Polycarbonate resin composition and molded article made therefrom

Abstract

To provide a polycarbonate resin composition exhibiting excellent thermal stability, moisture and heat resistance, rigidity, and chemical resistance.SOLUTION: A polycarbonate resin composition comprises: 0.002 to 0.28 pt.wt. of a phosphorous-based stabilizer (component C) and 5 to 30 pts.wt. of an inorganic filler (component D) relative to 100 pts.wt. of a resin component composed of (A) an aromatic polycarbonate resin (component A) and (B) a recycled polyethylene terephthalate resin (component B), wherein the content of methyl terephthalate vinyl ester in the component B is less than 5.5 wt.%.SELECTED DRAWING: None

Description

Technical Field

[0001] The present invention relates to a polycarbonate resin composition excellent in heat stability, heat and humidity resistance, rigidity and chemical resistance, and a molded article made therefrom.

Background Art

[0002] A PC / PET alloy obtained by alloying a polycarbonate resin (hereinafter referred to as PC) and a polyethylene terephthalate resin (hereinafter referred to as PET) has excellent mechanical properties and chemical resistance properties, and thus is widely used in the automotive field. Among them, for CO 2 reduction, in recent years, the application of recycled materials (recycled PET) obtained from open sources has become active. The problem in applying recycled PET is that since the quality of recycled PET varies depending on the source of the recycled material, stable heat stability, heat and humidity resistance, rigidity and chemical resistance cannot be ensured. In addition, a method of premixing a phosphorus-based stabilizer with PET as a method of improving the heat stability and heat and humidity resistance of PET has been disclosed. (For example, see Patent Document 1) However, in this method, since a step of kneading the phosphorus-based stabilizer and PET and further kneading with a polycarbonate resin is required, it takes a lot of man-hours and is not preferable in terms of production and economy.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In view of the above, an object of the present invention is to provide a polycarbonate resin composition excellent in heat stability, heat and humidity resistance, rigidity and chemical resistance, and a molded article made therefrom, particularly an automotive exterior part.

Means for Solving the Problems

[0005] As a result of intensive studies to solve the above problems, the present inventors have found that the above problems can be solved by the following configuration and have reached the present invention. 1. A polycarbonate resin composition containing 0.002 to 0.28 parts by weight of a phosphorus-based stabilizer (component C) and 5 to 30 parts by weight of an inorganic filler (component D) with respect to 100 parts by weight of a resin component composed of (A) an aromatic polycarbonate resin (component A) and (B) a recycled polyethylene terephthalate resin (component B), wherein the content of methyl vinyl terephthalate in component B is less than 5.5% by weight. 2. The polycarbonate resin composition according to item 1 above, wherein component D is a silicate mineral. 3. A molded article comprising the polycarbonate resin composition according to item 1 or 2 above. 4. The molded article according to item 3 above, which is an automobile exterior part.

Effects of the Invention

[0006] The polycarbonate resin composition of the present invention is excellent in thermal stability, heat and humidity resistance, rigidity, and chemical resistance, and thus is widely useful in various applications such as electrical and electronic applications, mechanical applications, OA applications, automobile exterior parts, medical applications, and other various applications. In particular, it provides a molded article that is extremely useful as an automobile exterior part, and the industrial effect of the present invention is extremely large.

Modes for Carrying Out the Invention

[0007] Hereinafter, the details of the present invention will be further described.

[0008] <Component A: Aromatic Polycarbonate Resin> The aromatic polycarbonate resin used in the present invention is obtained by reacting a dihydric phenol with a carbonate precursor. Examples of the reaction method include an interfacial polycondensation method, a melt transesterification method, a solid-phase transesterification method of a carbonate prepolymer, and a ring-opening polymerization method of a cyclic carbonate compound.

