WO2019235644A1 - ポリカーボネート樹脂組成物、成形品、積層体 - Google Patents
ポリカーボネート樹脂組成物、成形品、積層体 Download PDFInfo
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- WO2019235644A1 WO2019235644A1 PCT/JP2019/022919 JP2019022919W WO2019235644A1 WO 2019235644 A1 WO2019235644 A1 WO 2019235644A1 JP 2019022919 W JP2019022919 W JP 2019022919W WO 2019235644 A1 WO2019235644 A1 WO 2019235644A1
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- polycarbonate resin
- resin
- weight
- structural unit
- resin composition
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Definitions
- the present disclosure relates to a polycarbonate resin composition containing two or more kinds of polycarbonate resins, and a molded article and a laminate using the polycarbonate resin composition.
- Polycarbonate resins generally contain bisphenols as monomer components and take advantage of transparency, heat resistance, mechanical strength, etc., in the optical field such as electrical / electronic parts, automotive parts, optical recording media, and lenses. Widely used as so-called engineering plastics.
- engineering plastics On the other hand, the development of plastics using carbon-neutral plant-derived monomers as a raw material has been demanded due to concerns over global warming due to the depletion of petroleum resources and an increase in carbon dioxide emissions.
- polycarbonate resins produced using isosorbide hereinafter sometimes referred to as “ISB”), which is a plant-derived material, have been developed, and are used for automotive parts, optical applications, and glass replacement. It has begun to be used for applications (see, for example, Patent Documents 1 and 2).
- the polycarbonate resin obtained from ISB is not only excellent in optical properties, but also extremely excellent in weather resistance and surface hardness compared to conventional general-purpose aromatic polycarbonate resins. Utilizing this characteristic, a polarizer protective film (Patent Document 5) and a retardation film (Patent Document 6), which are constituent members of a polarizing plate, surface protective films and decorative films such as automobile parts, electrical and electronic parts, and building materials ( Applications such as Patent Documents 7 and 8) have been developed. On the other hand, the polycarbonate resin obtained from ISB is required to further improve mechanical properties such as tensile resistance or impact resistance at a portion where stress is concentrated.
- Patent Document 3 discloses improving the impact resistance by adding a core-shell type elastomer to the polycarbonate resin as a technique for improving the impact resistance.
- Patent Document 4 discloses a polycarbonate resin composition having an improved balance of physical properties such as heat resistance, fluidity, and impact resistance.
- the polycarbonate resin obtained by using ISB is hereinafter referred to as “ISB polycarbonate resin” as appropriate.
- Patent Document 3 an improvement in excellent impact resistance can be expected by including a core-shell type elastomer in a polycarbonate resin.
- the optical properties inherent in the resin are impaired, The present inventors have found that toughness may be impaired under severe conditions such as an environment where temperature change or humidity change is repeated.
- the present disclosure has been made in view of such a background, and intends to provide a polycarbonate resin composition from which a high-quality molded product can be obtained.
- a resin composition in which a plurality of properties among transparency, heat resistance, color tone, moldability, chemical resistance, moist heat resistance, and impact resistance are excellent in balance, more specifically, transparency and heat resistance.
- Polycarbonate resin composition excellent in moldability, moldability, chemical resistance, and wet heat resistance, and a molded article formed by molding the resin composition, and a layer containing the resin composition It is intended to provide a laminate having the following.
- the inventors of the present invention provide a polycarbonate resin composition containing at least two types of polycarbonate resins having a specific structural unit at a predetermined ratio, and a composition having two or more glass transition temperatures can solve the above problem. It was discovered that the present disclosure was reached. That is, the gist of the present disclosure resides in the following [1] to [23].
- At least one of the first polycarbonate resin and the second polycarbonate resin is an aliphatic dihydroxy compound, an alicyclic dihydroxy compound, and an ether group-containing dihydroxy other than the dihydroxy compound represented by the formula (1).
- polycarbonate resin composition according to any one of [1] to [4], preferably having a number average molecular weight of 6000 or more and 12000 or less as measured by 1 H-NMR.
- the second polycarbonate resin has a melt viscosity of 1800 Pa ⁇ s or more and 3000 Pa ⁇ s or less at a measurement temperature of 220 ° C. and a shear rate of 91.2 sec ⁇ 1 .
- a polycarbonate resin composition according to any one of the above.
- the second polycarbonate resin has a melt viscosity of 80 Pa ⁇ s or more and 500 Pa ⁇ s or less at a measurement temperature of 220 ° C. and a shear rate of 91.2 sec ⁇ 1 of [1] to [6].
- the polycarbonate resin composition in any one.
- a third polycarbonate resin containing 50% by weight or more of the structural unit represented by the following formula (3) and / or an acrylic containing 50% by weight or more of the structural unit represented by the following formula (4) The polycarbonate resin composition according to [1], which contains a resin.
- R 1 to R 6 are each independently a hydrogen atom or an optionally substituted alkyl group having 1 to 10 carbon atoms.
- R 7 is a hydrogen atom or an alkyl group having 1 to 10 carbon atoms which may have a substituent.
- R 8 is an aryl group which may have a substituent or an aralkyl group which may have a substituent.
- the first polycarbonate resin is 60 parts by weight or more and 95 parts by weight with respect to 100 parts by weight in total of the first polycarbonate resin, the second polycarbonate resin, the third polycarbonate resin, and the acrylic resin.
- the polycarbonate resin composition according to [11] or [12], wherein both the first polycarbonate resin and the second polycarbonate resin contain a structural unit represented by the following formula (2).
- the glass transition temperature of the first polycarbonate resin is from 90 ° C. to 160 ° C.
- the glass transition temperature of the second polycarbonate resin is from 40 ° C. to 110 ° C.
- the polycarbonate resin composition according to any one of the above.
- a molded article comprising the polycarbonate resin composition according to any one of [1] to [14].
- the laminate structure of the resin layer A and the resin layer B is asymmetric in thickness and / or material with respect to the center line of the thickness of the laminate.
- the thickness ratio of the resin layer A to the resin layer B is 0.02 to 50 in the resin layer B / resin layer A, according to any one of [18] to [20].
- Laminated body is 0.02 to 50 in the resin layer B / resin layer A, according to any one of [18] to [20].
- the glass transition temperature of the first polycarbonate resin is 90 ° C. or higher and 160 ° C. or lower, and the glass transition temperature of the second polycarbonate resin is 40 ° C. or higher and 80 ° C. or lower.
- the polycarbonate resin composition a high-quality molded product or laminate can be obtained. That is, the polycarbonate resin composition is excellent in a plurality of properties among transparency, heat resistance, color tone, moldability, chemical resistance, moist heat resistance, and impact resistance. More specifically, it is excellent in transparency and heat resistance, and is also excellent in any one or more of moldability, chemical resistance, and wet heat resistance. Such a polycarbonate resin composition makes it possible to provide a molded product having a good balance of a plurality of properties among transparency, heat resistance, color tone, moldability, chemical resistance, moist heat resistance, and impact resistance. In addition, the polycarbonate resin composition is excellent in mechanical properties, weather resistance, and optical properties, and can provide a laminate that can suppress warpage that occurs in a use environment or a storage environment.
- FIG. 1A is a cross-sectional view of a laminate in which a resin layer A and a resin layer B are laminated one by one
- FIG. 1B is a diagram in which the resin layer A, the resin layer B, and the resin layer A are sequentially formed.
- FIG. 1C is a cross-sectional view of a laminated body in which a resin layer A, a resin layer B, a resin layer A, and a resin layer B are sequentially laminated
- FIG. ) Is a cross-sectional view of a laminate in which a resin layer A, a resin layer B, a resin layer B, and a resin layer A are sequentially laminated.
- a combination of a preferable upper limit value and a lower limit value, a combination of a more preferable upper limit value and a lower limit value, and a more preferable combination of an upper limit value and a lower limit value are the most preferable, but are not necessarily limited to these combinations. Absent.
- the “repeating structural unit” means a structural unit in which the same structure repeatedly appears in the resin, and means a structural unit that constitutes the resin by being connected to each other.
- a repeating structural unit including a carbonyl group in the case of a polycarbonate resin, it is referred to as a repeating structural unit including a carbonyl group.
- the “structural unit” is a partial structure constituting the resin and means a specific partial structure included in the repeating structural unit.
- a partial structure sandwiched between adjacent linking groups in a resin or a partial structure sandwiched between a polymerizable reactive group present at a terminal portion of a polymer and a linking group adjacent to the polymerizable reactive group.
- a partial structure in which a carbonyl group is a linking group and is sandwiched between adjacent carbonyl groups is referred to as a structural unit.
- a polycarbonate resin composition (hereinafter sometimes simply referred to as “resin composition”) includes two or more polycarbonate resins containing a structural unit represented by the following formula (1).
- the structural unit represented by the following formula (1) may be referred to as the structural unit (a).
- the resin composition contains at least a first polycarbonate resin and a second polycarbonate resin as a polycarbonate resin.
- the first polycarbonate resin and the second polycarbonate resin both contain the structural unit (a), but the content of the structural unit (a) constituting each resin is at least different.
- the first polycarbonate resin is a resin containing 40% by weight or more of the structural unit (a).
- the second polycarbonate resin is a resin containing less than 40% by weight of the structural unit (a).
- the first polycarbonate resin may be referred to as “resin A” as appropriate, and the second polycarbonate resin may be referred to as “resin B” as appropriate.
- the weight ratio of the first polycarbonate resin to the second polycarbonate resin is 55/45 to 99/1. If the weight ratio is within this range, the effects of moist heat resistance and chemical resistance can be obtained while maintaining sufficient heat resistance, mechanical properties and moldability in practical use. From the viewpoint of further improving this effect, the weight ratio of the first polycarbonate resin to the second polycarbonate resin is preferably 60/40 to 98/2, and more preferably 65/35 to 97/3. 70/30 to 95/5 is more preferable.
- the resin composition preferably further contains at least one of a polycarbonate resin and an acrylic resin as the third resin.
- the polycarbonate resin as the third resin is an aromatic polycarbonate resin containing 50% by weight or more of the structural unit represented by the following formula (3).
- the “third polycarbonate resin” or “resin C1” is appropriately used.
- the acrylic resin is an aromatic acrylic resin containing 50% by weight or more of the structural unit represented by the following formula (4), and is hereinafter referred to as “resin C2” as appropriate.
- Resin C1 and resin C2 are collectively referred to as “resin C” as appropriate.
- R 1 to R 6 are each independently a hydrogen atom or an optionally substituted alkyl group having 1 to 10 carbon atoms.
- R 7 is a hydrogen atom or an alkyl group having 1 to 10 carbon atoms which may have a substituent.
- R 8 is an aryl group which may have a substituent or an aralkyl group which may have a substituent.
- the polycarbonate resin composition contains the resin C
- the polycarbonate resin composition contains the first polycarbonate resin with respect to 100 parts by weight of the total amount of the first polycarbonate resin, the second polycarbonate resin, and the resin C.
- the amount is preferably 60 parts by weight or more, more preferably 65 parts by weight or more, and further preferably 70 parts by weight or more.
- the content of the first polycarbonate resin is preferably 95 parts by weight or less, more preferably 92 parts by weight or less, and still more preferably 90 parts by weight or less.
- the content of the second polycarbonate resin is preferably 3 parts by weight or more, more preferably 6.5 parts by weight or more, and further preferably 9 parts by weight or more.
- the content of the second polycarbonate resin is preferably 40 parts by weight or less, more preferably 35 parts by weight or less, and further preferably 30 parts by weight or less.
- the content of the resin C is preferably 0.01 parts by weight or more, more preferably 0.05 parts by weight or more, and further preferably 0.1 parts by weight or more.
- the content of the resin C is preferably 2 parts by weight or less, more preferably 1.5 parts by weight or less, and particularly preferably 1 part by weight or less. Note that the content of the resin C is the total content of the resin C1 and the resin C2, and either one of the contents may be zero.
- the first polycarbonate resin is the main component of the polycarbonate resin composition and mainly bears heat resistance
- the content is excellent in heat resistance when it is at least the lower limit of the above range, and below the upper limit of the above range, The characteristic obtained by the 2nd polycarbonate resin mentioned later can be provided.
- the second polycarbonate resin mainly bears mechanical properties such as impact resistance, the mechanical properties are excellent when the content is not less than the lower limit of the above range. Moreover, in a laminated body, 2nd polycarbonate resin is mix
- the first polycarbonate resin and the second polycarbonate resin are polycarbonate resins having a common structural unit and different composition ratios. Therefore, when these two types of resins are mixed, a phase separation structure is formed.
- the two types of resins have partial compatibility, it is not necessary to apply strong shearing force or high temperature to the resin during kneading.
- the refractive indexes of the two resins are close to each other, good transparency is exhibited.
- the second polycarbonate resin having excellent flexibility and toughness and having a relatively high molecular weight forms a domain in the resin composition, and this domain is dispersed in a matrix composed of the first polycarbonate resin. Contributes to the improvement of heat and chemical resistance.
- the morphology of the resin composition such as the matrix-domain structure and the compatibility can be examined by an ordinary method, and specifically, can be examined by observation with a transmission electron microscope.
- Resin C is a polycarbonate resin and / or an acrylic resin having an aromatic structure.
- the resin C is at least one of a polycarbonate resin and an acrylic resin having an aromatic structure.
- Resin C is incompatible with the first polycarbonate resin and is compatible with the second polycarbonate resin. Therefore, by further mixing the resin C with the first polycarbonate resin and the second polycarbonate resin, the resin C dissolves in the phase of the second polycarbonate resin, and the refractive index of the phase of the second polycarbonate resin can be adjusted. .
- the refractive index of the first polycarbonate resin and the second polycarbonate resin are close to each other, but because the temperature dependence of the refractive index is different between them, the transparency of the resin composition becomes cloudy at a high temperature and the transparency is impaired. There is. By further adding the resin C to the resin composition, the refractive indices of the two phases can be matched exactly, so that the transparency at high temperature can be improved. Further, the difference in transparency between the high temperature and the room temperature can
- the content of the resin C is not less than the lower limit of the above range, the effect of improving transparency is excellent. If it is below the upper limit of the above range, the refractive index of the phase of the resin A (that is, the first polycarbonate resin) and the phase of the resin B (that is, the second polycarbonate resin) will not deviate, and the transparency will not be impaired. That is, when the amount is not more than the above upper limit, high transparency of the molded product of the resin composition can be maintained at room temperature or high temperature. In addition, since the resin C has an aromatic structure, if the upper limit is exceeded, the weather resistance of the resin composition may be impaired.
- Examples of the dihydroxy compound (hereinafter referred to as “compound (1)”) that forms the structural unit of the formula (1) include isosorbide, isomannide, and isoidet, which have a stereoisomeric relationship. These may be used individually by 1 type and may be used in combination of 2 or more type. Above all, isosorbide obtained by dehydration condensation of sorbitol produced from various easily available starches, which are abundant as plant-derived resources, is easy to obtain and manufacture, moldability, and characteristics of the obtained molded product Most preferable in terms of (for example, heat resistance, impact resistance, surface hardness, carbon neutral).
- the polycarbonate resin contains at least the first polycarbonate resin and the second polycarbonate resin described above, but contains other polycarbonate resins other than the first polycarbonate resin and the second polycarbonate resin as long as the effects of the present disclosure are not hindered. It is also possible to do. Specifically, for example, a third polycarbonate resin (that is, resin C1) can be contained. Further, the polycarbonate resin in the polycarbonate resin composition can be substantially composed of a first polycarbonate resin and a second polycarbonate resin.
- the weight ratio of the structural unit (a) is different between the first polycarbonate resin and the second polycarbonate resin.
- the weight ratio of the structural unit (a) in the first polycarbonate resin is the weight ratio of the structural unit (a) to the total weight of the first polycarbonate resin.
- the weight ratio of the structural unit (a) in the second polycarbonate resin is the weight ratio of the structural unit (a) to the total weight of the second polycarbonate resin.
- the first polycarbonate resin contains 40% by weight or more of the structural unit (a).
- the first polycarbonate resin may be a homopolymer substantially free of structural units other than the structural unit (a), or may be a copolymer polycarbonate resin containing structural units other than the structural unit (a). Good. While the homopolymer of the structural unit (a) has high heat resistance, it has characteristics such as insufficient impact resistance and chemical resistance and poor dimensional stability due to high water absorption. Therefore, from the viewpoint of improving the balance of various physical properties for use as a molding material, the first polycarbonate resin is preferably a copolymer polycarbonate resin containing the structural unit (a) and other structural units.
- the upper limit of the content of the structural unit (a) in the first polycarbonate resin is preferably 80% by weight, more preferably 70% by weight, and 65% by weight. Is more preferable, and 60% by weight is particularly preferable. Further, the lower limit of the content of the structural unit (a) is preferably 45% by weight, and more preferably 50% by weight.
- structural units other than the structural unit (a) constituting the polycarbonate resin are appropriately referred to as “structural unit (b)”.
- a numerical value of an upper limit and a lower limit is shown, it means a range including the numerical value. That is, it means that it is less than or equal to the upper limit value and greater than or equal to the lower limit value.
- the second polycarbonate resin contains less than 40% by weight of the structural unit (a). Since the second polycarbonate resin contains the structural unit (a) similarly to the first polycarbonate resin, the second polycarbonate resin tends to exhibit compatibility with the first polycarbonate resin.
- the second polycarbonate resin contains the structural unit (a) to such an extent that compatibility with the first polycarbonate resin can be ensured, and the content of the structural unit (b) is larger than that of the structural unit (a), for example. It is preferable to increase the content of the structural unit (b) in the first polycarbonate resin. Since the second polycarbonate resin is a component mainly responsible for impact resistance, chemical resistance, and moisture and heat resistance, the second polycarbonate resin preferably contains 35% by weight or less of the structural unit (a).
- the lower limit of the content of the structural unit (a) in the second polycarbonate resin is usually 1% by weight, preferably 5% by weight, more preferably 10% by weight. preferable.
- At least one of the first polycarbonate resin and the second polycarbonate resin is preferably a copolymer polycarbonate resin containing the structural unit (a) and the structural unit (b), and the first polycarbonate resin and the second polycarbonate resin It is more preferable that both are copolymer polycarbonate resins containing the structural unit (a) and the structural unit (b).
- the structural unit (b) is preferably a structural unit derived from a dihydroxy compound other than the formula (1), but may be a structural unit derived from a compound other than the dihydroxy compound.
- dihydroxy compound forming the structural unit (b) examples include an aliphatic hydrocarbon dihydroxy compound, an alicyclic hydrocarbon dihydroxy compound, an ether-containing dihydroxy compound, and an acetal-containing dihydroxy compound. These dihydroxy compounds have a flexible molecular structure. Therefore, the chemical resistance of the polycarbonate resin can be improved by using these dihydroxy compounds as raw materials for the polycarbonate resin.
- an aliphatic hydrocarbon dihydroxy compound and an alicyclic hydrocarbon dihydroxy compound are preferable, and an alicyclic hydrocarbon dihydroxy compound is most preferable from the viewpoint that the effect of improving chemical resistance is great.
- Specific examples of the aliphatic hydroxy dihydroxy compound, the alicyclic hydrocarbon dihydroxy compound, the ether-containing dihydroxy compound, and the acetal-containing dihydroxy compound are as follows.
- Examples of the aliphatic hydrocarbon dihydroxy compound include the following dihydroxy compounds. Ethylene glycol, 1,3-propanediol, 1,2-propanediol, 1,4-butanediol, 1,5-heptanediol, 1,6-hexanediol, 1,9-nonanediol, 1,10-decane Linear aliphatic dihydroxy compounds such as diol and 1,12-dodecanediol; aliphatic dihydroxy compounds having a branched chain such as 1,3-butanediol, 1,2-butanediol, neopentyl glycol and hexylene glycol.
