). The stretch ratio was 1.1 times.

[0315] A hard coat anti-glare layer was formed in the same manner as in Example 1. The method for forming the wet anti-reflection layer on the resin sheet was carried out in the same manner as in Example 1 to produce a resin sheet for molding.

Comparative Example 8: MS-H (Tg 115° C.)/S1000 (Tg 147° C.)/0.5 mmt

[0316] In Comparative Example 5, the discharge rate during extrusion of the high-hardness resin (B1) and the polycarbonate resin with a single screw extruder was set to 4.8 kg/h and 35.0 kg/h, respectively, and the thickness of the laminate of the high-hardness resin layer and the polycarbonate resin layer (substrate layer) was 0.5 mm (the thickness of the high-hardness resin layer near the center was 60 μm). The stretch ratio was 1.5 times.

[0317] A hard coat anti-glare layer was formed in the same manner as in Example 1. The method for forming the wet anti-reflection layer on the resin sheet was carried out in the same manner as in Example 1 to produce a resin sheet for molding.

Comparative Example 9: PMMA (Tg 105° C.)/Low Tg PC (Tg 125° C.)/0.8 mmt

[0318] Using a multi-screw extruder having a single-screw extruder with a screw diameter of 32 mm, a single-screw extruder with a screw diameter of 65 mm, a feed block connected to each extruder, and a T-die connected to the feed block, a laminate composed of a substrate layer and a high-hardness resin layer was molded. Specifically, a high-hardness resin (an acrylic resin (Parapet HR-1000L (PMMA); manufactured by Kuraray Co., Ltd.) was continuously introduced into the single-screw extruder having a screw diameter of 32 mm, and extruded under conditions of a cylinder temperature of 250° C. and a discharge rate of 2.6 kg/h. Further, a polycarbonate resin (Iupizeta T-1380; manufactured by Mitsubishi Gas Chemical) was continuously introduced into the single-screw extruder having a screw diameter of 65 mm, and extruded under conditions of a cylinder temperature of 240° C. and a discharge rate of 32.0 kg/h.

[0319] The extruded high-hardness resin and the polycarbonate resin were introduced into a feed block equipped with two types of two-layer distribution pins, and the high-hardness resin and the polycarbonate resin were laminated at a temperature of 240° C. Further, the laminated product was introduced into a T-die having a temperature of 240° C., extruded into a sheet, and cooled while transferring a mirror surface with three mirror-finishing rolls having temperatures of 110° C., 140° C., and 185° C. from the upstream side to obtain a laminate of a high-hardness resin layer and a polycarbonate resin layer (substrate layer). The thickness of the obtained laminate was 0.8 mm, and the thickness of the high-hardness resin layer near the center was 60 μm. The stretch ratio was 1.43 times.

[0320] A hard coat anti-glare layer was formed in the same manner as in Example 1. The method for forming the wet anti-reflection layer on the resin sheet was carried out in the same manner as in Example 1 to produce a resin sheet for molding.

Comparative Example 10: FPC0220 (Tg 184° C.)/T1380 (Tg 125° C.)/1.2 mmt

[0321] Using the same multi-layer extrusion apparatus as in Example 1, a laminate composed of a substrate layer and a high-hardness resin layer was molded. Specifically, the high-hardness resin (B5) (a polycarbonate resin including a structural unit represented by formula (7); Iupizeta FPC0220 (manufactured by Mitsubishi Gas Chemical)) was continuously introduced into the single-screw extruder having a screw diameter of 35 mm, and extruded under conditions of a cylinder temperature of 300° C. and a discharge rate of 2.6 kg/h. Further, a polycarbonate resin (Iupizeta T1380; manufactured by Mitsubishi Gas Chemical) was continuously introduced into the single-screw extruder having a screw diameter of 65 mm, and extruded under conditions of a cylinder temperature of 240° C. and a discharge rate of 50.0 kg/h.

[0322] The extruded high-hardness resin and the polycarbonate resin were introduced into a feed block equipped with two types of two-layer distribution pins, and the high-hardness resin and the polycarbonate resin were laminated at a temperature of 280° C. Further, the laminated product was extruded into a sheet with a T-die having a temperature of 280° C., and cooled and stretched while transferring a mirror surface with three mirror-finishing rolls having temperatures of 120° C., 130° C., and 190° C. from the upstream side to obtain a laminate of a high-hardness resin layer and a polycarbonate resin layer (substrate layer). The stretch ratio was 1.3 times. The thickness of the obtained laminate was 1.2 mm, and the thickness of the high-hardness resin layer near the center was 60 μm.