[0009] Typical examples of the diphenols used herein include hydroquinone, resorcinol, 4,4'-dihydroxydiphenyl, bis(4-hydroxyphenyl)methane, bis{(4-hydroxy-3,5-dimethyl)phenyl}methane, 1,1-bis(4-hydroxyphenyl)ethane, 1,1-bis(4-hydroxyphenyl)-1-phenylethane, 2,2-bis(4-hydroxyphenyl)propane (commonly known as bisphenol A), 2,2-bis{(4-hydroxy-3-methyl)phenyl}propane, 2,2-bis{(4-hydroxy-3,5-dimethyl)phenyl}propane, 2,2-bis{(3-isopropyl-4-hydroxy)phenyl}propane, 2,2-bis{(4-hydroxy-3-phenyl)phenyl}propane, 2,2-bis(4-hydroxyphenyl)butane, 2,2-bis(4-hydroxyphenyl)-3-methylbutane, 2,2-bis(4-hydroxyphenyl)-3,3-dimethylbutane, 2,4-bis(4-hydroxyphenyl)-2-methylbutane, 2,2-bis(4-hydroxyphenyl)pentane, 2,2-bis(4-hydroxyphenyl)-4-methylpentane, 1,1-bis(4-hydroxyphenyl)cyclohexane, 1,1-bis(4-hydroxyphenyl)-4-isopropylcyclohexane, 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, 9,9-bis(4-hydroxyphenyl)fluorene, 9,9-bis{(4-hydroxy-3-methyl)phenyl}fluorene, α,α'-bis(4-hydroxyphenyl)-o-diisopropylbenzene, α,α'-bis(4-hydroxyphenyl)-m-diisopropylbenzene, α,α'-bis(4-hydroxyphenyl)-p-diisopropylbenzene, 1,3-bis(4-hydroxyphenyl)-5,7-dimethyladamantane, 4,4'-dihydroxydiphenyl sulfone, 4,4'-dihydroxydiphenyl sulfoxide, 4,4'-dihydroxydiphenyl sulfide, 4,4'-dihydroxydiphenyl ketone, 4,4'-dihydroxydiphenyl ether, and 4,4'-dihydroxydiphenyl ester, etc. These can be used alone or in admixture of two or more thereof.

[0010] Among them, a homopolymer or copolymer obtained from at least one bisphenol selected from the group consisting of bisphenol A, 2,2-bis{(4-hydroxy-3-methyl)phenyl}propane, 2,2-bis(4-hydroxyphenyl)butane, 2,2-bis(4-hydroxyphenyl)-3-methylbutane, 2,2-bis(4-hydroxyphenyl)-3,3-dimethylbutane, 2,2-bis(4-hydroxyphenyl)-4-methylpentane, 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, and α,α'-bis(4-hydroxyphenyl)-m-diisopropylbenzene is preferred. In particular, a homopolymer of bisphenol A and a copolymer of 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane and bisphenol A, 2,2-bis{(4-hydroxy-3-methyl)phenyl}propane or α,α'-bis(4-hydroxyphenyl)-m-diisopropylbenzene are preferably used.

[0011] As the carbonate precursor, carbonyl halide, carbonate ester, haloformate, etc. are used, and specifically, phosgene, diphenyl carbonate, dihaloformate of dihydric phenol, etc. are mentioned.

[0012] When producing an aromatic polycarbonate resin by reacting the above dihydric phenol and carbonate precursor by an interfacial polycondensation method or a melt transesterification method, a catalyst, a terminal stopper, an antioxidant for the dihydric phenol, etc. may be used as necessary. Also, the aromatic polycarbonate resin may be a branched aromatic polycarbonate resin copolymerized with a polyfunctional aromatic compound having three or more functional groups, a polyester carbonate resin copolymerized with an aromatic or aliphatic dicarboxylic acid, or a mixture of two or more of the obtained aromatic polycarbonate resins.