- Examples of the alicyclic hydrocarbon dihydroxy compound include the following dihydroxy compounds. 1,2-cyclohexanedimethanol, 1,3-cyclohexanedimethanol, 1,4-cyclohexanedimethanol, tricyclodecane dimethanol, pentacyclopentadecane dimethanol, 2,6-decalin dimethanol, 1,5-decalindi Examples thereof include dihydroxy compounds derived from terpene compounds such as methanol, 2,3-decalin dimethanol, 2,3-norbornane dimethanol, 2,5-norbornane dimethanol, 1,3-adamantane dimethanol and limonene.
- Dihydroxy compounds which are primary alcohols of alicyclic hydrocarbons; 1,2-cyclohexanediol, 1,4-cyclohexanediol, 1,3-adamantanediol, hydrogenated bisphenol A, 2,2,4,4-tetra Methyl-1,3-cyclobutane Illustrated in Lumpur like, secondary alcohols alicyclic hydrocarbon, or dihydroxy compound is a tertiary alcohol.
- Examples of the ether-containing dihydroxy compound include oxyalkylene glycols.
- Examples of oxyalkylene glycols that can be used include diethylene glycol, triethylene glycol, tetraethylene glycol, polyethylene glycol, and polypropylene glycol.
- dihydroxy compound containing an acetal ring examples include spiroglycol (also known as 3,9-bis (1,1-dimethyl-2-hydroxyethyl-2,4,8,10-tetraoxaspiro [5,5]).
- Undecane or dioxane glycol (also known as 2- (1,1-dimethyl-2-hydroxyethyl) -5-ethyl-5-hydroxymethyl-1,3-dioxane) can be used.
- 1,4-cyclohexanedimethanol and tricyclodecane dimethanol are preferable, and 1,4-cyclohexanedimethanol is particularly preferable.
- 1,4-cyclohexanedimethanol it becomes easy to obtain a high-molecular-weight polycarbonate resin due to the good polymerization reactivity of 1,4-cyclohexanedimethanol, and it has extremely high mechanical properties such as impact resistance.
- An excellent polycarbonate resin can be obtained. For example, in the laminate, the warp suppressing effect by the second polycarbonate resin is more sufficiently exhibited.
- the structural unit (b) derived from 1,4-cyclohexanedimethanol is represented by the following formula (2).
- the second polycarbonate resin preferably contains 45% by weight or more of the structural unit represented by the formula (2). In this case, impact resistance and fluidity are more excellent. From the viewpoint of improving this effect, the second polycarbonate resin preferably contains 50% by weight or more of the structural unit represented by the formula (2), and more preferably 55% by weight or more.
- Tricyclodecane dimethanol is preferably used for the first polycarbonate resin.
- optical properties such as heat resistance and a low photoelastic coefficient required for an optical film can be obtained.
- the content ratio of the structural unit (b) in the first polycarbonate resin and the second polycarbonate resin is preferably 15% by weight or more, more preferably 20% by weight or more, and preferably 85% by weight or less, more preferably 80% by weight or less. .
- the content of the structural unit (b) is preferably 20% by weight or more, more preferably 25% by weight or more, and preferably 60% by weight or less, more preferably 55% by weight or less. Within the above range, the balance of heat resistance, impact resistance and chemical resistance is excellent.
- the content of the structural unit (b) is preferably 45% by weight or more, more preferably 50% by weight or more, particularly preferably 55% by weight or more, and preferably 80% by weight or less, 75% by weight.
- the following is more preferable.
- impact resistance, chemical resistance, and high fluidity which are in a trade-off relationship with each other, are excellent in a balanced manner at a high level.
- the first polycarbonate resin and the second polycarbonate resin may contain other structural units other than the structural units derived from the compounds exemplified above as the structural unit (b).
- Examples of other dihydroxy compounds that form such a structural unit include dihydroxy compounds and diester compounds containing aromatic groups such as bisphenol compounds.
- a polycarbonate resin partially incorporating a structural unit derived from a diester compound is referred to as a polyester carbonate resin.
- the polycarbonate resin includes a polyester carbonate resin.
- the heat resistance of the polycarbonate resin can be improved by using a dihydroxy compound or dicarboxylic acid compound containing an aromatic group such as a bisphenol compound as a copolymerization component.
- a dihydroxy compound or dicarboxylic acid compound containing an aromatic group such as a bisphenol compound as a copolymerization component.
- the polycarbonate resin contains many structural units derived from a dihydroxy compound containing an aromatic group, the weather resistance tends to decrease.
- the content ratio of the structural unit derived from the dihydroxy compound or dicarboxylic acid compound containing an aromatic group is preferably 10% by weight or less, and more preferably 5% by weight or less.
- dihydroxy compound containing an aromatic group for example, the following dihydroxy compounds can be used.
- diester compound examples include the following dicarboxylic acids. Terephthalic acid, phthalic acid, isophthalic acid, 4,4'-diphenyldicarboxylic acid, 4,4'-diphenyl ether dicarboxylic acid, 4,4'-benzophenone dicarboxylic acid, 4,4'-diphenoxyethanedicarboxylic acid, 4,4 '-Diphenylsulfone dicarboxylic acid, aromatic dicarboxylic acid such as 2,6-naphthalenedicarboxylic acid; 1,2-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, alicyclic dicarboxylic acid such as 1,4-cyclohexanedicarboxylic acid Acid; aliphatic dicarboxylic acids such as malonic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid and
- dicarboxylic acid components can be used as raw materials for polyester carbonate resins as dicarboxylic acid itself, but depending on the production method, dicarboxylic acid esters such as methyl ester and phenyl ester, and dicarboxylic acids such as dicarboxylic acid halides can be used.
- An acid derivative can also be used as a raw material.
- the dihydroxy compound used as a raw material for the polycarbonate resin may contain a stabilizer such as a reducing agent, an antioxidant, an oxygen scavenger, a light stabilizer, an antacid, a pH stabilizer or a heat stabilizer.
- a stabilizer such as a reducing agent, an antioxidant, an oxygen scavenger, a light stabilizer, an antacid, a pH stabilizer or a heat stabilizer.
- Examples of the carbonic acid diester used as a raw material for the polycarbonate resin usually include a compound represented by the following formula (5). These carbonic acid diesters may be used alone or in combination of two or more.
- a 1 and A 2 are each independently a substituted or unsubstituted aliphatic hydrocarbon group having 1 to 18 carbon atoms or a substituted or unsubstituted aromatic hydrocarbon group.
- a 1 and A 2 may be the same or different.
- a 1 and A 2 are preferably a substituted or unsubstituted aromatic hydrocarbon group, more preferably an unsubstituted aromatic hydrocarbon group.
- Examples of the carbonic acid diester represented by the formula (5) include substituted diphenyl carbonates such as diphenyl carbonate (DPC) and ditolyl carbonate; alkyl carbonates such as dimethyl carbonate, diethyl carbonate, and di-tert-butyl carbonate. It can.
- diphenyl carbonate or substituted diphenyl carbonate is preferably used, and diphenyl carbonate is particularly preferably used.
- the carbonic acid diester may contain impurities such as chloride ions. Impurities contained may inhibit the polycondensation reaction or may deteriorate the color tone of the obtained polycarbonate resin. Therefore, it is preferable to use the carbonic acid diester after purification by distillation or the like, if necessary.
- the first polycarbonate resin and the second polycarbonate resin can be synthesized by polycondensation of the above-described dihydroxy compound and carbonic acid diester by an ester exchange reaction. More specifically, it can be obtained by removing the monohydroxy compound and the like by-produced in the transesterification reaction from the system together with the polycondensation.
- the transesterification reaction proceeds in the presence of a transesterification reaction catalyst (hereinafter, the transesterification reaction catalyst is referred to as “polymerization catalyst”).
- the type of polymerization catalyst can greatly affect the reaction rate of the transesterification reaction and the quality of the resulting polycarbonate resin.
- the polymerization catalyst is not particularly limited as long as it can satisfy the transparency, color tone, heat resistance, weather resistance and mechanical strength of the obtained polycarbonate resin.
- Examples of the polymerization catalyst include metal compounds of Group I or Group II (hereinafter simply referred to as “Group 1” and “Group 2”) in the long-period periodic table, as well as basic boron compounds and basic phosphorus compounds.
- a basic compound such as a compound, a basic ammonium compound, or an amine compound can be used, and among them, a Group 1 metal compound and / or a Group 2 metal compound is preferable.
- Examples of the Group 1 metal compound include the following compounds. Sodium hydroxide, potassium hydroxide, lithium hydroxide, cesium hydroxide, sodium bicarbonate, potassium bicarbonate, lithium bicarbonate, cesium bicarbonate, sodium carbonate, potassium carbonate, lithium carbonate, cesium carbonate, sodium acetate, potassium acetate, Lithium acetate, cesium acetate, sodium stearate, potassium stearate, lithium stearate, cesium stearate, sodium borohydride, potassium borohydride, lithium borohydride, cesium borohydride, sodium borohydride, boron phenyl Potassium, lithium borohydride, cesium phenyl borohydride, sodium benzoate, potassium benzoate, lithium benzoate, cesium benzoate, disodium hydrogen phosphate, dipotassium hydrogen phosphate, phosphorus 2 lithium hydrogen, 2 cesium hydrogen phosphate, 2 sodium phenyl phosphate, 2 potassium phenyl phosphate, 2 lithium
- Examples of the Group 2 metal compound include the following compounds. Calcium hydroxide, barium hydroxide, magnesium hydroxide, strontium hydroxide, calcium bicarbonate, barium bicarbonate, magnesium bicarbonate, strontium bicarbonate, calcium carbonate, barium carbonate, magnesium carbonate, strontium carbonate, calcium acetate, barium acetate, Magnesium acetate, strontium acetate, calcium stearate, barium stearate, magnesium stearate and strontium stearate.
- a magnesium compound, a calcium compound or a barium compound is preferable. From the viewpoint of polymerization activity and the color tone of the obtained polycarbonate resin, a magnesium compound and / or a calcium compound is further preferable, and a calcium compound is most preferable.
- a basic compound such as a basic boron compound, a basic phosphorus compound, a basic ammonium compound, and an amine compound in combination with the group 1 metal compound and / or the group 2 metal compound.
- a basic compound such as a basic boron compound, a basic phosphorus compound, a basic ammonium compound, and an amine compound in combination with the group 1 metal compound and / or the group 2 metal compound.
- the basic phosphorus compound for example, the following compounds can be employed. Triethylphosphine, tri-n-propylphosphine, triisopropylphosphine, tri-n-butylphosphine, triphenylphosphine, tributylphosphine, quaternary phosphonium salt and the like.
- Tetramethylammonium hydroxide Tetramethylammonium hydroxide, tetraethylammonium hydroxide, tetrapropylammonium hydroxide, tetrabutylammonium hydroxide, trimethylethylammonium hydroxide, trimethylbenzylammonium hydroxide, trimethylphenylammonium hydroxide, triethylmethylammonium hydroxide, triethylbenzylammonium Hydroxide, triethylphenylammonium hydroxide, tributylbenzylammonium hydroxide, tributylphenylammonium hydroxide, tetraphenylammonium hydroxide, benzyltriphenylammonium hydroxide, methyltriphenylammonium hydroxide and butyltriphenylammonium hydroxide Rokishido like.
- amine compound for example, the following compounds can be employed. 4-aminopyridine, 2-aminopyridine, N, N-dimethyl-4-aminopyridine, 4-diethylaminopyridine, 2-hydroxypyridine, 2-methoxypyridine, 4-methoxypyridine, 2-dimethylaminoimidazole, 2-methoxy Imidazole, imidazole, 2-mercaptoimidazole, 2-methylimidazole, aminoquinoline, guanidine and the like.
- the amount of the polymerization catalyst used is preferably 0.1 ⁇ mol or more, more preferably 0.3 ⁇ mol or more, and particularly preferably 0.5 ⁇ mol or more per 1 mol of all dihydroxy compounds used in the reaction. Further, the amount of the polymerization catalyst used is preferably 300 ⁇ mol or less, more preferably 100 ⁇ mol or less, and particularly preferably 50 ⁇ mol or less, per 1 mol of all dihydroxy compounds used in the reaction.
- the polymerization rate can be increased by adjusting the amount of the polymerization catalyst used within the above range, a polycarbonate resin having a desired molecular weight can be obtained without necessarily increasing the polymerization temperature.
- the deterioration of the color tone can be suppressed.
- it can prevent that the unreacted raw material volatilizes during the polymerization and the molar ratio of the dihydroxy compound and the carbonic acid diester collapses, a resin having a desired molecular weight and copolymerization ratio can be obtained more reliably. it can.
- side reactions can be suppressed, deterioration of the color tone of the polycarbonate resin or coloring during molding can be further prevented.
- the total of sodium, potassium, cesium and iron in the polycarbonate resin (A) The content is preferably 1 ppm by weight or less. In this case, the deterioration of the color tone of the polycarbonate resin can be further prevented, and the color tone of the polycarbonate resin can be further improved. From the same viewpoint, the total content of sodium, potassium, cesium, and iron in the polycarbonate resin is more preferably 0.5 ppm by weight or less. In addition, these metals may mix not only from the catalyst to be used but from a raw material or a reaction apparatus. Regardless of the source, the total amount of these metal compounds in the polycarbonate resin is preferably in the above-mentioned range as the total content of sodium, potassium, cesium and iron.
- the raw material dihydroxy compound and carbonic acid diester are preferably melted separately or uniformly mixed before the transesterification reaction.
- the melting or mixing temperature is usually 80 ° C. or higher, preferably 90 ° C. or higher, and usually 200 ° C. or lower, preferably 150 ° C. or lower, particularly preferably 120 ° C. or lower.
- the dissolution rate can be increased or the solubility can be sufficiently improved, and problems such as solidification can be sufficiently avoided.
- the thermal degradation of the dihydroxy compound can be sufficiently suppressed, and the quality represented by the color tone of the obtained polycarbonate resin can be further improved.
- the operation of melting or mixing the dihydroxy compound and the carbonic acid diester as raw materials is performed at an oxygen concentration of 10 vol% or less, more preferably 0.0001 vol% or more and 10 vol% or less, especially 0.0001 vol% or more and 5 vol% or less, and particularly preferably 0.8. It is preferable to carry out in an atmosphere of 0001 vol% or more and 1 vol% or less. In this case, the color tone can be improved and the reactivity can be increased.
- the method of polycondensing a dihydroxy compound and a carbonic acid diester is performed in multiple stages using a plurality of reactors in the presence of the above-mentioned catalyst.
- the jacket temperature, the internal temperature, and the pressure in the reaction system according to the reaction stage it is preferable to obtain a prepolymer at a relatively low temperature and low vacuum in the early stage of the polycondensation reaction and to increase the molecular weight to a predetermined value at a relatively high temperature and high vacuum in the latter stage of the reaction.
- distillation of unreacted monomers is suppressed, and the molar ratio of the dihydroxy compound and the carbonic acid diester can be easily adjusted to a desired ratio.
- a decrease in the polymerization rate can be suppressed.
- a polymer having a desired molecular weight and terminal group can be obtained more reliably.
- the polymerization catalyst can be added to the raw material preparation tank or the raw material storage tank, or can be added directly to the polymerization reactor. From the viewpoint of supply stability and control of the polycondensation reaction, it is preferable to install a catalyst supply line in the middle of the raw material line before being supplied to the polymerization reactor and supply the polymerization catalyst in an aqueous solution.
- the temperature of the polycondensation reaction By adjusting the temperature of the polycondensation reaction, it is possible to improve productivity and avoid an increase in the thermal history of the product. Furthermore, it is possible to further prevent the volatilization of the monomer and the decomposition and coloring of the polycarbonate resin.
- the following conditions can be adopted as reaction conditions in the first stage reaction. That is, the maximum internal temperature of the polymerization reactor is usually set in the range of 160 to 230 ° C, preferably 170 to 220 ° C, more preferably 180 to 210 ° C.
- the pressure in the polymerization reactor (hereinafter, the pressure represents an absolute pressure) is usually set in the range of 1 to 110 kPa, preferably 5 to 50 kPa, and more preferably 7 to 30 kPa.
- the reaction time is usually set in the range of 0.1 to 10 hours, preferably 1 to 5 hours.
- the first stage reaction is preferably carried out while distilling off the generated monohydroxy compound out of the reaction system.
- the pressure in the reaction system is gradually reduced from the pressure in the first stage, and the monohydroxy compound that is subsequently generated is removed from the reaction system. It is preferable to make it 1 kPa or less.
- the maximum internal temperature of the polymerization reactor is usually set in the range of 200 to 260 ° C., preferably 210 to 240 ° C., particularly preferably 215 to 230 ° C.
- the reaction time is usually set in the range of 0.1 to 10 hours, preferably 0.5 to 5 hours, particularly preferably 1 to 3 hours.
- the glass transition temperature of the first polycarbonate resin and the second polycarbonate resin is preferably 40 ° C or higher, and more preferably 220 ° C or lower.
- the glass transition temperature of the first polycarbonate resin is preferably 90 ° C or higher, more preferably 100 ° C or higher, still more preferably 110 ° C or higher, particularly preferably 120 ° C or higher, and preferably 160 ° C or lower, more preferably 150 ° C or lower. More preferably, it is 140 ° C. or lower. When it is within the above range, it has sufficient heat resistance and can be easily molded.
- the glass transition temperature of 1st polycarbonate resin and 2nd polycarbonate resin becomes like this.
- it is 40 degreeC or more, Preferably it is 180 degrees C or less.
- the glass transition temperature of the first polycarbonate resin is preferably 100 ° C. or higher, more preferably 110 ° C. or higher, further preferably 120 ° C. or higher, more preferably 160 ° C. or lower, more preferably 150 ° C. or lower, more preferably 140 ° C. or lower. It is. When it is within the above range, it has sufficient heat resistance and can be easily molded.
- the glass transition temperature of the second polycarbonate resin is preferably 40 ° C. or higher, more preferably 50 ° C. or higher, still more preferably 60 ° C. or higher, more preferably 110 ° C. or lower, more preferably 100 ° C. or lower, still more preferably 90 ° C. or lower. Particularly preferably, it is 80 ° C. or lower. Within the above range, the decrease in heat resistance is suppressed, and impact strength, chemical resistance, moist heat resistance, fluidity and the like are improved.
- the difference in glass transition temperature between the first polycarbonate resin and the second polycarbonate resin is preferably 20 ° C. or higher, more preferably 30 ° C. or higher, and further preferably 40 ° C. or higher.
- the first polycarbonate resin and the second resin polycarbonate resin can be combined so as to have such a glass transition temperature difference.
- the polycarbonate resin composition has a difference in glass transition temperature between the first polycarbonate resin and the second polycarbonate resin, so that the warping directions of the first polycarbonate resin and the second polycarbonate resin can be reversed. it can. Thereby, the curvature of a laminated body can be reduced by adjusting the compounding ratio of 1st polycarbonate resin and 2nd polycarbonate resin.
- the molecular weight of the first polycarbonate resin and the second polycarbonate resin can be represented by a reduced viscosity or a number average molecular weight measured by 1 H-NMR. The values obtained by these measuring methods indicate that the higher the numerical value, the higher the molecular weight.
- the reduced viscosity of the first polycarbonate resin and the second polycarbonate resin is usually 0.30 dL / g or more, preferably 0.35 dL / g or more. In this case, the mechanical strength of the molded product can be further improved.
- the reduced viscosity is usually 1.00 dL / g or less, preferably 0.90 dL / g or less, and more preferably 0.80 dL / g or less.
- fluidity at the time of molding can be improved, and productivity and moldability can be further improved. Details of the method for measuring the reduced viscosity will be described in Examples.
- the reduced viscosity of the first polycarbonate resin is preferably 0.35 dL / g or more, more preferably 0.38 dL / g or more, further preferably 0.40 dL / g or more, and preferably 0.80 dL / g or less, more preferably Is 0.70 dL / g or less, more preferably 0.65 dL / g or less.
- the mechanical strength of the molded product can be further improved.