[0323] A hard coat anti-glare layer was formed in the same manner as in Example 1. The method for forming the wet anti-reflection layer on the resin sheet was carried out in the same manner as in Example 1 to produce a resin sheet for molding.

Comparative Example 11: S-1000 (Tg 147° C.) Alone/2 mmt

[0324] A laminate was molded using the same polycarbonate resin included in the substrate layer instead of a high-hardness resin. The same multi-layer extrusion apparatus as in Example 1 was used for the extrusion apparatus. Specifically, a polycarbonate resin (Iupilon S-1000; manufactured by Mitsubishi Engineering-Plastics; pencil hardness 3B) was continuously introduced into the single-screw extruder having a screw diameter of 35 mm, and extruded under conditions of a cylinder temperature of 280° C. and a discharge rate of 2.6 kg/h. Further, a polycarbonate resin (Iupilon S-1000; manufactured by Mitsubishi Engineering-Plastics) was continuously introduced into the single-screw extruder having a screw diameter of 65 mm, and extruded under conditions of a cylinder temperature of 280° C. and a discharge rate of 83.0 kg/h.

[0325] The extruded the polycarbonate resin was introduced into a feed block equipped with two types of two-layer distribution pins, and laminated at a temperature of 280° C. Further, the laminated product was introduced into a T-die having a temperature of 280° C., extruded into a sheet, and cooled and stretched while transferring a mirror surface with three mirror-finishing rolls having temperatures of 120° C., 130° C., and 190° C. from the upstream side to obtain a laminate of a polycarbonate resin layer. The stretch ratio was 1.17 times. The thickness of the obtained laminate was 2 mm

[0326] A hard coat anti-glare layer was formed in the same manner as in Example 1. The method for forming the wet anti-reflection layer on the resin sheet was carried out in the same manner as in Example 1 to produce a resin sheet for molding.

[0327] The pencil hardness, the presence or absence of cracks after molding, and flow marks were evaluated for the resin sheets produced in the examples and comparative examples. The results are shown in Table 1 below.

TABLE-US-00001 TABLE 1 Tg Sheet Pencil Cracks in HC and TgB*.sup.1 TgA*.sup.2 Difference Thickness*.sup.3 Hardness of Flow Anti-reflection (° C.) (° C.) (TgB − TgA) (mm) Resin Sheet marks Layer after Molding Example 1 124 125 −1 1.2 2H no no Example 2 124 125 −1 2 2H no no Example 3 124 125 −1 0.5 2H no no Example 4 124 125 −1 3.5 2H no no Example 5 141 125 16 2 3H no no Example 6 141 147 −6 2 3H no no Example 7 120 125 −5 1.5 3H no no Example 8 126 125 1 2 3H no no Example 9 118 125 −7 2 4H no no Example 10 123 125 −2 1.2 3H no no Example 11 141 125 16 0.5 3H no no Example 12 184 147 37 1.2 2H no no Example 13 115 125 −10 1.2 3H no no Example 14 132 125 7 1.2 3H no no Example 15 132 125 7 1.2 3H no no Comparative Example 1 115 125 −10 0.5 3H no yes Comparative Example 2 115 125 −10 1.2 3H no yes Comparative Example 3 124 125 −1 1.2 2H no yes Comparative Example 4 124 125 −1 1.2 2H no yes Comparative Example 5 115 147 −32 1.2 3H no yes Comparative Example 6 115 147 −32 2 3H no yes Comparative Example 7 115 147 −32 3.5 3H no yes Comparative Example 8 115 147 −32 0.5 3H no yes Comparative Example 9 105 125 −20 0.8 3H no yes Comparative Example 10 184 125 59 1.2 2H yes no Comparative Example 11 — 147 — 2 HB no no *.sup.1“TgB” means the Tg of the high-hardness resin. *.sup.2“TgA” means the Tg of the polycarbonate resin. *.sup.3“Sheet thickness” means the total thickness of the substrate layer and the high-hardness resin layer.