[0013] Reaction methods such as the interfacial polymerization method, melt transesterification method, solid-phase transesterification method of carbonate prepolymer, and ring-opening polymerization method of cyclic carbonate compound in the method for producing an aromatic polycarbonate resin of the present invention are methods well known in various literatures and patent gazettes. The viscosity-average molecular weight of the aromatic polycarbonate resin is not specified, but if the viscosity-average molecular weight is less than 1×10 4 , the high-temperature characteristics and the like deteriorate, and if it exceeds 4×10 4 , the moldability deteriorates. Therefore, those represented by the viscosity-average molecular weight of 1×10 4 to 4×10 4 are preferable, those of 1.4×10 4 to 3×10 4 are more preferable, and those of 1.6×10 4 to 2.5×10 4 are even more preferable.

[0014] Two or more kinds of aromatic polycarbonate resins may be mixed. In this case, it is of course possible to mix an aromatic polycarbonate resin having a viscosity-average molecular weight outside the above range.

[0015] The viscosity-average molecular weight referred to in the present invention is obtained by inserting the specific viscosity (η SP ) of a solution prepared by dissolving 0.7 g of an aromatic polycarbonate resin in 100 ml of methylene chloride at 20°C into the following formula. η SP / c = [η] + 0.45×[η] 2 c (where [η] is the intrinsic viscosity) [η] = 1.23×10 -4 M 0.83 c = 0.7

[0016] The content of component A is preferably 43 to 88 parts by weight, more preferably 45 to 85 parts by weight, even more preferably 48 to 80 parts by weight, and particularly preferably 50 to 75 parts by weight in 100 parts by weight in total of component A and component B. If the content of component A is less than 43 parts by weight, the thermal stability may deteriorate, and if it exceeds 88 parts by weight, the fluidity may deteriorate.

[0017] <Component B: Recycled polyethylene terephthalate resin> The recycled polyethylene terephthalate resin used in the present invention is preferably a resin produced by pelletizing the end materials of molded products or films of polyethylene terephthalate resin, but is not limited thereto.

[0018] The content of Component B is preferably 12 to 57 parts by weight, more preferably 15 to 55 parts by weight, still more preferably 20 to 52 parts by weight, and particularly preferably 25 to 50 parts by weight in 100 parts by weight in total of Component A and Component B. If the content of Component B is less than 12 parts by weight, the fluidity may deteriorate, and if it exceeds 57 parts by weight, the thermal stability may deteriorate.

[0019] The content of methyl vinyl terephthalate in Component B needs to be less than 5.5% by weight, more preferably less than 4.7% by weight, and still more preferably less than 3.5% by weight. When the amount of methyl vinyl terephthalate exceeds 5.5% by weight, the low-molecular-weight methyl vinyl terephthalate promotes the decomposition of the resin, thereby deteriorating the thermal stability, moisture and heat resistance, and chemical resistance. The lower limit of the content of methyl vinyl terephthalate is not particularly limited, but it is preferably 0% by weight. The content of methyl vinyl terephthalate can be reduced by, in addition to selecting the recycling source of the recovered polyethylene terephthalate resin, performing washing using an acid, a base, an organic solvent, etc. The content of methyl vinyl terephthalate in Component B can be analyzed by performing reaction thermal decomposition GC-MS.

[0020] <Component C: Phosphorus-based stabilizer> Examples of the phosphorus stabilizer used in the present invention include phosphorous acid, phosphoric acid, phosphonic acid, phosphonic acid, and their esters, and tertiary phosphine. Among these, phosphorous acid, phosphoric acid, phosphonic acid, phosphonic acid and its esters, triorganophosphate compounds, acid phosphate compounds and their metal salts are particularly preferred. In addition, the organic group in the acid phosphate compound includes any of monosubstituted, disubstituted, and mixtures thereof. The same shall apply to the following exemplary compounds corresponding to the compound, including any of them.