- the reduced viscosity of the second polycarbonate resin is preferably 0.60 dL / g or more, more preferably 0.65 dL / g or more, still more preferably 0.70 dL / g or more, and preferably 1.00 dL / g or less, more preferably Is 0.90 dL / g or less, more preferably 0.80 dL / g or less.
- the impact strength of the molded product is improved, and the occurrence of cracks in a moist heat environment, chemical resistance test and the like can be suppressed.
- the reduced viscosity of the second polycarbonate resin is preferably 0.30 dL / g or more, more preferably 0.35 dL / g or more.
- it is 0.60 dL / g or less, More preferably, it is 0.55 dL / g or less, More preferably, it is 0.50 dL / g or less.
- the number average molecular weights of the first polycarbonate resin and the second polycarbonate resin measured by 1 H-NMR are usually 6000 or more, preferably 8000 or more, and usually 30000 or less, preferably 25000 or less, more preferably 20000 or less. is there.
- the number average molecular weight of the first polycarbonate resin and the second polycarbonate resin can be obtained by measuring 1 H-NMR using deuterated chloroform as a solvent and analyzing the obtained spectrum. Details of the measurement method will be described in Examples.
- the number average molecular weight of the first polycarbonate resin is preferably 7000 or more, more preferably 8000 or more, further preferably 9000 or more, more preferably 18000 or less, more preferably 17000 or less, and further preferably 16000 or less.
- the number average molecular weight of the second polycarbonate resin is preferably 17000 or more, more preferably 17500 or more, further preferably 18000 or more, more preferably 50000 or less, more preferably 40000 or less, and further preferably 30000 or less.
- the number average molecular weight of the second polycarbonate resin is preferably 6000 or more, more preferably 7000 or more, further preferably 8000 or more, and preferably 12000 or less, more preferably 11000 or less.
- the melt viscosity of the first polycarbonate resin and the second polycarbonate resin is preferably 50 Pa ⁇ s to 3000 Pa ⁇ s.
- the molded article of the resin composition can be prevented from becoming brittle, and the mechanical properties can be further improved.
- the fluidity at the time of molding can be improved, and the appearance of the molded product can be prevented from being deteriorated or the dimensional accuracy can be prevented from being deteriorated.
- coloring and foaming caused by the increase in the resin temperature due to shearing heat generation can be further prevented.
- the melt viscosity of the first polycarbonate resin and the second polycarbonate resin is preferably 50 Pa ⁇ s to 5000 Pa ⁇ s.
- the melt viscosity means a melt viscosity at a temperature of 220 ° C. and a shear rate of 91.2 sec ⁇ 1 , measured using a capillary rheometer (manufactured by Toyo Seiki Co., Ltd.). Details of the method for measuring the melt viscosity will be described in Examples described later.
- the melt viscosity of the first polycarbonate resin is preferably 1800 Pa ⁇ s or more, more preferably 2000 Pa ⁇ s or more, further preferably 2200 Pa ⁇ s or more, and preferably 3000 Pa ⁇ s or less, more preferably 2800 Pa ⁇ s or less. Within the above range, the mechanical properties of the molded product are improved.
- the melt viscosity of the first polycarbonate resin is preferably 1800 Pa ⁇ s or more, more preferably 2000 Pa ⁇ s or more, and further preferably 2200 Pa ⁇ s or more. . Further, it is preferably 4500 Pa ⁇ s or less, more preferably 4000 Pa ⁇ s or less.
- the melt viscosity of the second polycarbonate resin is preferably 1800 Pa ⁇ s or more, more preferably 2000 Pa ⁇ s or more, further preferably 2200 Pa ⁇ s or more, and preferably 3000 Pa ⁇ s or less, more preferably 2800 Pa ⁇ s or less. Within the above range, it is possible to obtain impact resistance, excellent chemical resistance and wet heat resistance while ensuring fluidity during molding.
- the melt viscosity of the second polycarbonate resin is not less than 80 Pa ⁇ s, more preferably not less than 90 Pa ⁇ s, from the viewpoint that the fluidity during molding can be remarkably improved while ensuring impact resistance. More preferably, it is 100 Pa ⁇ s or more, preferably 500 Pa ⁇ s or less, more preferably 450 Pa ⁇ s or less, and further preferably 300 Pa ⁇ s or less.
- Resin C contains a third polycarbonate resin (resin C1) containing 50% by weight or more of the structural unit represented by the following formula (3) and / or 50% by weight or more of the structural unit represented by the following formula (4).
- Acrylic resin (resin C2) may be used individually by 1 type and may be used in combination of 2 or more type.
- the structural unit represented by the following formula (3) may be referred to as the structural unit (c)
- the structural unit represented by the following formula (4) may be referred to as the structural unit (d).
- R 1 to R 6 are each independently a hydrogen atom or an optionally substituted alkyl group having 1 to 10 carbon atoms.
- R 7 is a hydrogen atom or an alkyl group having 1 to 10 carbon atoms which may have a substituent.
- R 8 is an aryl group which may have a substituent or an aralkyl group which may have a substituent.
- the resin C is preferably compatible with the second polycarbonate resin.
- R 1 to R 6 in the formula (3) are preferably a hydrogen group or a methyl group.
- examples of the dihydroxy compound forming the structural unit represented by the formula (3) include 2,2-bis (4-hydroxyphenyl) propane and 2,2-bis (3-methyl-4-hydroxyphenyl) propane.
- 2,2-bis (4-hydroxy-3,5-dimethylphenyl) propane, 2,2-bis (4-hydroxyphenyl) methane, 2,2-bis (4-hydroxyphenyl) ethane and the like are preferable.
- 2,2-bis (4-hydroxyphenyl) propane and 2,2-bis (3-methyl-4-hydroxyphenyl) propane are more preferable, and 2,2-bis (4-hydroxyphenyl) propane is particularly preferable.
- the resin C1 may be a homopolymer substantially free of structural units other than the structural unit (c), or may be a copolymer polycarbonate resin containing structural units other than the structural unit (c). From the viewpoint of compatibility between the resin C1 and the second polycarbonate resin, the content of the structural unit (c) in the resin C1 is preferably 50% by weight or more, more preferably 70% by weight or more, and still more preferably 85% by weight or more.
- the structural unit other than the structural unit (c) the structural unit (a) or the structural unit (b) described above can be used.
- the above-mentioned aromatic bisphenol compound is preferable among the structural units (b).
- R 7 is preferably a hydrogen atom or a methyl group
- R 8 is a phenyl group or a benzyl group.
- the vinyl compound forming the structural unit (d) is preferably phenyl acrylate, phenyl methacrylate, benzyl acrylate, or benzyl methacrylate. Of these, phenyl acrylate and phenyl methacrylate are preferable, and phenyl methacrylate is particularly preferable.
- the resin C2 may be a homopolymer substantially free of structural units other than the structural unit (d), or may be a copolymer acrylic resin including structural units other than the structural unit (d). From the viewpoint of compatibility between the resin C2 and the second polycarbonate resin, the content of the structural unit (d) in the resin C2 is preferably 50% by weight or more, more preferably 70% by weight or more, and still more preferably 90% by weight or more.
- Examples of the vinyl compound forming the structural unit other than the structural unit (d) include methyl acrylate, ethyl acrylate, n-butyl acrylate, tert-butyl acrylate, methyl methacrylate, ethyl methacrylate, n-butyl methacrylate, tert-butyl methacrylate, acrylonitrile.
- Styrene, ⁇ -methylstyrene, butadiene and the like can be used.
- methyl acrylate and n-butyl acrylate are preferred from the viewpoint of improving thermal stability and mechanical properties.
- the resin C may be a polycarbonate resin (resin C1) containing the structural unit (c) or an acrylic resin (resin C2) containing the structural unit (d), and the two resins may be mixed in any proportion. May be used simultaneously. From the viewpoint of improving the accuracy of adjusting the refractive index of the resin composition, it is preferable to use one of the resin C1 and the resin C2.
- the resin C plays a role of adjusting the refractive index of the phase made of the second polycarbonate resin.
- the amount of the third resin (that is, the resin C) added is smaller.
- the refractive index of the third resin is 1. It is preferable that they are 54 or more and 1.65 or less.
- the lower limit of the refractive index of the third resin is more preferably 1.55, and further preferably 1.56.
- the upper limit is more preferably 1.63, and even more preferably 1.60.
- Resin C may be a commercially available product or may be produced by a known method.
- the resin composition may contain other components such as additives in addition to the first polycarbonate resin, the second carbonate resin, and the resin C.
- the polycarbonate resin may contain a catalyst deactivator.
- the catalyst deactivator is not particularly limited as long as it is an acidic substance and has a deactivation function of the polymerization catalyst, but among them, it is a phosphorus acidic compound that is excellent in catalyst deactivation and coloring suppression effect, Phosphonic acid (phosphorous acid) and phosphonic acid esters are more preferred, and phosphonic acid (phosphorous acid) is particularly preferred.
- the content of the phosphorus acidic compound is preferably 0.5 times mol or more, more preferably 0.7 times mol or more, and 0.8 times the amount of phosphorus atom with respect to 1 mol of the metal atom of the polymerization catalyst.
- the above is more preferable. Further, it is preferably 5 times mol or less, more preferably 3 times mol or less, and further preferably 1.5 times mol or less.
- additives include antioxidants, heat stabilizers, light stabilizers, UV absorbers, fillers such as fillers, neutralizers, lubricants, antifogging agents, antiblocking agents, slip agents, dispersants, coloring agents.
- Light diffusing agents such as an agent, and the like, and these additives can be used as long as the effects of the present disclosure are not impaired.
- the polycarbonate resin composition may be a polymer alloy.
- the resin composition can be produced, for example, by a method of mechanically melting and kneading the above-described components constituting the resin composition.
- a method of mechanically melting and kneading for example, by a method of mechanically melting and kneading the above-described components constituting the resin composition.
- the melt kneader a single screw extruder, a twin screw extruder, a Brabender, a Banbury mixer, a kneader blender, a roll mill, or the like can be used.
- kneading each component may be kneaded all at once, or a multistage division kneading method may be used in which any component is kneaded and then the other remaining components are added and kneaded.
- the kneading temperature is usually 150 ° C. or higher, preferably 180 ° C. or higher, more preferably 200 ° C. or higher.
- the kneading temperature is usually 280 ° C. or lower, preferably 260 ° C. or lower, more preferably 250 ° C. or lower.
- the resin composition is a mixture of a plurality of polycarbonate resins having different copolymerization ratios, that is, whether the above-described first polycarbonate resin and second polycarbonate resin are contained, for example, gradient polymer elution chromatography ( (GPEC) can be analyzed and confirmed (see JP-A-2014-208800).
- GPEC gradient polymer elution chromatography
- the resin composition has two or more peaks of the glass transition temperature measured by solid viscoelasticity.
- the detection of two or more glass transition temperatures indicates that the resin composition is in the form of phase separation.
- the glass transition temperature on the low temperature side is preferably 40 ° C. or higher, more preferably 50 ° C. or higher, still more preferably 60 ° C. or higher, preferably 100 ° C. or lower, more preferably 90 ° C. or lower, still more preferably 80 ° C. It is as follows. Within the above range, impact resistance and fluidity are more excellent. When the resin composition is used in the laminate, the mechanical properties such as impact resistance are further improved and warpage of the laminate is further suppressed when the resin composition is within the above range.
- the glass transition temperature on the high temperature side is preferably 100 ° C. or higher, more preferably 110 ° C. or higher, further preferably 120 ° C. or higher, particularly preferably 130 ° C. or higher, and preferably 200 ° C. or lower, more preferably 190 ° C.
- it is more preferably 180 ° C. or less, particularly preferably 160 ° C. or less.
- the molding temperature is further suppressed and the heat resistance is more excellent.
- the glass transition temperature on the high temperature side is preferably 100 ° C. or higher, more preferably 110 ° C. or higher, still more preferably 120 ° C. or higher, and preferably 160 ° C.
- it is more preferably 150 ° C. or lower, and further preferably 140 ° C. or lower.
- practically required heat resistance can be obtained, and mechanical properties and moldability can be achieved at a higher level.
- the resin composition preferably has a melt viscosity of 500 Pa ⁇ s to 4000 Pa ⁇ s.
- the molded product of the resin composition has sufficient mechanical properties while also having good moldability.
- the melt viscosity is more preferably 700 Pa ⁇ s or more, and further preferably 1000 Pa ⁇ s or more.
- the melt viscosity is more preferably 3500 Pa ⁇ s or less, and further preferably 3000 Pa ⁇ s or less.
- the resin composition is used for the laminate, it is particularly effective to adjust it within the above range.
- the deflection temperature under load of the resin composition is preferably 85 ° C. or higher and 120 ° C. or lower.
- the molded article of the resin composition can ensure heat resistance that is practically required while having sufficient mechanical properties.
- the deflection temperature under load is more preferably 90 ° C. or higher, and further preferably 92 ° C. or higher.
- the deflection temperature under load is more preferably 115 ° C. or less, and further preferably 110 ° C. or less.
- the impact strength of a resin composition can be evaluated by, for example, a notched Charpy impact strength test described in detail in Examples.
- Charpy impact strength with the tip radius R 0.25mm notch of the notch is preferably 7 kJ / m 2 or more, more preferably 9 kJ / m 2 or more, more preferably 10 kJ / m 2 or more, particularly preferably 11 kJ / m 2 That's it. By being in the said range, it has the more outstanding impact strength.
- the total light transmittance, haze in a resin composition can be evaluated by the measuring method explained in full detail in an Example, for example.
- the total light transmittance is preferably 85% or more, and more preferably 90% or more. Since it has more excellent transparency within the above range, the molded product is suitably used for optical members such as a display front plate and transparent electric and electronic members. From the same viewpoint, the value of the total light transmittance is preferably 85% or more, more preferably 90% or more at both temperatures of 25 ° C. and 90 ° C.
- the haze value is preferably 15% or less, more preferably 7% or less, and still more preferably 5% or less at both temperatures of 25 ° C. and 90 ° C.
- the value of haze is 5% or less, and it is more preferable that it is 3% or less.
- the color tone of the resin composition can be evaluated by, for example, a method of measuring yellowness (YI) described in detail in Examples.
- the yellowness (YI) is preferably 5.0 or less.
- the molded article of the resin composition has more excellent transparency, the molded article is suitably used for optical members such as a display front plate and transparent electric and electronic members. From the viewpoint of further improving the transparency, the yellowness is more preferably 3.0 or less, further preferably 2.5 or less, and particularly preferably 2.0 or less.
- the chemical resistance of the resin composition can be evaluated by, for example, the critical strain measured by the 1/4 ellipse method described in detail in Examples.
- the critical strain value is preferably 0.3% or more, more preferably 0.4% or more. By being in this range, since it has more excellent chemical resistance, it is suitably used for applications requiring chemical resistance such as automobile interior and exterior members.
- the moisture heat resistance of the resin composition can be evaluated by, for example, the number of crack generation cycles in the wet heat cycle crack test described in the examples.
- the number of crack generation cycles is preferably 20 times or more, more preferably 30 times or more. Since it has more excellent heat and humidity resistance within the above range, it is suitably used for applications that are assumed to be used in high-temperature and high-humidity environments such as automobile interior parts.
- the pencil hardness (surface hardness) in a resin composition can be evaluated by the method explained in full detail in an Example, for example.
- the pencil hardness is preferably HB or higher, and more preferably F or higher.
- the molded article or laminate of the resin composition is suitably used for applications requiring scratch resistance such as a display front plate and an automobile interior / exterior.
- a molded article and a laminated body are used for an optical film, since the damage at the time of conveyance can be suppressed, the merit that a protective film is reduced, for example is acquired.
- a hard coat can be further applied to the surface of the molded product or laminate of the resin composition.
- the photoelastic coefficient in a resin composition can be evaluated by the method explained in full detail in an Example, for example.
- the absolute value of the photoelastic coefficient of the resin composition is preferably 25 ⁇ 10 ⁇ 12 Pa ⁇ 1 or less.
- the absolute value of the photoelastic coefficient is more preferably 20 ⁇ 10 ⁇ 12 Pa ⁇ 1 or less, and further preferably 15 ⁇ 10 ⁇ 12 Pa ⁇ 1 or less.
- the surface impact resistance in a resin composition can be evaluated by, for example, the DuPont impact test described in detail in Examples.
- surface impact resistance turns into a ductile fracture on the test conditions described in an Example.
- applications requiring impact resistance such as display front plates, building materials, and design films for automobile interior members, and applications for punching.
- the weather resistance of a resin composition can be evaluated by the test using the xenon weather meter explained in full detail in an Example, for example.
- the absolute value ( ⁇ YI) of the difference in YI before and after the treatment under the test conditions described later is preferably 0.5 or less, more preferably 0.3 or less, and particularly preferably 0.1 or less. Within this range, it is suitably used for applications requiring weather resistance, such as building materials used outdoors and front panels such as digital signage, automobile interior and exterior members.
- ⁇ YI is preferably in the above range.
- the component that forms the domain structure has sufficient mechanical strength and high fluidity, and therefore improves fluidity without impairing mechanical strength. Can do.
- one glass transition temperature appears between the two types depending on the composition of both components, resulting in a decrease in heat resistance.
- the chemical resistance, heat and humidity resistance, and fluidity can be improved without lowering the heat resistance of the component having the higher glass transition temperature.
- the 1st polycarbonate resin and 2nd polycarbonate resin component which comprise a resin composition contain the same structural unit, two types of components have partial compatibility.
- the morphology of the resin composition such as matrix-domain structure and compatibility can be examined by a conventional method, and specifically, can be examined by observation with a transmission electron microscope.
- Resin compositions include, for example, injection molding (insert molding method, two-color molding method, sandwich molding method, gas injection molding method, etc.), extrusion molding method, inflation molding method, T-die film molding method, laminate molding method, blow molding method. It can be processed into various molded products by molding methods such as a hollow molding method, a compression molding method, and a calendar molding method.
- molding methods such as a hollow molding method, a compression molding method, and a calendar molding method.
- limiting in particular in the shape of a molded article A sheet
- the formed film can be uniaxially or biaxially stretched.
- the stretching method include a roll method, a tenter method, and a tubular method.
- surface treatments such as corona discharge treatment, flame treatment, plasma treatment, ozone treatment and the like which are usually used industrially can also be applied.
- a molded article may be called a molded object.
- a molded article is not specifically limited, As an example, the following uses can be mentioned. That is, coating materials such as electric wires, cords, wire harnesses, insulation sheets, OA equipment displays and touch panels, membrane switches, photo covers, relay parts, coil bobbins, IC sockets, fuse cases, camera pressure plates, etc.
- bottles such as houseware, tupperware, cable ties, braces
- bottles such as infusion bottles, food bottles, water bottles, cosmetics bottles, and other personal care bottles, medical components, catheters, syringes, syringe gaskets, drip tubes, tubes, ports, caps, rubber stoppers, diamonds
- examples include risers, blood connectors, dentures, disposable containers, and the like, and can also be applied to applications using foam molding.
- the tube is particularly suitable for a medical tube that can prevent the adsorption of medicinal components
- the multilayer tube is most suitable for an inner layer material or an intermediate layer material thereof.
- the use of the molded product in the film / sheet field is not particularly limited, but examples include the following uses. That is, stretch film for packaging, wrap film for business use or household use, pallet stretch film, stretch label, shrink film, shrink label, sealant film, retort film, retort sealant film, perfume heat seal film, A- PET sealant, frozen food containers and lids, cap seals, heat-sealing films, heat-bonding films, heat-sealing films, bag-in-box sealant films, retort pouches, standing pouches, spout pouches, laminated tubes, heavy bags , Food packaging such as fiber wrapping film, miscellaneous goods packaging field, house film, multi-film agricultural film field, infusion bag, high-calorie infusion and peritoneal dialysis (CAPD), antibiotic kit bag, etc.