[0021] Examples of the triorganophosphate compound include trimethyl phosphate, triethyl phosphate, tributyl phosphate, trioctyl phosphate, tridecyl phosphate, tridodecyl phosphate, trilauryl phosphate, tristearyl phosphate, tricresyl phosphate, triphenyl phosphate, trichlorophenyl phosphate, diphenyl cresyl phosphate, diphenyl monoorthoxenyl phosphate, tributoxyethyl phosphate, etc. Among these, trialkyl phosphate is preferred. The carbon number of such trialkyl phosphate is preferably 1 to 22, more preferably 2 to 20. Particularly preferred trialkyl phosphate is trimethyl phosphate.

[0022] Examples of the acid phosphate compound include methyl acid phosphate, ethyl acid phosphate, butyl acid phosphate, butoxyethyl acid phosphate, octyl acid phosphate, decyl acid phosphate, lauryl acid phosphate, stearyl acid phosphate, oleyl acid phosphate, behenyl acid phosphate, phenyl acid phosphate, nonylphenyl acid phosphate, cyclohexyl acid phosphate, phenoxyethyl acid phosphate, alkoxypolyethylene glycol acid phosphate, and bisphenol A acid phosphate. Among these, long-chain dialkyl acid phosphates having 10 or more carbon atoms are effective in improving the thermal stability, and are preferred because the acid phosphate itself has high stability.

[0023] As the acid phosphate metal salt, zinc monostearyl phosphate and zinc distearyl phosphate are preferred.

[0024] Examples of the phosphite compound include triphenyl phosphite, tris(nonylphenyl) phosphite, tridecyl phosphite, trioctyl phosphite, trioctadecyl phosphite, didecyl monophenyl phosphite, dioctyl monophenyl phosphite, diisopropyl monophenyl phosphite, monobutyl diphenyl phosphite, monodecyl diphenyl phosphite, monooctyl diphenyl phosphite, tris(diethylphenyl) phosphite, tris(di-iso-propylphenyl) phosphite, tris(di-n-butylphenyl) phosphite, tris(2,4-di-tert-butylphenyl) phosphite, tris(2,6-di-tert-butylphenyl) phosphite, distearyl pentaerythritol diphosphite, bis(2,4-di-tert-butylphenyl) pentaerythritol diphosphite, bis(2,6-di-tert-butyl-4-methylphenyl) pentaerythritol diphosphite, bis(2,6-di-tert-butyl-4-ethylphenyl) pentaerythritol diphosphite, bis{2,4-bis(1-methyl-1-phenylethyl)phenyl} pentaerythritol diphosphite, phenyl bisphenol A pentaerythritol diphosphite, bis(nonylphenyl) pentaerythritol diphosphite, dicyclohexyl pentaerythritol diphosphite, and the like.

[0025] As other phosphite compounds, those having a cyclic structure formed by reacting with divalent phenols can also be used. Examples thereof include 2,2'-methylenebis(4,6-di-tert-butylphenyl)(2,4-di-tert-butylphenyl) phosphite, 2,2'-methylenebis(4,6-di-tert-butylphenyl)(2-tert-butyl-4-methylphenyl) phosphite, 2,2-methylenebis(4,6-di-tert-butylphenyl) octyl phosphite, and the like.

[0026] Examples of phosphonite compounds include tetrakis(2,4-di-tert-butylphenyl)-4,4'-biphenylenediphosphonite, tetrakis(2,4-di-tert-butylphenyl)-4,3'-biphenylenediphosphonite, tetrakis(2,4-di-tert-butylphenyl)-3,3'-biphenylenediphosphonite, tetrakis(2,6-di-tert-butylphenyl)-4,4'-biphenylenediphosphonite, tetrakis(2,6-di-tert-butylphenyl)-4,3'-biphenylenediphosphonite, tetrakis(2,6-di-tert-butylphenyl)-3,3'-biphenylenediphosphonite, bis(2,4-di-tert-butylphenyl)-4-phenyl-phenylphosphonite, bis(2,4-di-tert-butylphenyl)-3-phenyl-phenylphosphonite, bis(2,6-di-n-butylphenyl)-3-phenyl-phenylphosphonite, bis(2,6-di-tert-butylphenyl)-4-phenyl-phenylphosphonite, bis(2,6-di-tert-butylphenyl)-3-phenyl-phenylphosphonite, etc. Among them, tetrakis(di-tert-butylphenyl)-biphenylenediphosphonite and bis(di-tert-butylphenyl)-phenyl-phenylphosphonite are preferred, and tetrakis(2,4-di-tert-butylphenyl)-biphenylenediphosphonite and bis(2,4-di-tert-butylphenyl)-phenyl-phenylphosphonite are more preferred. Such phosphonite compounds can be preferably used in combination with phosphite compounds having an aryl group substituted with two or more of the above alkyl groups.

[0027] Examples of phosphonate compounds include dimethyl benzenephosphonate, diethyl benzenephosphonate, dipropyl benzenephosphonate, etc.

[0028] Examples of the tertiary phosphine include triethylphosphine, tripropylphosphine, tributylphosphine, trioctylphosphine, triamylphosphine, dimethylphenylphosphine, dibutylphenylphosphine, diphenylmethylphosphine, diphenyloctylphosphine, triphenylphosphine, tri-p-tolylphosphine, trinaphthylphosphine, diphenylbenzylphosphine and the like. Particularly preferred tertiary phosphine is triphenylphosphine.

[0029] As the phosphonate compound, phosphonic acid monoester, phosphonic acid diester and phosphonic acid triester can be used, with phosphonic acid triester being preferred. The carbon number of the ester can be various combinations from 1 to 22, and triethyl phosphonoacetate is most preferred.

[0030] Suitable phosphorus stabilizers are phosphonite compounds represented by the following formula (1), acid phosphate compounds represented by the following formula (2), acid phosphate metal salts represented by the following formula (3), phosphonate compounds represented by the following formula (4) and phosphonate compounds represented by the following formula (5).

[0031]

Chemical formula

[0032] [In formula (1), R and R’ represent an alkyl group having 6 to 30 carbon atoms, an aryl group having 6 to 30 carbon atoms or an alkylaryl group, and may be the same as or different from each other.]

[0033] O=P(OH) m (OR) 3-m (2) [In formula (2), R is an alkyl group or an aryl group, and may be the same as or different from each other. m is an integer of 0 to 2.]

[0034]

Chemical formula

[0035] [In formula (3), R and R' represent an alkyl group having 6 to 30 carbon atoms, an aryl group having 1 to 22 carbon atoms, or an alkylaryl group, and may be the same as or different from each other.]

[0036] [Chemical formula]

[0037] [In formula (4), R represents an alkyl group having 1 to 22 carbon atoms, an aryl group having 6 to 22 carbon atoms, or an alkylaryl group.]

[0038] [Chemical formula]

[0039] [In formula (5), R, R', and R'' represent an alkyl group having 1 to 22 carbon atoms, an aryl group having 6 to 22 carbon atoms, or an alkylaryl group, and may be the same as or different from each other.]

[0040] The stabilizer having the above as the main component is commercially available and can be used as SONGNOX6260PW (trademark, manufactured by SONGWON), AX-71 (trademark, manufactured by ADEKA), JP-518Zn (trademark, manufactured by Johoku Chemical Co., Ltd.), and JC-224 (trademark, manufactured by Johoku Chemical Co., Ltd.).

[0041] The content of component C is 0.002 to 0.28 parts by weight, preferably 0.03 to 0.25 parts by weight, and more preferably 0.05 to 0.21 parts by weight with respect to a total of 100 parts by weight of components A and B. When the content of component C is less than 0.002 parts by weight, the thermal stability deteriorates, and when it exceeds 0.28 parts by weight, the thermal stability and chemical resistance deteriorate.