- stretch film for packaging wrap film for business use or household use
- pallet stretch film stretch label, shrink film, shrink label, sealant film, retort film, ret
- medical film and sheet fields such as PTP packaging, civil engineering impermeable sheets, waterproofing materials, mats, joint materials, Building materials related fields such as flooring, roofing, decorative film, skin film, wallpaper, leather, ceiling material, trunk lining, interior skin material, vibration control sheet, sound insulation sheet, etc., display cover, battery case, mouse Pads, cell phone cases, IC card holders,
- toiletries and sanitary fields for stationery Film / sheet, clear file, pencil case, notebook cover Desk mats, keyboard covers, book covers, office supplies related fields such as binders, furniture leather, beach ball toys, umbrellas, raincoats, tablecloths, blister packages, bath lids, towel cases, fancy cases, General household use such as tag cases, pouches, amulet bags, insurance card covers, passbook cases, passport cases, knife cases, etc., miscellaneous goods field, retroreflective sheets, synthetic paper, and the like.
- a pressure-sensitive adhesive composition or as a film / sheet field in which a pressure-sensitive adhesive is applied to a base material to provide adhesiveness, carrier tape, pressure-sensitive adhesive tape, marking film, semiconductor or glass dicing film, surface protective film, Steel plate / plywood protective film, automotive protective film, adhesive tape for packaging / bundling, office / house adhesive tape, bonding adhesive tape, coating masking adhesive tape, surface protective adhesive tape, sealing adhesive tape, anti-corrosion / waterproof Adhesive tape for electrical insulation, adhesive tape for electrical insulation, adhesive tape for electronic equipment, adhesive film, adhesive tape for medical and sanitary materials such as base material film, identification and decoration adhesive tape, display tape, packaging tape, surgical tape, For example, an adhesive tape for labels.
- the molded product is preferably an automobile interior part or an automobile exterior part. That is, it is preferable that the method of using the molded product is an automobile interior part or an automobile exterior part. In this case, the above-described effects of the resin composition can be fully utilized.
- the molded article is preferably used for an in-vehicle display, car navigation, car audio, console panel, dashboard or door trim article. That is, the method of using the molded product is preferably a vehicle-mounted display, car navigation, car audio, console panel, dashboard, or door trim article. Specifically, it can be used for a display front plate or a housing of a vehicle-mounted display, car navigation, or car audio.
- a film made of resin A and a film made of resin B are made to have a symmetric configuration of two types and three layers (A / B / A), and the dimensional change rates of the front and back sides are matched. In this way, warping is suppressed.
- the laminated body becomes thick, so that there is a problem that it cannot be applied to an application in which a thin member is required, and the cost increases because an extra layer is provided.
- the laminated body which has the resin layer A containing the said resin composition can solve such a problem.
- the ISB-based polycarbonate resin means a polycarbonate resin obtained by using ISB, and specifically means a polycarbonate resin having the structural unit (a).
- the laminate 1 includes a resin layer A11 containing a resin composition and a resin layer B12.
- the resin layer B12 is made of a resin different from the resin layer A11.
- the laminate 1 has one or more resin layers A11 and B12. That is, the laminated body 1 has at least one resin layer A11 and at least one resin layer B12.
- the arrangement pattern (that is, the lamination pattern) and the number of laminations of the resin layer A11 and the resin layer B12 in the laminate 1 can be changed as appropriate.
- the configuration is not particularly limited. Absent.
- a resin layer A11 can be laminated on both surfaces of the resin layer B12.
- the resin layer A11, the resin layer B12, and the resin layer A11 are sequentially laminated, and two types of resin layers (that is, the resin layer A11 and the resin layer B12) are laminated in three layers.
- Such a laminated structure can be expressed as resin layer A / resin layer B / resin layer A.
- each resin layer constituting the laminated body can have a symmetrical structure with a virtual center line L c that bisects the thickness of the laminated body.
- the laminate 1 is less likely to be warped or twisted.
- the layer structure of the laminate may be asymmetric.
- the stacked structure of the resin layer A11 and the resin layer B12 is stacked in at least one of the material and the thickness. It can be made asymmetric with respect to a virtual center line L c that bisects the body thickness.
- the laminated structure is asymmetric in at least the material.
- a laminated body 1 in which one resin layer A11 and one resin layer B12 are laminated, and the laminated structure is represented as resin layer A / resin layer B.
- FIG.1 (c) it is the laminated body 1 by which two resin layer A11 and two resin layer B12 were laminated
- the laminated structure is expressed as resin layer A / resin layer B / resin layer A / resin layer B.
- the resin layer A is comprised from the said specific polycarbonate resin composition, even if a layer structure is not a symmetrical structure but an asymmetrical structure, it is possible to suppress the curvature of the laminated body 1. .
- the layer structure of the laminate 1 is preferably asymmetric.
- the layer structure of the laminate 1 is preferably asymmetric.
- an extra layer is provided in order to make the laminate 1 a symmetric structure. There is no need to provide it separately. That is, the degree of freedom of the stacked structure of the stacked body is increased.
- 1A and 1C illustrate a configuration in which the resin layers 11 and 12 constituting the laminate 1 are asymmetric in material, but the thickness may be asymmetric. is there.
- FIG. 1D shows a laminate 1 in which two resin layers A11 and two resin layers B12 are laminated.
- the resin layer A11, the resin layer B12, the resin layer B12, and the resin layer are shown.
- A11 are sequentially stacked.
- the laminated structure is expressed as resin layer A / resin layer B / resin layer B / resin layer A.
- the laminate 1 has a symmetrical structure at least in the material.
- the laminate 1 has an asymmetric structure at least in material.
- the resin layers constituting the laminate may be bonded to each other with an adhesive or a pressure-sensitive adhesive, or the resin layers may be directly bonded to each other by, for example, fusion.
- the material of the resin layer B is not particularly limited as long as the material is different from that of the resin layer A.
- the resin layer B is preferably a thermoplastic resin from the viewpoint of increasing the degree of freedom of the molding process, such as forming a laminate by coextrusion or producing a stretched film by co-stretching the laminate.
- the resin layer B is composed of at least one selected from the group consisting of polycarbonate resin, polyester resin, acrylic resin, styrene resin, polyolefin, and cycloolefin polymer, for example. These are suitably selected according to the use which uses a laminated body. Examples of applications utilizing the characteristics of each resin are given below.
- the resin layer B When a polycarbonate resin is used for the resin layer B, the resin layer A is used on the surface layer side, and the resin layer B is inferior in scratch resistance and weather resistance while the high impact resistance of the resin layer B is utilized. can do.
- the resin layer B When using a polyester resin or polyolefin for the resin layer B, the resin layer B may be used as a protective film. Before forming the resin layer A and winding it on a roll, the resin layer B is laminated to prevent the resin layer A from being damaged during storage and transportation, or when unrolled from the roll and used. , Can improve peeling and slipping.
- an acrylic resin is used for the resin layer B, a higher surface hardness can be imparted to the original characteristics of the resin layer A by using an acrylic resin having excellent surface hardness on the surface layer side.
- the resin layer A expresses positive birefringence and the resin layer B expresses negative birefringence by stretching, so that each phase difference is strictly controlled.
- a highly functional retardation film such as a broadband quarter-wave plate can be produced.
- the film which compensated the weak point of the chemical resistance of the resin layer B can be produced by using the resin layer A excellent in chemical resistance on the surface layer side.
- the manufacturing method of the resin used for the resin layer B is not particularly limited, and may be manufactured using a known method, or a commercially available product may be used.
- the total thickness of the laminate can be adjusted as appropriate according to the requirements of the application.
- the total thickness of the laminate is preferably in the range of 10 ⁇ m or more and 500 ⁇ m or less. In this range, the warp caused by the dimensional change of the laminate cannot be suppressed by the rigidity of the laminate itself, and therefore the warp cannot be suppressed unless the dimensional change of the material itself constituting the laminate is suppressed. Therefore, the characteristic that the dimensional change rate exhibited by the resin composition is small is more sufficiently exhibited.
- the total thickness of the laminate is more preferably 20 ⁇ m or more, and further preferably 30 ⁇ m or more. From the same viewpoint, the total thickness is more preferably 300 ⁇ m or less, and further preferably 200 ⁇ m or less.
- the thickness of the resin layer A varies depending on the use, but is preferably in the range of 1 ⁇ m or more and 300 ⁇ m or less from the viewpoint that the effect of the resin composition can be exhibited most. From the same viewpoint, it is more preferably 5 ⁇ m or more, and further preferably 10 ⁇ m or more. Moreover, 200 micrometers or less are more preferable, and 150 micrometers or less are still more preferable.
- the thickness of the resin layer B varies depending on the application, but is preferably in the range of 1 ⁇ m or more and 300 ⁇ m or less. 5 ⁇ m or more is more preferable, and 10 ⁇ m or more is even more preferable. Moreover, 200 micrometers or less are more preferable, and 150 micrometers or less are still more preferable. If it is in the said range, the characteristic of resin used for the resin layer B can fully be expressed.
- the thickness ratio between the resin layer A and the resin layer B in the laminate is preferably 0.02 to 50 in terms of resin layer B / resin layer A. That is, the ratio of the thickness of the resin layer B to the thickness of the resin layer A is preferably 0.02 to 50.
- the molded product of the polycarbonate resin composition of the present disclosure has a high surface hardness.
- molded articles of polycarbonate resin compositions and laminates of resin layers A and B are, for example, hard Without being subjected to a coating treatment, it can be used for various purposes as it is.
- a hard coat treatment can be applied on the surface of a molded article of polycarbonate resin or a laminate having resin layer A and resin layer B.
- the hard coat layer may be formed on either surface of the resin layer A or the resin layer B, but it is preferable to apply a hard coat to the polycarbonate resin composition or acrylic resin layer of the present disclosure having high surface hardness.
- the hard coat layer can be composed of acrylic resin, urethane resin, melamine resin, organic silicate compound, silicone resin, metal oxide, or the like. From the viewpoint of excellent hardness and durability, the hard coat layer is preferably composed of a silicone resin and an acrylic resin. From the viewpoint of not only excellent hardness and durability, but also excellent curability, flexibility, and productivity, the hard coat layer is more preferably composed of an acrylic resin. More preferably, it is made of a resin or a thermosetting acrylic resin.
- additives can be further blended as necessary within the range where the effects of the present disclosure are not impaired.
- additives include antioxidants, light stabilizers, stabilizers such as ultraviolet absorbers, surfactants, leveling agents, and antistatic agents.
- the laminate has a front surface and a back surface
- the front surface may be hard-coated, or the front and back surfaces may be hard-coated.
- the back side hard coat treatment is preferably performed in the same manner as the front side.
- ⁇ Hard coat treatment is roughly divided into two types: offline coating and in-line coating.
- a coating material for forming a hard coat layer is applied to a base film (for example, a laminate).
- In-line coating is performed by applying a coating material in a film forming process of a base film (for example, resin layer A, resin layer B).
- a coating method of the coating material for example, a reverse coating method, a gravure coating method, a rod coating method, a bar coating method, a die coating method, or a spray coating method can be used.
- the thickness of the hard coat layer may be determined according to the use, but is usually preferably 0.1 to 30 ⁇ m, and more preferably 1 to 15 ⁇ m.
- the thickness of the hard coat layer is less than 0.1 ⁇ m, the surface hardness is insufficient and the surface tends to be easily scratched because it is too thin.
- the thickness exceeds 30 ⁇ m, cracks are likely to occur in the cured film due to stress such as punching or bending, and workability may be impaired.
- a decorative layer, an adhesive layer, an antireflection layer, an antifouling layer, and the like can be formed on the surface of the laminate without departing from the essence of the present disclosure.
- a pretreatment can be performed on the surface of the laminate.
- the pretreatment corona discharge treatment, UV treatment, application of an anchor coating agent, or the like is used.
- the anchor coating agent for example, at least one resin selected from the group consisting of a polyester resin, an acrylic resin, an acrylic-modified polyester resin, a polyurethane resin, a polysiloxane, and an epoxy resin is preferably used.
- the laminate is particularly suitable for a display cover of an image display device used outdoors. In this case, the visibility of the image can be further improved.
- layers having each function may be laminated on the laminate, or layers having both functions may be laminated.
- the antireflection layer is, for example, a layer that enhances the antireflection function, and is a layer that enhances the wear resistance, the antistatic function, and the water repellency function.
- the antireflection layer can be provided by coating a laminate with a conventionally known material, for example, a liquid containing an inorganic substance (optical filler), a binder resin, an additive, a solvent, and the like.
- the antifouling layer is a layer that improves antifouling properties.
- the antifouling layer can be formed using, for example, a conventionally known material such as a fluorine-based silane coupling agent.
- the antireflection layer and the antifouling layer can be formed, for example, by coating the laminate in the same manner as the hard coat layer described above. Further, if necessary, a film-like or sheet-like antireflection agent or antifouling layer may be laminated and adhered to the laminate using a known adhesive.
- the antireflection layer and antifouling layer are made of a thermoplastic resin, the antireflection layer or antifouling layer is provided on the surface of the laminate by coextrusion of the laminate and the antireflection layer or antifouling layer. be able to.
- a decorative layer can be formed on the laminate.
- a decoration layer a printing layer and a vapor deposition layer can be formed, for example.
- a colored resin layer formed on the base film may be used.
- the binder resin material for the printing layer is preferably a polyurethane resin, vinyl resin, polyamide resin, polyester resin, acrylic resin, polyvinyl acetal resin, polyester urethane resin, cellulose ester resin, alkyd resin, thermoplastic elastomer resin, or the like. Among these, a resin that forms a flexible film is more preferable.
- a coloring ink of a desired color it is preferable to add a coloring ink of a desired color.
- the colored ink contains, for example, a pigment or a dye as a colorant.
- Examples of the method for forming the printing layer include an offset printing method, a gravure printing method, and a screen printing method.
- an offset printing method or a gravure printing method is preferable.
- a gravure coating method, a roll coating method, a comma coating method, or the like can also be employed.
- a print layer may be formed on the entire surface of the laminate, or a print layer may be partially formed on the laminate. The printing method can be appropriately changed according to the printing area of the laminate.
- the material constituting the vapor deposition layer is preferably a metal such as aluminum, silicon, zinc, magnesium, copper, chromium, or nickel chromium.
- Aluminum metal is more preferable in terms of design and cost, but an alloy composed of two or more metal components may be used.
- These metal thin film layers can be formed into a laminate by vapor deposition.
- a vacuum vapor deposition method is usually used, but ion plating, sputtering, a method of activating an evaporant with plasma, or the like may be used.
- a chemical vapor deposition method (CVD method) is also included in the vapor deposition method in a broad sense, and the CVD method may be used.
- the evaporation source for vapor deposition includes a resistance heating type board type, a crucible type by radiation or high frequency heating, a type by electron beam heating, and the like, but is not limited to these methods.
- a colored resin layer is formed on the base film.
- the formation method include, but are not limited to, a method in which a resin colored with a colorant is laminated by a coating method or an extrusion lamination method.
- the colorant include dyes, organic pigments, and inorganic pigments.
- the laminate can be used as a molding sheet, and the molded body can be subjected to various secondary processes.
- the molded body can be thermoformed.
- the method of thermoforming is not particularly limited, and examples thereof include known forming methods such as blister forming, vacuum forming, and pressure forming.
- the warpage in the laminate can be evaluated by, for example, the method described in detail in Examples.
- the absolute value of the warp value is preferably 5 mm or less, more preferably 3 mm or less. If it is below the upper limit, it is suitably used for applications where warpage is likely to be a problem in the assembly process and product use environment, such as a front protective plate for large displays, a protective film for polarizing plates, and a retardation film.
- the resin composition is formed by a molding method such as an injection molding method, extrusion molding method, inflation molding method, T-die film molding method, laminate molding method, blow molding method, hollow molding method, compression molding method, calendar molding method, sheet, It can be set as a film and a plate-shaped molded article.
- Injection molding includes an insert molding method, a two-color molding method, a sandwich molding method, a gas injection molding method, and the like. It is also possible to uniaxially or biaxially stretch the film. Examples of the stretching method include a roll method, a tenter method, and a tubular method.
- surface treatments such as corona discharge treatment, flame treatment, plasma treatment, ozone treatment and the like, which are usually used industrially, can be applied to sheets, films, and plate-shaped molded articles.
- the laminate can be produced by a conventionally known method. For example, each layer is formed separately in advance and laminated, or thermocompression-pressed, and the other layer is formed by coating on one or both sides of a pre-formed film of one layer. And a method of laminating and forming each resin layer constituting the laminate by a coextrusion method.
- the temperature setting of the extruder and die used for molding the polycarbonate resin composition is preferably 200 ° C. or higher and 280 ° C. or lower. In this case, thermal decomposition can be suppressed and a laminate having a good appearance can be obtained. From the viewpoint of further improving this effect, the temperature setting of the extruder and the die is more preferably 210 ° C. or higher, and further preferably 220 ° C. or higher. From the same viewpoint, the temperature setting of the extruder and the die is more preferably 260 ° C. or less, and further preferably 250 ° C. or less.
- the laminate can also be used after being stretched.
- a known method such as longitudinal uniaxial stretching between rolls, lateral uniaxial stretching using a tenter or oblique stretching, or simultaneous biaxial stretching combining them, sequential biaxial stretching can be used.
- the optimum stretching method may be selected accordingly. From the viewpoint of productivity, it is preferable to perform stretching in a continuous manner, but it may be performed in a batch manner, and there is no particular limitation on the selection of both.
- the laminate has a plurality of properties such as impact resistance, transparency, weather resistance, optical properties such as low photoelastic coefficient, chemical resistance, and high surface hardness in a well-balanced manner.
- Applications in the field of films and sheets are not particularly limited. Examples of applications that can be used particularly suitably include building materials (resin windows, carport sheets, transparent sound insulation walls, resin-coated metal sheet sheets, etc.), automotive interior / exterior members.
- the resin was dissolved in methylene chloride to prepare a resin solution having a concentration of 0.6 g / dL.
- a Ubbelohde viscometer manufactured by Moriyu Rika Kogyo Co., Ltd.
- the solvent passage time t 0 and the solution passage time t were measured under a temperature condition of 20.0 ° C. ⁇ 0.1 ° C.
- the relative viscosity ⁇ rel was determined by the following formula (i) using the obtained values t 0 and t, and the specific viscosity ⁇ sp was determined by the following formula (ii) using the obtained relative viscosity ⁇ rel . .
- 1 H-NMR analysis of a copolymer polycarbonate resin of ISB and CHDM is performed as follows.
- the ISB double bond terminal and the CHDM double bond terminal are terminal group structures generated by a thermal decomposition reaction during the polymerization reaction.
- the pellet-shaped resin was vacuum-dried for 5 hours or more at the highest possible temperature in the range which the pellet does not fuse
- the pellets were pressed at 10 MPa with a mini test press [manufactured by Toyo Seiki Co., Ltd.] set at 200 ° C., then cooled by pressing at 15 MPa with a mini test press set at 25 ° C., and a sheet having a thickness of 0.5 mm It was created.
- the sheet was cut into a width of 5 mm and a length of 20 mm to prepare a sheet-like test piece.
- This test piece was measured with a dynamic viscoelasticity measuring apparatus [manufactured by TA Instruments Co., Ltd.] under the conditions of a frequency of 1 Hz, a heating rate of 2 ° C./min, and a temperature from 30 ° C. to the melting temperature. The peak temperature was taken as the glass transition temperature.
- the pellet-shaped resin was vacuum-dried for 5 hours or more at a temperature as high as possible within a range where the pellets were not fused. Subsequently, the melt viscosity of the pellet was measured with a capillary rheometer (manufactured by Toyo Seiki Co., Ltd.). The measurement temperature was 220 ° C., and the shear rate was in the range of 9.12 to 1824 sec ⁇ 1 . The value at a shear rate of 91.2 sec ⁇ 1 was used as the melt viscosity of the resin to be measured.
- 1 mm ⁇ ⁇ 10 mmL was used when the melt viscosity was 500 Pa ⁇ s or more, and 1 mm ⁇ ⁇ 40 mmL was used when the melt viscosity was less than 500 Pa ⁇ s.