[0042] [Component D: Inorganic filler] The inorganic filler used in the present invention is preferably a silicate mineral such as mica, wollastonite, and talc, more preferably mica and wollastonite, and even more preferably wollastonite. The number average fiber length of wollastonite is preferably 2 to 10 μm, more preferably 3 to 9 μm, and even more preferably 3 μm to 8 μm. When the number average fiber length is less than 2 μm, the effect of improving rigidity may be small, and when it exceeds 10 μm, the decrease in impact resistance may be large.

[0043] Wollastonite may be surface-treated with a coupling agent such as a silane-based coupling agent or a titanate-based coupling agent. Examples of the silane-based coupling agent include epoxy silane, amino silane, and vinyl silane. Examples of the titanate-based coupling agent include those of the monoalkoxy type, chelate type, and coordinate type. The method for surface-treating wollastonite with a coupling agent is not particularly limited and can be carried out by a normal method. For example, it can be carried out by adding 0.1 to 10% by weight of the coupling agent to wollastonite and mixing at high speed while heating.

[0044] The content of component D is 5 to 30 parts by weight, preferably 5 to 25 parts by weight, more preferably 8 to 20 parts by weight, and even more preferably 10 to 18 parts by weight, based on 100 parts by weight in total of components A and B. When the content of component D is less than 5 parts by weight, the rigidity decreases, and when it exceeds 30 parts by weight, the thermal stability deteriorates.

[0045] <Other components> <Impact modifier> An impact modifier can be blended into the resin composition of the present invention. Examples of the impact modifier include core-shell types in which a vinyl monomer is graft-polymerized onto a composite rubber composed of an acrylic polymer and a polyorganosiloxane, and they are commercially available as "Metablen S2001", "Metablen S2030", "Metablen S2130", and "Metablen SX006" manufactured by Mitsubishi Rayon Co., Ltd. The content of the impact modifier is preferably 0 to 10 parts by weight, more preferably 1 to 8 parts by weight, based on 100 parts by weight in total of Component A and Component B. If the content exceeds 10 parts by weight, the rigidity may decrease.

[0046] <Release agent> For the purpose of improving the productivity during molding and the dimensional accuracy of the molded article of the resin composition of the present invention, known release agents such as fatty acid esters, polyolefin waxes, silicone compounds, fluorine compounds (fluorine oils typified by polyfluoroalkyl ethers, etc.), paraffin waxes, and beeswax can also be blended.

[0047] Such fatty acid esters are esters of aliphatic alcohols and aliphatic carboxylic acids. Such aliphatic alcohols may be monohydric alcohols or polyhydric alcohols having two or more valences. The carbon number of the alcohol is preferably 3 to 32, more preferably 5 to 30. On the other hand, the aliphatic carboxylic acid is preferably an aliphatic carboxylic acid having 3 to 32 carbon atoms, more preferably 10 to 30 carbon atoms. Among them, saturated aliphatic carboxylic acids are preferred. Fatty acid esters are preferred in that all esters (full esters) have excellent thermal stability at high temperatures. The acid value of the fatty acid ester is preferably 20 or less (substantially 0 can be taken). The hydroxyl value of the fatty acid ester is preferably in the range of 0.1 to 30. Further, the iodine value of the fatty acid ester is preferably 10 or less (substantially 0 can be taken). These properties can be determined by the methods specified in JIS K 0070.

[0048] Examples of polyolefin waxes include those having a molecular weight of 1,000 to 10,000, such as homopolymers or copolymers of ethylene alone, homopolymers or copolymers of α-olefins having 3 to 60 carbon atoms, or copolymers of ethylene and α-olefins having 3 to 60 carbon atoms. Such molecular weight is the number average molecular weight measured in terms of standard polystyrene by the GPC (gel permeation chromatography) method. The upper limit of such number average molecular weight is more preferably 6,000, and even more preferably 3,000. The number of carbon atoms of the α-olefin component in the polyolefin wax is preferably 60 or less, and more preferably 40 or less. More preferred specific examples include propylene, 1-butene, 1-hexene, 4-methyl-1-pentene, and 1-octene. Preferred polyolefin waxes are homopolymers of ethylene or copolymers of ethylene and α-olefins having 3 to 60 carbon atoms. The proportion of α-olefins having 3 to 60 carbon atoms is preferably 20 mol% or less, and more preferably 10 mol% or less. Those commercially available as so-called polyethylene waxes are preferably used.