- the refractive index nD was measured with a multi-wavelength Abbe refractometer DR-M4 / 1550 manufactured by Atago Co., Ltd. using an interference filter of 589 nm (D line). The measurement was performed at 20 ° C. using monobromonaphthalene as the interfacial liquid.
- the pellets of the polycarbonate resin composition were dried at 90 ° C. for 4 hours or more using a hot air dryer.
- the pellet used for a measurement is a polycarbonate resin composition manufactured in each Example etc. which will be described later, and is transparent in appearance and not colored. The same applies to the subsequent measurement methods.
- the pellets were supplied to a 75-ton injection molding machine (EC-75 manufactured by Toshiba Machine Co., Ltd.) and molded under the conditions of a resin temperature of 240 ° C., a mold temperature of 60 ° C., and a molding cycle of 60 seconds, whereby an injection molded plate (Width 100 mm ⁇ length 100 mm ⁇ thickness 2 mm) was obtained.
- the total light transmittance and haze of the injection-molded plate were measured with a D65 light source using a haze meter NDH2000 (manufactured by Nippon Denshoku Industries Co., Ltd.). The difference in each temperature is expressed by subtracting the value of 25 ° C. from the value of 90 ° C.
- the total light transmittance was determined to be 90% or more.
- the injection molded plate was adjusted to 25 ° C. and 90 ° C. before the measurement, and the measurement was performed at two temperatures.
- the total light transmittance is 90% or more and the haze is 15% or less at both temperatures of 25 ° C. and 90 ° C. Also, the difference between the total light transmittance at a temperature of 90 ° C. and the total light transmittance at a temperature of 25 ° C. (that is, ⁇ Trans) is calculated, and the difference between the haze at a temperature of 90 ° C. and the haze at a temperature of 25 ° C. ( That is, ⁇ Haze) was calculated.
- the pellet of the transparent polycarbonate resin composition was dried at 90 degreeC for 4 hours or more using the hot air dryer.
- the pellets were supplied to a 75-ton injection molding machine EC-75 (manufactured by Toshiba Machine Co., Ltd.), using a spiral flow mold having a flow path thickness of 2 mm and a flow path width of 8 mm, a resin temperature of 240 ° C., an injection pressure of 100 MPa, a mold
- a spiral-shaped injection molded product was obtained.
- the flow length was measured from this injection molded product.
- the flow length by this spiral flow is an indicator of the fluidity of the resin during molding. The higher the numerical value, the better the fluidity. For example, the productivity of a molded product by injection molding can be improved, and a more complicated shape or a thin shape can be formed.
- the pellet of the polycarbonate resin composition was dried at 90 ° C for 4 hours or more by using a hot air dryer. Next, the pellets are supplied to a 75-ton injection molding machine EC-75 (manufactured by Toshiba Machine Co., Ltd.) and molded under the conditions of a resin temperature of 240 ° C., a mold temperature of 60 ° C., and a molding cycle of 60 seconds. An ISO test piece was obtained. Next, a strip-shaped test piece having a length of 80 mm, a width of 10 mm, and a thickness of 4 mm was cut out from the ISO test piece.
- EC-75 manufactured by Toshiba Machine Co., Ltd.
- the pellet of the polycarbonate resin composition was dried at 90 degreeC for 4 hours or more using the hot air dryer.
- the MFR of the pellet was measured with a melt indexer (manufactured by Toyo Seiki Co., Ltd.) in accordance with JIS K7210 under conditions of a temperature of 230 ° C. and a load of 2.16 kg.
- Example 1-1 to Example 1-10 and Comparative Example 1-1 to Comparative Example 1-3 it was determined that the heat resistance was excellent when the number of cycles in which all five sheets had cracks was 20 cycles or more. When no cracks occurred on all five sheets even at the 35th cycle, the result was over 35 cycles (that is, “> 35”).
- the pellet of the polycarbonate resin composition was dried at 90 degreeC for 4 hours or more using the hot air dryer.
- the pellets were supplied to a 75-ton injection molding machine EC-75 (manufactured by Toshiba Machine Co., Ltd.) and molded under the conditions of a resin temperature of 240 ° C., a mold temperature of 60 ° C., and a molding cycle of 60 seconds, whereby an injection molded plate (Width 100 mm ⁇ length 100 mm ⁇ thickness 1 mm) was obtained.
- the molded plate was pressed for 1 minute at a temperature of 200 ° C.
- ⁇ is the strain at the crack occurrence point (that is, critical strain) (%)
- a is the major axis length (mm) of the 1/4 elliptical jig
- b is the short length of the 1/4 elliptical jig.
- t is the specimen thickness (mm)
- X is the crack occurrence point (mm).
- the same press molding as in “Measuring method of glass transition temperature by dynamic viscoelasticity measurement” was performed to produce a film having a thickness of 0.2 mm.
- a test piece having a width of 5 mm and a length of 20 mm was cut out from the film.
- the test piece was fixed to a viscoelasticity measuring apparatus, and the storage elastic modulus E ′ was measured under conditions of room temperature (specifically 25 ° C.) and a frequency of 96 Hz.
- the emitted laser light was passed through a polarizer, a test piece, a compensation plate, and an analyzer in this order, detected by a photodetector (photodiode), and a waveform with an angular frequency ⁇ or 2 ⁇ was obtained by a lock-in amplifier. .
- the phase difference with respect to the amplitude and strain was determined, and the strain optical coefficient O ′ was determined.
- the photoelastic coefficient C was obtained from the following equation ( ⁇ ) using the storage elastic modulus E ′ and the strain optical coefficient O ′.
- C O '/ E' ( ⁇ )
- an injection-molded plate having a thickness of 2 mm was prepared by the same method as the measurement of the total light transmittance and haze.
- a xenon weather meter [Atlas Weatherometer Ci4000 manufactured by Toyo Seiki Seisakusho Co., Ltd.] the light was irradiated from the light source to the injection-molded plate under the conditions of irradiation intensity of 60 W / m 2 and black panel temperature of 65 ° C. Irradiation was carried out for 100 hours under a rain cycle condition of 12 minutes with rain / 48 minutes without rain.
- the color tone of the injection-molded plate before and after irradiation was measured according to ASTM D1925 using a spectrocolorimeter CM-5 manufactured by Konica Minolta.
- the injection molded plate was placed in the measurement chamber, and the YI (yellowness index) value of the transmitted light was measured.
- -Color tone (YI) First, an injection-molded plate having a thickness of 2 mm was produced by the same method as the measurement of the total light transmittance and haze. The injection molded plate was placed in the measurement chamber, and the YI (yellowness index) value of the transmitted light was measured.
- the injection molding board of thickness 2mm was produced by the method similar to the measurement of the said total light transmittance and haze.
- a pencil scratch coating film hardness tester manufactured by Toyo Seiki Seisakusho Co., Ltd.
- the pencil hardness of the injection-molded plate was measured by the method described in JIS K5600-5-4.
- test piece A a film-like test piece made of a polycarbonate resin composition and a film-like test piece (test piece B) made of another resin was prepared.
- the warpage of this laminate sample was evaluated.
- a polycarbonate resin composition was press-molded to produce a film having a thickness of 0.2 mm.
- BPA-PC, COP, and PMMA were formed into films by press molding.
- a test piece A and a test piece B were superposed and pressed in the laminating direction using a hot press to produce a laminate sample.
- This laminate sample is a laminate of a layer of the test piece A corresponding to the resin layer A and a layer of the test piece B corresponding to the resin layer B.
- the pressurizing conditions are temperature: 110 to 160 ° C., pressure: 1 MPa, time: 5 minutes.
- the heating temperature was appropriately adjusted according to the glass transition temperature of the material.
- the laminated body sample was immersed in 60 degreeC warm water for 3 hours. Thereafter, the laminate sample was placed on a horizontal table with the layer of the test piece A facing up, and the warpage was measured.
- the laminate sample is warped and the center portion on the layer side of the test piece A is lifted, the lifted distance is the size of the warp.
- the distance of the center part was measured with the laminate sample turned upside down, and the distance was expressed as a negative value. That is, it shows that the curvature of a laminated body is so small that the absolute value of distance is small.
- Irganox 1010 Pentaerythritol-tetrakis (3- (3,5-di-tert-butyl-4-hydroxyphenyl) propionate] (manufactured by BASF)
- AS2112 Tris (2,4-di-tert-butylphenyl) phosphite (made by ADEKA)
- PC-C1 Bisphenol A polycarbonate
- Product name Iupilon S3000 (Mitsubishi Engineering Plastics)
- first vertical stirring reactor 190 ° C., 25 kPa, 120 minutes
- second vertical stirring reactor 195 ° C., 10 kPa, 90 minutes
- Mold stirring reactor 205 ° C., 4 kPa, 45 minutes
- fourth horizontal stirring reactor 220 ° C., 0.1-1.0 kPa, 120 minutes.
- the operation was performed while finely adjusting the internal pressure of the fourth horizontal stirring reactor so that the obtained polycarbonate resin had a reduced viscosity of 0.42 dL / g to 0.44 dL / g.
- the polycarbonate resin extracted from the fourth horizontal stirring reactor was supplied to a vented twin-screw extruder TEX30 ⁇ (manufactured by Nippon Steel Works) in a molten state.
- the extruder has three vacuum vents, where the residual low molecular weight components in the resin are devolatilized and phosphonic acid is used as a catalyst deactivator before the first vent with respect to the polycarbonate resin.
- PC-A2 Polycarbonate resin: PC-A2
- the obtained polycarbonate resin is referred to as “PC-A2”.
- PC-A3 Polycarbonate resin
- the same procedure as in Production Example 1 was conducted except that the amount of phosphonic acid added was 1.3 ppm by weight based on the polycarbonate resin.
- the obtained polycarbonate resin is referred to as “PC-A3”.
- the content of the ISB structural unit in PC-A3 is 53.9% by weight, and the content of the TCDDM structural unit is 31.1% by weight.
- PC-B1 Polycarbonate resin
- the same procedure as in Production Example 1 was conducted except that the amount of acid added was 1.3 ppm by weight based on the polycarbonate resin.
- the obtained polycarbonate resin is referred to as “PC-B1”.
- PC-B2 Polycarbonate resin
- the same procedure as in Production Example 1 was conducted except that the amount of acid added was 1.3 ppm by weight based on the polycarbonate resin.
- the obtained polycarbonate resin is referred to as “PC-B2”.
- PC-B3 Polycarbonate resin: PC-B3
- the same procedure as in Production Example 1 was conducted except that the amount of acid added was 1.3 ppm by weight based on the polycarbonate resin.
- the obtained polycarbonate resin is referred to as “PC-B3”.
- PC-B4 Polycarbonate resin
- the addition amount of calcium acetate monohydrate is 3 ⁇ mol with respect to 1 mol of all dihydroxy compounds, and the reduced viscosity of the obtained polycarbonate resin is adjusted to be 0.44 dL / g to 0.46 dL / g, and the addition of phosphonic acid
- the same procedure as in Production Example 1 was conducted except that the amount was 1.3 ppm by weight based on the polycarbonate resin.
- the obtained polycarbonate resin is referred to as “PC-B4”.
- PC-B5 Polycarbonate resin
- the same procedure as in Production Example 1 was conducted except that the amount of acid added was 1.3 ppm by weight based on the polycarbonate resin.
- the obtained polycarbonate resin is referred to as “PC-B5”.
- PC-B6 Polycarbonate resin
- the obtained polycarbonate resin is referred to as “PC-B6”.
- Table 1, Table 6, and Table 9 show the structural units and physical properties of the first polycarbonate resin and the second polycarbonate resin obtained in the above production examples.
- components other than the structural units shown in Table 1, Table 6, and Table 9 are linking groups such as carbonyl groups.
- Table 6 shows the physical properties of Resin C (that is, PC-C1, PA-C1).
- Table 1 shows the structural units and physical properties constituting the resins used in Examples 1-1 to 1-10 and Comparative Examples 1-1 to 1-3.
- Table 6 shows the structural units and physical properties constituting the resins used in Reference Examples 1 to 4, Examples 2-1 to 2-8, and Comparative Examples 2-1 to 2-3.
- Table 9 shows the structural units and physical properties constituting the resins used in the following Examples 3-1 to 3-3 and Comparative Examples 3-1 to 3-3.
- Example 1-1 After blending 700 parts by weight of the polycarbonate resin PC-A1 pellets obtained in Production Example 1 with 300 parts by weight of the polycarbonate resin PC-B1 pellets obtained in Production Example 4, twin-screw extrusion provided with a vacuum vent Extrusion kneading was performed at a cylinder temperature of 240 ° C. and an extrusion rate of 18 kg / hr using a machine TEX30HSS [manufactured by Nippon Steel Works, Ltd.] to obtain pellets of a polycarbonate resin composition. Next, the pellets of the resin composition were dried with a hot air dryer at a temperature of 90 ° C.
- the test piece which consists of a plate-shaped molded article of width 100mm x length 100mm x thickness 2mm was obtained. Further, by performing molding in the same manner, an ISO tensile test piece was obtained. A Charpy impact test piece with a 0.25 mm notch was cut out from the ISO tensile test piece, and a Charpy impact test was performed. Moreover, about the plate-shaped molded article, total light transmittance, YI, chemical resistance, and wet heat cycle resistance were measured.
- Examples 1-2 to 1-10, Comparative Examples 1-1 to 1-5 The same operation as in Example 1 was performed except that the composition described in Table 2 was changed. In addition, for Examples 1-1 to 1-10 and Comparative Examples 1-1 to 1-5, various characteristics were evaluated by the method described above. The results are shown in Tables 3-5.
- the polycarbonate resin compositions of Examples 1-1 to 1-10 are excellent in transparency and heat resistance, and are further in any one of moldability, chemical resistance, and moist heat resistance. It can be seen that one or more characteristics are also excellent.
- Comparative Example 1-1 was inferior in moist heat resistance and cracks occurred at an early stage, whereas Examples 1-1 to 1-4 Has significantly improved resistance to moist heat.
- Comparative Examples 1-2 and 1-5 are excellent in wet heat crack resistance but inferior in heat resistance.
- the resin compositions of Examples 1-3 and 1-4 are excellent in transparency, color tone, heat resistance, impact resistance, fluidity, and chemical resistance. I understand. Further, as can be seen from Table 5, it can be seen that the resin compositions of Examples 1-5 to 1-10 are excellent in transparency, color tone, heat resistance, impact resistance and fluidity. In contrast, Comparative Examples 1-1 to 1-3 are inferior in fluidity.
- Reference Example 2 The same procedure as in Reference Example 1 was carried out except that 80 parts by weight of PC-A1 pellets and 20 parts by weight of PA-C1 powder were used, and the cylinder temperature of the extruder was 240 ° C. (see Table 7). The obtained pellet was cloudy, and two glass transition temperatures were detected. Therefore, it can be judged that PC-A1 and PA-C1 are incompatible.
- Reference Example 4 The same procedure as in Reference Example 1 was carried out except that 80 parts by weight of PC-B3 pellets and 20 parts by weight of PA-C1 powder were used and the cylinder temperature of the extruder was 240 ° C. (see Table 7). The obtained pellets were transparent, and one glass transition temperature was detected at a position between the single glass transition temperatures of PC-B3 and PA-C1, so that PC-B3 and PA-C1 were compatible. Can be judged.
- Example 2-1 After blending 90 parts by weight of PC-A1 pellets, 9.76 parts by weight of PC-B1 pellets and 0.24 parts by weight of PC-C1 powder, twin-screw extruder TEX30HSS [ Nippon Steel Works Co., Ltd.] was used for extrusion kneading at a cylinder temperature of 240 ° C. and an extrusion rate of 12 kg / hr to obtain pellets of a polycarbonate resin composition. Next, the pellets of the resin composition were dried with a hot air dryer at a temperature of 90 ° C. for 5 hours, and then injection molded using a 75-ton injection molding machine EC-75 [manufactured by Toshiba Machine Co., Ltd.].
- Molding conditions are a mold temperature: 60 ° C. and a cylinder temperature: 240 ° C.
- the test piece which consists of a plate-shaped molded article of width 100mm x length 100mm x thickness 2mm was obtained.
- an ISO tensile test piece was obtained.
- a Charpy impact test piece with a 0.25 mm notch was cut out from the ISO tensile test piece, and a Charpy impact test was performed.
- total light transmittance, haze, YI, chemical resistance, and wet heat cycle resistance were measured. The results are shown in Table 8.
- Example 2-2 to 2-8, Comparative Examples 2-1 to 2-3 The same operation as in Example 2-1 was performed except that the composition was changed to the composition shown in Table 3. Further, for Examples 2-1 to 2-8 and Comparative Examples 2-1 to 2-3, various characteristics were evaluated by the method described above. The results are shown in Table 8.
- the polycarbonate resin compositions of Examples 2-1 to 2-8 have a plurality of properties such as transparency, heat resistance, color tone, moldability, chemical resistance, moist heat resistance, and impact resistance. The properties are excellent with a good balance. Further, when the resin C is further contained together with the first polycarbonate resin (that is, the resin A) and the second polycarbonate resin (that is, the resin B), the transparency at high temperature is improved, and the molded article of the resin composition However, it can maintain high transparency at room temperature and high temperature.
- Comparative Example 2-1 and Comparative Example 2-2 are a single resin, so that the transparency does not change due to the temperature change, but the wet heat resistance and chemical resistance are poor.
- Comparative Example 2-3 is a composition composed of two types of resins, but has a uniform structure due to the compatibility, so that the heat and chemical resistance and chemical resistance expressed by the phase separation structure are not obtained. .
- Example 3-1 After blending 90 parts by weight of PC-A1 pellets and 10 parts by weight of PC-B5 pellets, using a twin screw extruder TEX30HSS [manufactured by Nippon Steel Works] equipped with a vacuum vent, the cylinder temperature was 240 ° C. Then, extrusion kneading was performed at an extrusion rate of 12 kg / hr to obtain pellets of a polycarbonate resin composition. According to the above-mentioned method, various characteristics of the polycarbonate resin composition were evaluated. The results are shown in Table 10.
- Example 3-2 to Example 3-3 Comparative Example 3-1 to Comparative Example 3-3
- Example 3-1 The same operation as in Example 3-1 was performed except that the composition was changed to the composition shown in Table 10. Further, with respect to Example 3-2, Example 3-3, and Comparative Examples 3-1 to 3-3, various characteristics of the polycarbonate resin composition were evaluated by the method described above. The results are shown in Table 10.
- the resin compositions of Examples 3-1 to 3-3 have transparency, heat resistance, color tone, moldability, chemical resistance, mechanical properties, weather resistance, optical properties, and the like. Several characteristics are excellent in a good balance. In addition, in the laminate including the resin layer containing the resin composition of Examples 3-1 to 3-3, warpage generated in the use environment or the storage environment was suppressed.
- the resin composition contains the first polycarbonate resin, but does not contain the second polycarbonate resin. In this case, the warp of the laminate was large.
- the resin composition contains the second polycarbonate resin, but does not contain the first polycarbonate resin. Also in this case, the warp of the laminate was large.
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Abstract
Description
前記構造単位を40重量%未満含む第2ポリカーボネート樹脂と、を少なくとも含有し、
前記第1ポリカーボネート樹脂と前記第2ポリカーボネート樹脂との重量比が、第1ポリカーボネート樹脂/第2ポリカーボネート樹脂で、55/45~99/1であり、
ガラス転移温度を2つ以上有する、ポリカーボネート樹脂組成物。
ポリカーボネート樹脂組成物(以下、単に「樹脂組成物」と称する場合がある)は、下記式(1)で表される構造単位を含むポリカーボネート樹脂を2種以上含む。下記式(1)で表される構造単位のことを、以下、構造単位(a)と称する場合がある。樹脂組成物は、ポリカーボネート樹脂として、第1ポリカーボネート樹脂と、第2ポリカーボネート樹脂とを少なくとも含有する。第1ポリカーボネート樹脂と第2ポリカーボネート樹脂とは、いずれも構造単位(a)を含有するが、各樹脂を構成する構造単位(a)の含有量が少なくとも異なる。第1ポリカーボネート樹脂は、構造単位(a)を40重量%以上含む樹脂である。第2ポリカーボネート樹脂は、構造単位(a)を40重量%未満含む樹脂である。第1ポリカーボネート樹脂のことを、適宜、「樹脂A」といい、第2ポリカーボネート樹脂のことを、適宜「樹脂B」ということがある。
ポリカーボネート樹脂としては、上述の第1ポリカーボネート樹脂、第2ポリカーボネート樹脂を少なくとも含有するが、本開示の効果を妨げない範囲内において、第1ポリカーボネート樹脂、第2ポリカーボネート樹脂以外の他のポリカーボネート樹脂を含有することも可能である。具体的には、例えば第3ポリカーボネート樹脂(つまり、樹脂C1)を含有することができる。また、ポリカーボネート樹脂組成物におけるポリカーボネート樹脂は、実質的に第1ポリカーボネート樹脂と第2ポリカーボネート樹脂からなる構成とすることもできる。
第1ポリカーボネート樹脂、第2ポリカーボネート樹脂は、上述したジヒドロキシ化合物と炭酸ジエステルをエステル交換反応により重縮合させることにより合成できる。より詳細には、重縮合と共に、エステル交換反応において副生するモノヒドロキシ化合物等を系外に除去することによって得ることができる。
・ガラス転移温度
第1ポリカーボネート樹脂と第2ポリカーボネート樹脂のガラス転移温度は、好ましくは40℃以上、また好ましくは220℃以下である。第1ポリカーボネート樹脂のガラス転移温度は、好ましくは90℃以上、より好ましくは100℃以上、更に好ましくは110℃以上、特に好ましくは120℃以上、また好ましくは160℃以下、より好ましくは150℃以下、更に好ましくは140℃以下である。前記範囲内であると、十分な耐熱性を有し、成形加工も容易となる。
また、積層体に用いる場合には、第1ポリカーボネート樹脂と第2ポリカーボネート樹脂のガラス転移温度は、好ましくは40℃以上、また好ましくは180℃以下である。第1ポリカーボネート樹脂のガラス転移温度は、好ましくは100℃以上、より好ましくは110℃以上、さらに好ましくは120℃以上、また好ましくは160℃以下、より好ましくは150℃以下、さらに好ましくは140℃以下である。前記範囲内であると、十分な耐熱性を有し、成形加工も容易となる。
第1ポリカーボネート樹脂と第2ポリカーボネート樹脂の分子量は、還元粘度や1H-NMRにより測定される数平均分子量などで表すことができる。これらの測定法により得られる値は、数値が高いほど分子量が大きいことを示す。第1ポリカーボネート樹脂及び第2ポリカーボネート樹脂の還元粘度は、通常0.30dL/g以上であり、0.35dL/g以上が好ましい。この場合には、成形品の機械的強度をより向上させることができる。一方、還元粘度は、通常1.00dL/g以下であり、0.90dL/g以下が好ましく、0.80dL/g以下がより好ましい。この場合には、成形時の流動性を向上させることができ、生産性や成形性をより向上させることができる。還元粘度の測定方法の詳細は実施例において説明する。
第1ポリカーボネート樹脂と第2ポリカーボネート樹脂の溶融粘度は、50Pa・s以上3000Pa・s以下が好ましい。この場合には、樹脂組成物の成形品が脆くなることを防止し、機械物性をより向上させることができる。さらにこの場合には、成形加工時における流動性を向上させ、成形品の外観が損なわれたり、寸法精度が悪化したりすることを防止することができる。さらにこの場合には、剪断発熱により樹脂温度が上昇することに起因する、着色や発泡をより一層防止することができる。樹脂組成物を積層体に用いる場合には、同様の観点から、第1ポリカーボネート樹脂と第2ポリカーボネート樹脂の溶融粘度は、50Pa・s以上5000Pa・s以下が好ましい。なお、本明細書において溶融粘度とは、キャピラリーレオメータ(東洋精機社製)を用いて測定される、温度220℃、剪断速度91.2sec-1における溶融粘度をいう。溶融粘度の測定方法の詳細は、後述の実施例において説明する。
樹脂Cは下記式(3)で表される構造単位を50重量%以上含有する第3ポリカーボネート樹脂(樹脂C1)、及び/又は下記式(4)で表される構造単位を50重量%以上含有するアクリル樹脂(樹脂C2)である。これらは1種を単独で用いてもよく、2種以上を組み合わせて用いてもよい。以下、下記式(3)で表される構造単位のことを構造単位(c)、下記式(4)で表される構造単位のことを構造単位(d)と称する場合がある。
本開示の樹脂組成物において、樹脂Cは第2ポリカーボネート樹脂からなる相の屈折率を調整する役割を果たしている。第2ポリカーボネート樹脂の本来の特性を損なわないためには、第3樹脂(つまり、樹脂C)の添加量はより少量であることが好ましく、その観点から、第3樹脂の屈折率は、1.54以上、1.65以下であることが好ましい。第3樹脂の屈折率の下限は1.55がより好ましく、1.56がさらに好ましい。上限は1.63がより好ましく、1.60がさらに好ましい。屈折率が上記範囲内であると、第3樹脂の添加量を必要最小限に止めることができ、樹脂組成分の中での第3樹脂の配合比率の制御もしやすい。
樹脂Cは、市販品を用いてもよいし、公知の方法で製造してもよい。
ポリカーボネート樹脂は、触媒失活剤を含んでいてもよい。触媒失活剤としては、酸性物質で、重合触媒の失活機能を有するものであれば特に限定されないが、中でも触媒失活と着色抑制の効果が優れているのはリン系酸性化合物であり、ホスホン酸(亜リン酸)、ホスホン酸エステルがさらに好ましく、ホスホン酸(亜リン酸)が特に好ましい。
樹脂組成物は、例えば、樹脂組成物を構成する上述の各成分を機械的に溶融混練する方法によって製造することができる。溶融混練機としては、単軸押出機、二軸押出機、ブラベンダー、バンバリーミキサー、ニーダーブレンダー、ロールミル等を用いることができる。混練に際しては、各成分を一括して混練しても、また任意の成分を混練した後、他の残りの成分を添加して混練する多段分割混練法を用いてもよい。中でも真空ベントを備えた二軸押出機を用いて、各成分を連続的に投入し、連続的に樹脂組成物を取得する方法が生産性や品質均一性の観点で好ましい。混練温度は、通常150℃以上、好ましくは180℃以上、より好ましくは200℃以上である。また、混練温度は、通常280℃以下、好ましくは260℃以下、より好ましくは250℃以下である。このような範囲にすることで、混練中の樹脂の熱劣化を抑制でき、着色や機械物性の低下を抑えることができる。
樹脂組成物が、共重合比率が異なる複数のポリカーボネート樹脂を混合したものであるか、つまり、上述の第1ポリカーボネート樹脂と第2ポリカーボネート樹脂とを含有するかは、例えば、グラジエントポリマー溶出クロマトグラフィー(GPEC)にて分析し、確かめることができる(特開2014-208800参照)。
・ガラス転移温度
樹脂組成物は、固体粘弾性により測定したガラス転移温度のピークを2つ以上有することが好ましい。ガラス転移温度が2つ以上検出されることは、樹脂組成物が相分離の形態をとっていることを示す。低温側のガラス転移温度は、好ましくは40℃以上、より好ましくは50℃以上、更に好ましくは60℃以上であり、また、好ましくは100℃以下、より好ましくは90℃以下、更に好ましくは80℃以下である。前記範囲内であると、耐衝撃性、流動性がより優れる。樹脂組成物を積層体に用いる場合において前記範囲内であると、耐衝撃性等の機械物性がより向上し、積層体の反りがより抑制される。
樹脂組成物の溶融粘度は、500Pa・s以上、4000Pa・s以下が好ましい。この場合には、樹脂組成物の成形品が十分な機械物性を備えつつ、良好な成形性も有する。この効果をより高めることができるという観点から、溶融粘度は、700Pa・s以上がより好ましく、1000Pa・s以上がさらに好ましい。また、溶融粘度は、3500Pa・s以下がより好ましく、3000Pa・s以下がさらに好ましい。特に、樹脂組成物を前記積層体に用いる場合には、前記範囲内に調整することが特に有効である。
樹脂組成物の荷重たわみ温度は、85℃以上、120℃以下が好ましい。この場合には、樹脂組成物の成形品が十分な機械物性を備えつつ、実用上要求される耐熱性を確保することができる。この効果をより高めることができるという観点から、荷重たわみ温度は、90℃以上がより好ましく、92℃以上がさらに好ましい。また、荷重たわみ温度は、115℃以下がより好ましく、110℃以下がさらに好ましい。
樹脂組成物の衝撃強度は、例えば、実施例で詳述するノッチ付シャルピー衝撃強度試験で評価することができる。ノッチの先端半径Rが0.25mmのノッチ付シャルピー衝撃強度は、好ましくは7kJ/m2以上、より好ましくは9kJ/m2以上、さらに好ましくは10kJ/m2以上、特に好ましくは11kJ/m2以上である。前記範囲内であることにより、より優れた耐衝撃強度を有する。
樹脂組成物における全光線透過率、ヘーズは、例えば、実施例で詳述する測定方法で評価することができる。全光線透過率の値としては、好ましくは85%以上、より好ましくは90%以上である。前記範囲内であると、より優れた透明性を有するため、成形品がディスプレイ前面板など光学用部材や透明電気電子部材用途に好適に用いられる。同様の観点から、全光線透過率の値は、25℃及び90℃の両温度において、好ましくは85%以上、より好ましくは90%以上である。ヘーズの値は、25℃及び90℃の両温度において、好ましくは15%以下、より好ましくは7%以下、更に好ましくは5%以下である。また、樹脂組成物が積層体に用いられる場合には、ヘーズの値は、5%以下であることが好ましく、3%以下であることがより好ましい。
樹脂組成物の色調は、例えば、実施例で詳述する黄色度(YI)の測定方法で評価することができる。黄色度(YI)は、5.0以下であることが好ましい。この場合には、樹脂組成物の成形品がより優れた透明性を有するため、成形品はディスプレイ前面板等の光学用部材や透明電気電子部材用途に好適に用いられる。透明性がより向上するという観点から、黄色度は、3.0以下であることがより好ましく、2.5以下であることがさらに好ましく、2.0以下であることが特に好ましい。
樹脂組成物の耐薬品性は、例えば、実施例で詳述する1/4楕円法で測定した臨界歪みにより評価することができる。臨界歪みの値としては、好ましくは0.3%以上、さらに好ましくは0.4%以上である。この範囲であることにより、より優れた耐薬品性を有するため、自動車内外装部材といった耐薬品性が求められる用途に好適に用いられる。
樹脂組成物の耐湿熱性は、例えば、実施例で記述する湿熱サイクルクラック試験におけるクラック発生サイクル数で評価できることができる。クラック発生サイクル数としては、好ましくは20回以上、より好ましくは30回以上である。前記範囲内であると、より優れた耐湿熱性を有するため、自動車用内装部材など高温多湿環境下での使用が想定される用途に好適に用いられる。
樹脂組成物における鉛筆硬度(表面硬度)は、例えば、実施例で詳述する方法で評価することができる。鉛筆硬度はHB以上が好ましく、F以上がより好ましい。この場合に、樹脂組成物の成形品や積層体がディスプレイ前面板や自動車内外装等の耐傷付き性が求められる用途に好適に用いられる。また、成形品や積層体が光学フィルムに用いる場合も、搬送時の傷付きを抑制できるため、例えば保護フィルムを削減するというメリットが得られる。さらに高い表面硬度が求められる場合は、樹脂組成物の成形品や積層体の表面にさらにハードコートを施すことも可能である。
樹脂組成物における光弾性係数は、例えば、実施例で詳述する方法で評価することができる。樹脂組成物を例えば前記積層体に用いる場合には、樹脂組成物の光弾性係数の絶対値は25×10-12Pa-1以下が好ましい。この場合に、偏光板部材として用いる場合に、積層や曲げに伴う応力によって発生する複屈折を十分に小さくすることができる。特に大型ディスプレイやフレキシブル(ベンダブル、ローラルブル、フォルダブル)ディスプレイに用いられる光学フィルムとして好適に使用できる。複屈折をさらに小さくできるという観点から、光弾性係数の絶対値は20×10-12Pa-1以下がより好ましく、15×10-12Pa-1以下がさらに好ましい。
樹脂組成物における耐面衝撃性は、例えば、実施例で詳述するデュポン衝撃試験で評価することができる。樹脂組成物を例えば前記積層体に用いる場合には、実施例にて述べる試験条件において、耐面衝撃性が延性破壊となることが好ましい。このような特性が得られると、ディスプレイ前面板や建材、自動車内装部材用の意匠フィルム等、耐衝撃性が求められる用途や、打ち抜き加工を行う用途に好適に用いられる。
樹脂組成物の耐候性は、例えば、実施例で詳述するキセノンウェザーメータを用いた試験により評価することができる。試験前後でのプレート試験片の色調(YI)の差が小さいほどUV照射による着色が少なく、耐候性が優れることを示す。後述する試験条件による処理前後のYIの差の絶対値(ΔYI)は0.5以下が好ましく、0.3以下がさらに好ましく、0.1以下が特に好ましい。この範囲であると、屋外で用いられる建材やデジタルサイネージ等の前面板、自動車内外装部材等、耐候性が求められる用途に好適に用いられる。特に、樹脂組成物を例えば前記積層体に用いる場合において、ΔYIが前記範囲であることが好ましい。
前述の樹脂組成物が高品質な成形品の製造を可能にする理由については、下記の通り推測する。ガラス転移温度が2つ以上ある樹脂組成物は、2種以上の樹脂がマトリックス-ドメイン構造のような相分離構造を形成している。ガラス転移温度が低く分子量の高い成分がドメイン構造である場合、吸水膨張と乾燥収縮が繰り返される時に発生する歪みや、薬品による膨潤で発生した歪みを、マトリックス-ドメインの界面で吸収し、また高分子量成分によって強度が増すことによりクラックの発生を防ぐことができる。一方、ガラス転移温度が低く、分子量の低い成分がドメイン構造である場合、ドメイン構造をなす成分は十分な機械強度と高い流動性を兼ね備えるため、機械強度を損なうことなく、流動性を改良することができる。また、ガラス転移温度が違う2種の樹脂が相溶した場合は、一つのガラス転移温度が両成分の組成に応じて2種の中間に現れ、耐熱性が低下するが、非相溶の場合、ガラス転移温度の高い方の成分の耐熱性が低下せずに、耐薬品性、耐湿熱性、流動性を向上することができる。さらに、樹脂組成物を構成する第1ポリカーボネート樹脂と第2ポリカーボネート樹脂成分とが同一の構造単位を含有しているため、2種の成分は部分的な相溶性を有する。これにより、混練時に強い剪断力や高い温度を掛けなくとも、ドメインを透過光の散乱に寄与しない程度のサイズに細かく分散させることが可能となる。これより樹脂の熱劣化を抑制でき、透明性や色調の良好な樹脂組成物が得られる。なお、樹脂組成物のマトリックス-ドメイン構造や相溶性などのモルフォロジーは、常法により調べることができ、具体的には透過型電子顕微鏡観察により調べることが可能である。
樹脂組成物は、例えば射出成形(インサート成形法、二色成形法、サンドイッチ成形法、ガスインジェクション成形法等)、押出成形法、インフレーション成形法、Tダイフィルム成形法、ラミネート成形法、ブロー成形法、中空成形法、圧縮成形法、カレンダー成形法等の成形法により種々の成形品に加工することができる。成形品の形状には特に制限はなく、シート、フィルム、板状、粒子状、塊状体、繊維、棒状、多孔体、発泡体等が挙げられ、好ましくはシート、フィルム、板状である。また、成形されたフィルムは一軸あるいは二軸延伸することも可能である。延伸法としては、ロール法、テンター法、チューブラー法等が挙げられる。さらに、通常工業的に利用されるコロナ放電処理、火炎処理、プラズマ処理、オゾン処理等の表面処理を施すこともできる。なお、成形品は、一般に、成形体と呼ばれることもある。
成形品の用途は特に限定されないが、一例として、下記のような用途を挙げることができる。すなわち、電気・電子部品分野における電線、コード類、ワイヤーハーネス等の被覆材料、絶縁シート、OA機器のディスプレイやタッチパネル、メンブレンスイッチ、写真カバー、リレー部品、コイルボビン、ICソケット、ヒューズケース、カメラ圧板、FDDコレット、フロッピーハブ、光学部品分野における光ディスク基板、光ディスク用ピックアップレンズ、光学レンズ、LCD基板、PDP基板、プロジェクションテレビ用テレビスクリーン、位相差フィルム、フォグランプレンズ、照光スイッチレンズ、センサースイッチレンズ、フレネルレンズ、保護メガネ、プロジェクションレンズ、カメラレンズ、サングラス、導光板、カメラストロボリフレクター、LEDリフレクター、自動車部品におけるヘッドランプレンズ、ウインカーランプレンズ、テールランプレンズ、樹脂窓ガラス、メーターカバー、外板、ドアハンドル、リアパネル、ホイールキャップ、バイザー、ルーフレール、サンルーフ、インパネ、パネル類、コントロールケーブル被覆材、エアーバッグ・カバー、マッドガード、バンパー、ブーツ、エアホース、ランプパッキン類、ガスケット類、ウィンドウモール等の各種モール、サイトシールド、ウェザーストリップ、グラスランチャンネル、グロメット類、制震・遮音部材、建材分野における目地材、手すり、窓、テーブルエッジ材、サッシ、浴槽、窓枠、看板、照明カバー、水槽、階段腰板、カーポート、高速道路遮音壁、マルチウォールシート、鋼線被覆材、照明灯グローブ、スイッチブレーカー、工作機械の保護カバー、工業用深絞り真空成形容器、ポンプハウジング、家電、弱電分野における各種パッキン類、グリップ類、ベルト類、足ゴム、ローラー、プロテクター、吸盤、冷蔵庫等のガスケット類、スイッチ類、コネクターカバー、ゲーム機カバー、パチンコ台、OAハウジング、ノートPCハウジング、HDDヘッド用トレー、計器類の窓、透明ハウジング、OA用ギア付きローラー、スイッチケーススライダー、ガスコックつまみ、時計枠、時計輪列中置、アンバーキャップ、OA機器用各種ロール類、ホース、チューブ等の管状成形品、異型押し出し品、レザー調物品、咬合具、ソフトな触感の人形類等の玩具類、ペングリップ、ストラップ、吸盤、時計、傘骨、化粧品ケース、ハブラシ柄等の一般雑貨類、ハウスウェア、タッパーウェア等の容器類、結束バンド、ブロー成形による輸液ボトル、食品用ボトル、ウォーターボトル、化粧品用等のパーソナルケア用のボトル等各種ボトル、医療用部品におけるカテーテル、シリンジ、シリンジガスケット、点滴筒、チューブ、ポート、キャップ、ゴム栓、ダイヤライザー、血液コネクター、義歯、ディスポーザブル容器等、が挙げられ、また、発泡成形による用途にも適用可能である。
前記のうち、特にチューブでは、薬効成分の吸着を防止できる医療用チューブに好適であり、多層チューブの場合は、その内層材または中間層材に最適である。
例えば、前記の特許文献5~8では、多くの場合、ISB系ポリカーボネート樹脂からなるフィルムと、その他の樹脂からなるフィルムとを直接、又は接着剤や粘着剤を介して貼り合わせ、積層体として使用されている。しかし、樹脂の種類によって各樹脂層の熱や吸水による寸法変化率が異なるため、このような積層体は使用環境下や保管環境下において、反りが発生してしまう場合がある。特にISB系ポリカーボネート樹脂はISBの分子構造に起因して、吸水率が比較的に高く、吸水による寸法変化率が大きいため、他の樹脂からなるフィルムと積層した場合に反りが発生しやすい。積層体の反りを改善するために、例えば、樹脂Aからなるフィルムと樹脂Bからなるフィルムを2種3層(A/B/A)の対称な構成にして、表裏の寸法変化率を一致させることで反りを抑制することが行われている。しかし、このような手法では積層体が厚くなってしまうために、部材の薄型化が求められる用途には適用できないことや、余計な層を設けるためにコストアップになってしまう問題がある。これに対し、前記樹脂組成物を含有する樹脂層Aを有する積層体は、このような問題を解決することができる。つまり、ISB系ポリカーボネート樹脂の機械強度、耐候性、光学特性等の優れた特性を損なうことなく、積層体の構成の自由度を確保し、かつ、反りを抑制した積層体を提供することができる。なお、ISB系ポリカーボネート樹脂は、ISBを用いて得られるポリカーボネート樹脂のことを意味し、具体的には、構造単位(a)を有するポリカーボネート樹脂のことを意味する。
樹脂層Bにポリカーボネート樹脂を用いる場合、樹脂層Aを表層側に用いることで、樹脂層Bの高い耐衝撃性を活かしながら、耐傷付き性や耐候性に劣る樹脂層Bを樹脂層Aにより保護することができる。
樹脂層Bにポリエステル樹脂やポリオレフィンを用いる場合、樹脂層Bは保護フィルムとして用いられる場合がある。樹脂層Aを製膜し、ロールに巻き取る前に、樹脂層Bを積層することで、保管や輸送中に樹脂層Aに傷が付くことを防いだり、ロールから巻き出して使用する際に、剥がれやすべりをよくすることができる。
樹脂層Bにアクリル樹脂を用いる場合、表面硬度に優れるアクリル樹脂を表層側に用いることで、樹脂層Aの元々の特性にさらに高い表面硬度を付与することができる。
樹脂層Bにポリスチレン樹脂を用いる場合、それぞれ延伸することで樹脂層Aは正の複屈折を発現し、樹脂層Bは負の複屈折を発現するため、各々の位相差を厳密に制御することで、広帯域1/4波長板などの高機能な位相差フィルムを作製することができる。
樹脂層Bにシクロオレフィンポリマーを用いる場合、耐薬品性に優れる樹脂層Aを表層側に用いることで、樹脂層Bの耐薬品性の弱点を補ったフィルムを作製することができる。
・積層体の反り
積層体における反りは、例えば、実施例で詳述する方法で評価することができる。反りの値としては、その絶対値が、好ましくは5mm以下、より好ましくは3mm以下である。前記上限以下であれば、大型ディスプレイの前面保護板や、偏光板の保護フィルム、位相差フィルムなど、組み立て工程や製品使用環境下において反りが問題となりやすい用途に好適に用いられる。
樹脂組成物は、射出成形法、押出成形法、インフレーション成形法、Tダイフィルム成形法、ラミネート成形法、ブロー成形法、中空成形法、圧縮成形法、カレンダー成形法等の成形法により、シート、フィルム、板状の成形品とすることができる。射出成形は、インサート成形法、二色成形法、サンドイッチ成形法、ガスインジェクション成形法等を含む。また、フィルムを一軸又は二軸延伸することも可能である。延伸法としては、ロール法、テンター法、チューブラー法等が挙げられる。さらに、通常工業的に利用されるコロナ放電処理、火炎処理、プラズマ処理、オゾン処理等の表面処理をシート、フィルム、板状の成形品に施すこともできる。
積層体は、耐衝撃性、透明性、耐候性、低光弾性係数等の光学特性、耐薬品性、高表面硬度等の複数の特性をバランス良く兼ね備えている。フィルム・シート分野における用途は特に限定されないが、特に好適に用いることができる用途として、例えば、建材(樹脂窓、カーポート用シート、透明遮音壁、樹脂被覆金属板用シート等)、自動車内外装部材(インモールド成形に用いる加飾フィルム、真空・圧空成形や熱プレス成形用シート等)、光学フィルム・シート(ディスプレイ前面板、偏光板保護フィルム、位相差フィルム、透明基板フィルム、カバーフィルム等)、家電製品部材(スマートフォンやノートパソコンの筐体等)、事務用品関連分野(磁気ストライプカードや非接触式ICカード等のプラスチックカード用シート)等が挙げられる。
[測定方法]
樹脂を塩化メチレンに溶解させ、0.6g/dLの濃度の樹脂溶液を調製した。森友理化工業社製ウベローデ型粘度管を用いて、20.0℃±0.1℃の温度条件下で、溶媒の通過時間t0及び溶液の通過時間tを測定した。得られたt0及びtの値を用いて次式(i)により相対粘度ηrelを求め、更に、得られた相対粘度ηrelを用いて次式(ii)により比粘度ηspを求めた。
ηrel=t/t0 ・・・(i)
ηsp=(η-η0)/η0=ηrel-1 ・・・(ii)
その後、得られた比粘度ηspを濃度c(g/dL)で割って、還元粘度ηsp/cを求めた。この値が高いほど分子量が大きい。
ポリカーボネート樹脂試料約20mgを秤取し、重クロロホルム約0.7mLに溶解し、これを内径5mmのNMR用チューブに入れ、1H-NMRスペクトルを測定した。ポリカーボネート樹脂を構成する各ジヒドロキシ化合物に由来する構造単位に基づくシグナルと、各種末端基のシグナルの強度比より数平均分子量を計算した。用いた装置や条件は次のとおりである。なお、NMRは核磁気共鳴を意味する。
・装置:JNM-ECZ400S(日本電子社製)
・測定温度:30℃
・緩和時間:6秒
・積算回数:64回
(a):5.6-4.4ppm:全ISB繰り返し構造単位由来(プロトン数:4、分子量:172.14)
(b):2.2-0.5ppm:全CHDM繰り返し構造単位由来(プロトン数:10、分子量:170.21)
(c):4.4ppm:ISBのヒドロキシ末端基由来(プロトン数:1)
(d):3.6-3.5ppm:ISBヒドロキシ末端基由来(プロトン数:1)とCHDMヒドロキシ末端基由来(プロトン数:2)
(e):3.5-3.4ppm:CHDMヒドロキシ末端基由来(プロトン数:2)とISB二重結合末端基由来(プロトン数:1)
(f):2.6ppm:ISBヒドロキシ末端基由来(プロトン数:1)
(g):6.7-6.5ppm:ISB二重結合末端基由来(プロトン数:1)
(h):2.3ppm:CHDM二重結合末端基由来(プロトン数:2)
(i):7.4ppm:DPC末端基由来(プロトン数:2、分子量:93.10)
・全ISB繰り返し構造単位(a´):(a)積分値/4
・全CHDM繰り返し構造単位(b´):(b)積分値/10
・ISBヒドロキシ末端基(c´):(c)積分値+(f)積分値
・CHDMヒドロキシ末端基(d´):{(d)積分値-(f)積分値}/2+{(e)積分値-(g)積分値}/2
・ISB二重結合末端基(e´):(g)積分値
・CHDM二重結合末端基(f´):(h)積分値/2
・DPC末端基(i´):(i)積分値/2
{(a´)×172.14+(b´)×170.21+(i´)×93.10}/[{(c´)+(d´)+(e´)+(f´)+(i´)}/2]
ペレット状の樹脂を、ペレットが融着しない範囲で極力高い温度にて、5時間以上真空乾燥した。次いで、ペレットを200℃に設定したミニテストプレス[東洋精機社製]にて10MPaで加圧後、25℃に設定したミニテストプレスにて15MPaで加圧して冷却し、厚み0.5mmのシートを作成した。次に、シートを幅5mm、長さ20mmに切削してシート状の試験片を作成した。この試験片を動的粘弾性測定装置[ティーエーインスツルメント社製]にて、周波数1Hz、昇温速度2℃/min、温度30℃から融解温度までの条件で測定し、測定結果におけるtanδのピーク温度をガラス転移温度とした。
ペレット状の樹脂を、ペレットが融着しない範囲で極力高い温度にて、5時間以上、真空乾燥した。次いで、キャピラリーレオメータ(東洋精機社製)にて、ペレットの溶融粘度を測定した。測定温度は220℃とし、剪断速度は9.12~1824sec-1の範囲とした。剪断速度91.2sec-1における値を測定対象の樹脂の溶融粘度として用いた。なお、オリフィスには、溶融粘度が500Pa・s以上の場合は1mmφ×10mmLを用い、500Pa・s未満の場合は1mmφ×40mmLを用いた。
90℃で5時間以上、真空乾燥をした樹脂のペレット約4gを、縦14cm、横14cm、厚さ0.1mmのスペーサーを用い、試料の上下にポリイミドフィルムを敷いて、温度200~230℃で3分間予熱し、圧力30MPaの条件で5分間加圧後、スペーサーごと取り出し、冷却してフィルムを作製した。このフィルムから、長さ40mm、幅8mmの長方形の試験片を切り出して測定試料とした。589nm(D線)の干渉フィルターを用いて、(株)アタゴ製多波長アッベ屈折率計DR-M4/1550により屈折率nDを測定した。測定は界面液としてモノブロモナフタレンを用い、20℃で行った。
ポリカーボネート樹脂組成物のペレットを、熱風乾燥機を用いて、90℃で4時間以上乾燥した。なお、測定に用いるペレットは、後述の各実施例等にて製造されるポリカーボネート樹脂組成物であって着色などを行っていない外観上透明のものである。以降の各測定方法についても同様である。次に、ペレットを75トン射出成形機(東芝機械社製 EC-75)に供給し、樹脂温度240℃、金型温度60℃、成形サイクル60秒間の条件で成形を行うことにより、射出成形板(幅100mm×長さ100mm×厚さ2mm)を得た。JIS K7136(2000年)に準拠し、ヘーズメータNDH2000(日本電色工業社製)を使用し、D65光源にて、射出成形板の全光線透過率、ヘーズを測定した。各温度における差は、90℃の値から25℃の値を引いたもので表される。なお、実施例1-1~1-10、比較例1-1~1-3では、全光線透過率は、90%以上を合格とした。また、実施例2-1~2-8、比較例2-1~2-3では、測定前に射出成形板を25℃と90℃に調整して、2つの温度で測定を行った。なお、室温でも高温でも高い透明性を維持するという観点からは、25℃と90℃の両温度において、全光線透過率が90%以上であり、ヘーズが15%以下であることが好ましい。また、温度90℃での全光線透過率と温度25℃での全光線透過率との差(つまり、ΔTrans)を算出し、温度90℃でのヘーズと温度25℃でのヘーズとの差(つまり、ΔHaze)を算出した。
上述のとおり作製した射出成形板(幅100mm×長さ100mm×厚さ2mm)を用いて、ASTM E313-96に準拠し、分光測色計CM-5(コニカミノルタ社製)を使用し、C光源にて、射出成形板のYIを測定した。本実施例ではYI値は、3.0以下を合格とした。
下記で得られた機械物性用ISO試験片についてISO179(2000年)に準拠してノッチ付シャルピー衝撃試験を実施した。ノッチに関しては先端半径Rについて0.25mmについて測定を行った。なお、ノッチ付シャルピー衝撃強度は数値が大きいほど耐衝撃強度に優れるが、ノッチの先端半径Rが0.25mmの場合、本例ではシャルピー衝撃強度が7kJ/m2以上であれば実用的な機械的強度であると判断し、シャルピー衝撃強度が10kJ/m2以上であれば優れた機械的強度であると判断した。
透明のポリカーボネート樹脂組成物のペレットを、熱風乾燥機を用いて、90℃で4時間以上乾燥した。次に、ペレットを75トン射出成形機EC-75(東芝機械社製)に供給し、流路厚2mm、流路幅8mmのスパイラルフロー金型を用い、樹脂温度240℃、射出圧力100MPa、金型温度60℃、射出速度50mm/s、射出時間10sec、冷却時間10secの条件で成形を行うことによりスパイラル形状の射出成形品を得た。この射出成形品から流動長を計測した。このスパイラルフローによる流動長は、成形時における樹脂の流動性の指標となる。数値が高い方が流動性に優れ、例えば射出成形による成形品の生産性を向上できたり、より複雑な形状や薄い形状の成形が可能となる。
ポリカーボネート樹脂組成物のペレットを、熱風乾燥機を用いて、90℃で4時間以上乾燥した。次に、ペレットを75トン射出成形機EC-75(東芝機械社製)に供給し、樹脂温度240℃、金型温度60℃、成形サイクル60秒間の条件で成形を行うことにより、機械物性用ISO試験片を得た。次いで、ISO試験片から、長さ80mm、幅10mm、厚み4mmの短冊状試験片を切り出した。その後、加熱変形試験機(東洋精機社製)を用いて、JIS K7191-1(2007年)に準拠し、フラットワイズ法、曲げ応力1.8MPaにて、短冊状試験片の荷重たわみ温度を求めた。実施例2-1~2-8、比較例2-1~比較例2-3では、HDTが85℃以上の場合に、実用的な耐熱性を備えると判断し、90℃以上の場合に優れた耐熱性を備えると判断した。
ポリカーボネート樹脂組成物のペレットを、熱風乾燥機を用いて、90℃で4時間以上乾燥した。次に、メルトインデクサー(東洋精機社製)にてJIS K7210に準拠した方法にて、温度230℃、荷重2.16Kgの条件でペレットのMFRの測定を行った。
上述のとおり作製した射出成形板(幅100mm×長さ100mm×厚さ2mm)を用いて、射出成形板5枚を恒温恒湿槽ETAC HIFLEX FX410N(楠本化成製)内に配置し、温度65℃湿度95%RHにて48時間加熱し、さらに温度65℃湿度25%RHにて8時間加熱した。そして、この2つの加熱工程を1サイクルとし、5枚の射出成形板すべてにクラックが生じたときのサイクル数を測定し、その結果を耐湿熱性の指標として評価した。実施例1-1~実施例1-10、比較例1-1~比較例1-3では、5枚すべてにクラックが生じたサイクル数が20サイクル以上のものを耐湿熱性が優れると判断した。なお、35サイクル目でも5枚すべてにクラックが生じなかった場合には、その結果を35サイクル超え(つまり、「>35」)とした。
ポリカーボネート樹脂組成物のペレットを、熱風乾燥機を用いて、90℃で4時間以上乾燥した。次に、ペレットを75トン射出成形機EC-75(東芝機械社製)に供給し、樹脂温度240℃、金型温度60℃、成形サイクル60秒間の条件で成形を行うことにより、射出成形板(幅100mm×長さ100mm×厚さ1mm)を得た。次いで、成形板をプレス成形機(東洋精機製ミニテストプレス)にて温度200℃、圧力5MPaにて1分間プレスした後、温度25℃、圧力5MPaにて2分間プレスしてプレス成形板(幅100mm×長さ100mm×厚み1mm)を得た。その後、プレス成形板を幅40mm、長さ100mmに切削し試験片を作製した。この試験片の表面にIgepal CA-630(MP Biomedicals製)を塗布し、長軸120mm、短軸60mmの1/4楕円法治具に試験片を設置して70℃に設定したイナートオーブン(ヤマト科学製DN4101)中にて4時間加熱した。その後、試験片におけるクラック発生点距離を測定し、以下の式(I)により臨界歪みを求めた。
「動的粘弾性測定によるガラス転移温度の測定方法」と同様の方法により、厚み0.5mmのプレス成形シートを作製した。このシートを試験片に用いて、デュポン衝撃試験機[東洋精機製作所社製]にて面衝撃試験を行った。試験温度25℃、受け台内径30mm、外径50mm、撃芯半径1/4inch、重り800g、高さ50cmの条件で、重りを試験片に落下させた。10枚の試験片を用いて測定を行い、延性破壊となった割合が8割以上の場合を「延性」と評価し、それ以外を「脆性」と評価した。
He-Neレーザー、偏光子、補償板、検光子、光検出器を備える複屈折測定装置と振動型粘弾性測定装置(レオロジー社製DVE-3)を組み合わせた装置を用いて測定した(詳細は、日本レオロジー学会誌Vol.19,p93-97(1991)を参照)。「動的粘弾性測定によるガラス転移温度の測定方法」と同様のプレス成形を行い、厚み0.2mmのフィルムを作製した。このフィルムから幅5mm、長さ20mmの試験片を切り出した。試験片を粘弾性測定装置に固定し、室温(具体的には25℃)、周波数96Hzの条件にて、貯蔵弾性率E’を測定した。この測定時に、出射されたレーザー光を偏光子、試験片、補償板、検光子の順に通し、光検出器(フォトダイオード)で検出し、ロックインアンプにより角周波数ω又は2ωの波形を得た。その振幅とひずみに対する位相差を求め、ひずみ光学係数O’を求めた。このとき、偏光子と検光子の吸収軸の方向は直交し、それぞれが試験片の伸長方向に対してπ/4の角度をなすように調整した。光弾性係数Cは、貯蔵弾性率E’とひずみ光学係数O’を用いて次式(α)より求めた。
C=O’/E’・・・(α)
まず、前記の全光線透過率とヘーズの測定と同様の方法により、厚み2mmの射出成形板を作製した。キセノンウェザーメータ[東洋精機製作所社製アトラス・ウエザオメータCi4000]を用いて、照射強度60W/m2、ブラックパネル温度65℃の条件で、射出成形板に光源から光を照射した。照射は、雨あり12分/雨なし48分の降雨サイクル条件で100時間行った。照射前後の射出成形板の色調をコニカミノルタ(株)製分光測色計CM-5を用い、ASTM D1925に準拠して測定した。射出成形板を測定室に置き、透過光のYI(イエローネスインデックス)値を測定した。照射処理後のYIと処理前のYIの差(ΔYI)が小さいほどUV照射による着色が少なく、耐候性が優れることを示す。
・色調(YI)
まず、前記の全光線透過率とヘーズの測定と同様の方法により、厚み2mmの射出成形板を作製した。射出成形板を測定室に置き、透過光のYI(イエローネスインデックス)値を測定した。
まず、前記の全光線透過率とヘーズの測定と同様の方法により、厚み2mmの射出成形板を作製した。鉛筆引掻塗膜硬さ試験機[東洋精機製作所社製]を用いて、JIS K5600-5-4に記載の方法により、射出成形板の鉛筆硬度を測定した。
ポリカカーボート樹脂組成物からなるフィルム状の試験片(試験片A)と、他の樹脂からなるフィルム状の試験片(試験片B)との積層体サンプルを作製し、この積層体サンプルの反りを評価した。まず、前記の動的粘弾性測定によるガラス転移温度の測定方法と同様に、ポリカーボネート樹脂組成物のプレス成形を行い、厚み0.2mmのフィルムを作製した。そのフィルムから幅20mm、長さ100mmの短冊状の試験片(試験片A)を切り出した。この試験片と組み合わせる樹脂材料として、後述するBPA-PC、COP、PMMAを用いて評価を行った。BPA-PC、COP、PMMAはプレス成形にてフィルムに成形した。BPA-PC、COP、PMMAからなるフィルムから、それぞれ、幅20mm、長さ100mm、厚さ0.2mmの試験片(試験片B)を切り出した。試験片Aと試験片Bとを重ね合わせ、熱プレス機を用いて積層方向に加圧することにより、積層体サンプルを作製した。この積層体サンプルは、前記の樹脂層Aに相当する試験片Aの層と、樹脂層Bに相当する試験片Bの層との積層体である。なお、加圧条件は、温度:110~160℃、圧力:1MPa、時間:5分間である。加熱温度は材料のガラス転移温度に応じて適宜調整した。次に、積層体サンプルを60℃の温水に3時間浸漬した。その後、積層体サンプルを試験片Aの層を上にして、水平な台に置き、反りの大きさを測定した。積層体サンプルが反り、試験片Aの層側の中央部が浮き上がっている場合には、その浮き上がった距離が反りの大きさである。一方、試験片Bの層側の中央部が浮き上がっている場合は、積層体サンプルの上下を逆にして中央部の浮き上がった距離を測定し、その距離をマイナスの値で表した。つまり、距離の絶対値が小さいほど、積層体の反りがより小さいことを示す。
以下の製造例、実施例で用いた化合物の略号、および製造元は次の通りである。
・ISB:イソソルビド(ロケットフルーレ社製)
・CHDM:1,4-シクロヘキサンジメタノール(SKChemical社製)
・TCDDM:トリシクロデカンジメタノール(OXEA社製)
・DPC:ジフェニルカーボネート(三菱ケミカル社製)
・ホスホン酸(東京化成工業社製)
・Irganox1010:ペンタエリスリトール-テトラキス(3-(3,5-ジ-tert-ブチル-4-ヒドロキシフェニル)プロピオネート](BASF社製)
・AS2112:トリス(2,4-ジ-tert-ブチルフェニル)ホスファイト(ADEKA社製)
・E-275:エチレングリコールジステアレート(日油社製)
・SEESORB709:2-(2-ヒドロキシ-5-tert-オクチルフェニル)-2H-ベンゾトリアゾール(シプロ化成社製)
・PC-A1:ISB/CHDM=70/30mol%共重合ポリカーボネート(構造単位(a)/構造単位(b)=58.8/24.9重量%)
後述の製造例1のとおりに合成した。
・PC-A2:ISB/CHDM=50/50mol%共重合ポリカーボネート(構造単位(a)/構造単位(b)=42.1/41.5重量%)
後述の製造例2のとおりに合成した。
・PC-A3:ISB/TCDDM=70/30mol%共重合ポリカーボネート(構造単位(a)/構造単位(b)=53.9/31.1重量%)
後述の製造例3のとおりに合成した。
・PC-B1:ISB/CHDM=40/60mol%共重合ポリカーボネート(構造単位(a)/構造単位(b)=33.7/49.9重量%)
後述の製造例4のとおりに合成した。
・PC-B2:ISB/CHDM=35/65mol%共重合ポリカーボネート(構造単位(a)/構造単位(b)=29.5/54.1重量%)
後述の製造例5のとおりに合成した。
・PC-B3:ISB/CHDM=30/70mol%共重合ポリカーボネート(構造単位(a)/構造単位(b)=25.3/58.3重量%)
後述の製造例6のとおりに合成した。
・PC-B4:ISB/CHDM=35/65mol%共重合ポリカーボネート(構造単位(a)/構造単位(b)=29.5/54.1重量%)
後述の製造例7のとおりに合成した。
・PC-B5:ISB/CHDM=30/70mol%共重合ポリカーボネート(構造単位(a)/構造単位(b)=25.3/58.3重量%)
後述の製造例8のとおりに合成した。
・PC-B6:ISB/CHDM=30/70mol%共重合ポリカーボネート(構造単位(a)/構造単位(b)=25.3/58.3重量%)
後述の製造例9のとおりに合成した。
・PC-C1:ビスフェノールAポリカーボネート
製品名:ユーピロンS3000(三菱エンジニアリングプラスチックス社製)
・PA-C1:フェニルメタクリレート/メチルアクリレート=99/1重量%共重合体
特開2010-116501に記載の方法に従って合成した。
・BPA-PC:ビスフェノールAポリカーボネート
製品名:ノバレックス7022R(三菱エンジニアリングプラスチックス社製)
・PMMA:ポリメタクリレート
製品名:アクリペットMD001(三菱ケミカル社製)
・COP:シクロオレフィンポリマー
製品名:ZEONOR1420R(日本ゼオン社製)
竪型攪拌反応器3器と横型攪拌反応器1器、並びに二軸押出機からなる連続重合設備を用いて、ポリカーボネート樹脂の重合を行った。ISB、CHDM、及びDPCをそれぞれタンクで溶融させ、ISBを29.8kg/hr、CHDMを12.6kg/hr、DPCを63.1kg/hr(モル比でISB/CHDM/DPC=0.700/0.300/1.010)の流量で第1竪型攪拌反応器に連続的に供給した。同時に、重合触媒である酢酸カルシウム1水和物の水溶液を、全ジヒドロキシ化合物1molに対して酢酸カルシウム1水和物が1.5μmolとなる添加量にて第1竪型攪拌反応器に供給した。各反応器の内温、内圧、滞留時間は、それぞれ、第1竪型攪拌反応器:190℃、25kPa、120分、第2竪型攪拌反応器:195℃、10kPa、90分、第3竪型攪拌反応器:205℃、4kPa、45分、第4横型攪拌反応器:220℃、0.1~1.0kPa、120分とした。得られるポリカーボネート樹脂の還元粘度が0.42dL/g~0.44dL/gとなるように、第4横型攪拌反応器の内圧を微調整しながら運転を行った。第4横型攪拌反応器から抜き出したポリカーボネート樹脂を、溶融状態のままベント式二軸押出機TEX30α[日本製鋼所社製]に供給した。押出機は3つの真空ベント口を有しており、ここで樹脂中の残存低分子量成分を脱揮除去するとともに、第1ベントの手前で触媒失活剤としてホスホン酸を、ポリカーボネート樹脂に対して0.63重量ppm添加し、第3ベントの手前でIrganox1010、AS2112、E-275、SEESORB709をポリカーボネート樹脂に対して、それぞれ1000重量ppm、500重量ppm、3000重量ppm、200重量ppmを添加した。押出機を通過したポリカーボネート樹脂を引き続き溶融状態のまま、目開き10μmのウルチプリーツ・キャンドルフィルター[PALL社製]に通して、異物を濾過した。その後、ダイスからストランド状にポリカーボネート樹脂を押出し、水冷、固化させた後、回転式カッターで切断することによりペレット化した。このようにして得られたペレット状のポリカーボネート樹脂を「PC-A1」と表記する。
各種原料の供給量を、ISBを21.3kg/hr、CHDMを21.1kg/hr、DPCを62.9kg/hr(モル比でISB/CHDM/DPC=0.500/0.500/1.005)とし、得られるポリカーボネート樹脂の還元粘度が0.50dL/g~0.52dL/gとなるように調整した以外は製造例1と同様にして行った。得られたポリカーボネート樹脂を「PC-A2」と表記する。
各種原料の供給量を、ISBを27.3kg/hr、TCDDMを15.7kg/hr、DPCを57.6kg/hr(モル比でISB/TCDDM/DPC=0.700/0.300/1.007)とし、酢酸カルシウム1水和物の添加量を全ジヒドロキシ化合物1molに対して1.5μmolとし、得られるポリカーボネート樹脂の還元粘度が0.38dL/g~0.40dL/gとなるように調整し、ホスホン酸の添加量をポリカーボネート樹脂に対して1.3重量ppmとした以外は、製造例1と同様にして行った。得られたポリカーボネート樹脂を「PC-A3」と表記する。PC-A3中のISB構造単位の含有量は53.9重量%、TCDDM構造単位の含有量は31.1重量%である。
各種原料の供給量を、ISBを17.1kg/hr、CHDMを25.3kg/hr、DPCを62.6kg/hr(モル比でISB/CHDM/DPC=0.400/0.600/1.000)、酢酸カルシウム1水和物の添加量を全ジヒドロキシ化合物1molに対して3μmolとし、得られるポリカーボネート樹脂の還元粘度が0.66dL/g~0.68dL/gとなるように調整し、ホスホン酸の添加量をポリカーボネート樹脂に対して1.3重量ppmとした以外は、製造例1と同様にして行った。得られたポリカーボネート樹脂を「PC-B1」と表記する。
各種原料の供給量を、ISBを15.0kg/hr、CHDMを27.4kg/hr、DPCを62.7kg/hr(モル比でISB/CHDM/DPC=0.350/0.650/1.000)、酢酸カルシウム1水和物の添加量を全ジヒドロキシ化合物1molに対して3μmolとし、得られるカーボネート樹脂の還元粘度が0.73dL/g~0.75dL/gとなるように調整し、ホスホン酸の添加量をポリカーボネート樹脂に対して1.3重量ppmとした以外は、製造例1と同様にして行った。得られたポリカーボネート樹脂を「PC-B2」と表記する。
各種原料の供給量を、ISBを12.8kg/hr、CHDMを29.6kg/hr、DPCを62.7kg/hr(モル比でISB/CHDM/DPC=0.300/0.700/1.000)、酢酸カルシウム1水和物の添加量を全ジヒドロキシ化合物1molに対して3μmolとし、得られるポリカーボネート樹脂の還元粘度が0.75dL/g~0.77dL/gとなるように調整し、ホスホン酸の添加量をポリカーボネート樹脂に対して1.3重量ppmとした以外は、製造例1と同様にして行った。得られたポリカーボネート樹脂を「PC-B3」と表記する。
各種原料の供給量を、ISBを15.0kg/hr、CHDMを27.4kg/hr、DPCを63.3kg/hr(ISB/CHDM/DPC=0.350/0.650/1.010)、酢酸カルシウム1水和物の添加量を全ジヒドロキシ化合物1molに対して3μmolとし、得られるポリカーボネート樹脂の還元粘度が0.44dL/g~0.46dL/gとなるように調整し、ホスホン酸の添加量をポリカーボネート樹脂に対して1.3重量ppmした以外は、製造例1と同様にして行った。得られたポリカーボネート樹脂を「PC-B4」と表記する。
各種原料の供給量を、ISBを12.8kg/hr、CHDMを29.6kg/hr、DPCを63.3kg/hr(モル比でISB/CHDM/DPC=0.300/0.700/1.010)、酢酸カルシウム1水和物の添加量を全ジヒドロキシ化合物1molに対して3μmolとし、得られるポリカーボネート樹脂の還元粘度が0.44dL/g~0.46dL/gとなるように調整し、ホスホン酸の添加量をポリカーボネート樹脂に対して1.3重量ppmとした以外は、製造例1と同様にして行った。得られたポリカーボネート樹脂を「PC-B5」と表記する。
各種原料の供給量を、ISBを12.8kg/hr、CHDMを29.6kg/hr、DPCを63.7kg/hr(モル比でISB/CHDM/DPC=0.300/0.700/1.015)、酢酸カルシウム1水和物の添加量を全ジヒドロキシ化合物1molに対して3μmolとし、得られるポリカーボネート樹脂の還元粘度が0.38dL/g~0.40dL/gとなるように調整し、ホスホン酸の添加量をポリカーボネート樹脂に対して1.3重量ppmとした以外は、製造例1と同様にして行った。得られたポリカーボネート樹脂を「PC-B6」と表記する。
製造例1で得られたポリカーボネート樹脂PC-A1のペレット700重量部と、製造例4で得られたポリカーボネート樹脂PC-B1のペレット300重量部とをブレンドした後、真空ベントを設けた二軸押出機TEX30HSS[日本製鋼所社製]を使用して、シリンダー温度240℃、押出量18kg/hrにて押出混練を行い、ポリカーボネート樹脂組成物のペレットを得た。次いで、樹脂組成物のペレットを温度90℃の熱風乾燥機で5時間乾燥した後、75トン射出成形機EC-75[東芝機械社製]を用いて、射出成形を行った。成形条件は、金型温度:60℃、シリンダー温度:240℃である。このようにして、幅100mm×長さ100mm×厚さ2mmの板状の成形品からなる試験片を得た。さらに同様に成形を行うことにより、ISO引張試験片を得た。ISO引張試験片からは0.25mmノッチを付けたシャルピー衝撃試験片を切り出し、シャルピー衝撃試験を実施した。また、板状の成形品については、全光線透過率、YI、耐薬品性、耐湿熱サイクル性の測定を行った。
表2に記載した組成に変更した以外は実施例1と同様の操作を実施した。また、実施例1-1~1-10及び比較例1-1~1-5について、上述の方法により各種特性の評価を行った。その結果を表3~表5に示す。
PC-A1のペレット80重量部と、PC-C1の粉体20重量部とをブレンドした後、真空ベントを設けた二軸押出機TEX30HSS[日本製鋼所社製]を使用して、シリンダー温度260℃、押出量12kg/hrにて押出混練を行い、ポリカーボネート樹脂組成物のペレットを得た(表7参照)。得られたペレットは白濁していた。このペレットを用いて、動的粘弾性測定によるガラス転移温度を測定した結果、ガラス転移温度が2つ検出された。この結果から、PC-A1とPC-C1は非相溶であると判断できる。
PC-A1のペレット80重量部と、PA-C1の粉体20重量部とを用いて、押出機のシリンダー温度を240℃とした以外は参考例1と同様に行った(表7参照)。得られたペレットは白濁しており、ガラス転移温度が2つ検出されたことからPC-A1とPA-C1は非相溶であると判断できる。
PC-B3のペレット80重量部と、PC-C1の粉体20重量部とを用いた以外は参考例1と同様に行った(表7参照)。得られたペレットは透明であり、ガラス転移温度はPC-B3とPC-C1のそれぞれ単体のガラス転移温度の間の位置に1つ検出されたことからPC-B3とPC-C1は相溶していると判断できる。
PC-B3のペレット80重量部と、PA-C1の粉体20重量部とを用いて、押出機のシリンダー温度を240℃とした以外は参考例1と同様に行った(表7参照)。得られたペレットは透明であり、ガラス転移温度はPC-B3とPA-C1のそれぞれ単体のガラス転移温度の間の位置に1つ検出されたことからPC-B3とPA-C1は相溶していると判断できる。
PC-A1のペレット90重量部と、PC-B1のペレット9.76重量部と、PC-C1の粉体0.24重量部とをブレンドした後、真空ベントを設けた二軸押出機TEX30HSS[日本製鋼所社製]を使用して、シリンダー温度240℃、押出量12kg/hrにて押出混練を行い、ポリカーボネート樹脂組成物のペレットを得た。次いで、樹脂組成物のペレットを温度90℃の熱風乾燥機で5時間乾燥した後、75トン射出成形機EC-75[東芝機械社製]を用いて、射出成形を行った。成形条件は、金型温度:60℃、シリンダー温度:240℃である。このようにして、幅100mm×長さ100mm×厚さ2mmの板状の成形品からなる試験片を得た。さらに同様に成形を行うことにより、ISO引張試験片を得た。ISO引張試験片からは0.25mmノッチを付けたシャルピー衝撃試験片を切り出し、シャルピー衝撃試験を実施した。また、板状の成形品については、全光線透過率、ヘーズ、YI、耐薬品性、耐湿熱サイクル性の測定を行った。その結果を表8に示す。
表3に記載した組成に変更した以外は実施例2-1と同様の操作を実施した。また、実施例2-1~2-8及び比較例2-1~2-3について、上述の方法により各種特性の評価を行った。その結果を表8に示す。
PC-A1のペレット90重量部と、PC-B5のペレット10重量部とをブレンドした後、真空ベントを設けた二軸押出機TEX30HSS[日本製鋼所社製]を使用して、シリンダー温度240℃、押出量12kg/hrにて押出混練を行い、ポリカーボネート樹脂組成物のペレットを得た。前述の方法に従って、ポリカーボネート樹脂組成物の各種特性の評価を行った。その結果を表10に示す。
表10に記載した組成に変更した以外は実施例3-1と同様の操作を実施した。また、実施例3-2、実施例3-3、及び比較例3-1~比較例3-3について、上述の方法によりポリカーボネート樹脂組成物の各種特性の評価を行った。その結果を表10に示す。
Claims (23)
- 前記第1ポリカーボネート樹脂及び第2ポリカーボネート樹脂の少なくとも一方が、脂肪族ジヒドロキシ化合物、脂環式ジヒドロキシ化合物、及び前記式(1)で表されるジヒドロキシ化合物以外のエーテル基含有ジヒドロキシ化合物からなる群より選ばれる1種以上のジヒドロキシ化合物に由来する構造単位を含む、請求項1に記載のポリカーボネート樹脂組成物。
- 前記第1ポリカーボネート樹脂が、前記式(1)で表される構造単位を40重量%以上、80重量%以下含む、請求項1又は2に記載のポリカーボネート樹脂組成物。
- 前記第2ポリカーボネート樹脂が、前記式(1)で表される構造単位を1重量%以上、35重量%以下含む、請求項1~3のいずれか1項に記載のポリカーボネート樹脂組成物。
- 前記第2ポリカーボネート樹脂は、1H-NMRによって測定される数平均分子量が17000以上、50000以下である、請求項1~4のいずれか1項に記載のポリカーボネート樹脂組成物。
- 前記第2ポリカーボネート樹脂は、1H-NMRによって測定される数平均分子量が6000以上、12000以下である、請求項1~4のいずれか1項に記載のポリカーボネート樹脂組成物。
- 前記第2ポリカーボネート樹脂は、測定温度220℃、剪断速度91.2sec-1における溶融粘度が1800Pa・s以上、3000Pa・s以下である、請求項1~6のいずれか1項に記載のポリカーボネート樹脂組成物。
- 前記第2ポリカーボネート樹脂は、測定温度220℃、剪断速度91.2sec-1における溶融粘度が80Pa・s以上、500Pa・s以下である、請求項1~6のいずれか1項に記載のポリカーボネート樹脂組成物。
- 前記第2ポリカーボネート樹脂は、ガラス転移温度が40℃以上、80℃以下である、請求項1~8のいずれか1項に記載のポリカーボネート樹脂組成物。
- 前記第1ポリカーボネート樹脂と前記第2ポリカーボネート樹脂と前記第3ポリカーボネート樹脂と前記アクリル樹脂との合計100重量部に対して、前記第1ポリカーボネート樹脂を60重量部以上95重量部以下、前記第2ポリカーボネート樹脂を3重量部以上40重量部以下、前記第3ポリカーボネート樹脂と前記アクリル樹脂とを合計で0.01重量部以上2重量部以下含有する、請求項11に記載のポリカーボネート樹脂組成物。
- 前記第1ポリカーボネート樹脂のガラス転移温度が90℃以上、160℃以下であり、前記第2ポリカーボネート樹脂のガラス転移温度が40℃以上、110℃以下である、請求項11~13のいずれか1項に記載のポリカーボネート樹脂組成物。
- 請求項1~14のいずれか1項に記載のポリカーボネート樹脂組成物からなる成形品。
- 自動車内装部品又は自動車外装部品である、請求項15に記載の成形品。
- 車載用ディスプレイ、カーナビゲーション、カーオーディオ、コンソールパネル、ダッシュボード又はドアトリム用品に用いられる、請求項15に記載の成形品。
- 請求項1~9のいずれか1項に記載のポリカーボネート樹脂組成物を含有する樹脂層Aと、該樹脂層Aとは異なる樹脂を含有する樹脂層Bとをそれぞれ1層以上有する、積層体。
- 前記積層体の積層方向の断面において、前記樹脂層A及び前記樹脂層Bの積層構造が厚み及び/又は材質において前記積層体の厚みの中心線を挟んで非対称となる、請求項18に記載の積層体。
- 総厚さが10μm以上500μm以下である、請求項18又は19に記載の積層体。
- 前記樹脂層Aと前記樹脂層Bとの厚み比率が、樹脂層B/樹脂層Aで0.02~50である、請求項18~20のいずれか1項に記載の積層体。
- 前記第1ポリカーボネート樹脂のガラス転移温度が90℃以上、160℃以下であり、前記第2ポリカーボネート樹脂のガラス転移温度が40℃以上、80℃以下である、請求項18~22のいずれか1項に記載の積層体。
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WO2023110961A1 (en) * | 2021-12-17 | 2023-06-22 | Covestro Deutschland Ag | At least partially biobased layered structure with good favourable properties |
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Also Published As
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US11873370B2 (en) | 2024-01-16 |
JP7306385B2 (ja) | 2023-07-11 |
KR20210019027A (ko) | 2021-02-19 |
EP3805314A4 (en) | 2021-08-04 |
EP3805314B1 (en) | 2022-09-07 |
JPWO2019235644A1 (ja) | 2021-07-01 |
US20210253788A1 (en) | 2021-08-19 |
CN112262178B (zh) | 2023-02-17 |
CN112262178A (zh) | 2021-01-22 |
EP3805314A1 (en) | 2021-04-14 |
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