[0049] The content of the release agent is preferably 0.005 to 5 parts by weight, more preferably 0.01 to 4 parts by weight, and even more preferably 0.02 to 3 parts by weight based on 100 parts by weight in total of Component A and Component B.

[0050] <Colorant> The resin composition of the present invention can further contain various colorants to provide molded articles exhibiting various design properties. Examples of the dyes and pigments used in the present invention include perylene dyes, coumarin dyes, thioindigo dyes, anthraquinone dyes, thioxanthone dyes, ferrocyanides such as ultramarine, perinone dyes, quinoline dyes, quinacridone dyes, dioxazine dyes, isoindolinone dyes, phthalocyanine dyes, carbon black, and the like.

[0051] The resin composition of the present invention can also be blended with a metallic pigment to obtain a better metallic color. As the metallic pigment, aluminum powder is preferred. Further, by blending a fluorescent brightening agent or other fluorescent dyes that emit light, a better design effect utilizing the emission color can be imparted.

[0052] Examples of the fluorescent dyes (including fluorescent brightening agents) used in the present invention include coumarin-based fluorescent dyes, benzopyran-based fluorescent dyes, perylene-based fluorescent dyes, anthraquinone-based fluorescent dyes, thioindigo-based fluorescent dyes, xanthene-based fluorescent dyes, xanthone-based fluorescent dyes, thioxanthene-based fluorescent dyes, thiazine-based fluorescent dyes, and diamino stilbene-based fluorescent dyes. Among these, coumarin-based fluorescent dyes, benzopyran-based fluorescent dyes, and perylene-based fluorescent dyes, which have good heat resistance and little deterioration during the molding process of polycarbonate resin, are preferred.

[0053] The content of the coloring material is preferably 0.00001 to 1 part by weight, more preferably 0.00005 to 0.5 part by weight, based on 100 parts by weight in total of Component A and Component B.

[0054] <Regarding the production method of the resin composition> The production of the polycarbonate resin composition of the present invention can be carried out by any method. For example, it is produced by kneading with a single-screw or multi-screw extruder. The aromatic polycarbonate resin, recycled polyethylene terephthalate resin, phosphorus-based stabilizer, and inorganic filler can be mixed together, or a part of the components can be mixed first and then mixed and kneaded with the remaining part. The polycarbonate resin composition thus obtained can be molded into automotive parts, electrical and electronic parts, etc. by various known methods, such as injection molding and extrusion molding.

Examples

[0055] Hereinafter, the polycarbonate resin composition of the present invention will be specifically described based on examples. "Parts" in the following measurement conditions and examples represent "parts by weight", respectively.

[0056] <Materials Used> <Component A: Aromatic Polycarbonate Resin> A-1: L-1225WX (trade name) (manufactured by Teijin Limited, viscosity average molecular weight 19,700) A-2: CM-1000 (trade name) (manufactured by Teijin Limited, viscosity average molecular weight 16,000)

[0057] <Component B: Recycled Polyethylene Terephthalate Resin> B-1: 352R (trade name) (manufactured by Nan Ya, IV: 0.54, recycled aromatic polyethylene terephthalate resin, amount of methyl vinyl ester of terephthalic acid 0%) B-2: 368R (trade name) (manufactured by Nan Ya, IV: 0.69, recycled aromatic polyethylene terephthalate resin, amount of methyl vinyl ester of terephthalic acid 2.9%) B-3: 358R (trade name) (manufactured by Nan Ya, IV: 0.58, recycled aromatic polyethylene terephthalate resin, amount of methyl vinyl ester of terephthalic acid 3.3%) B-4 (comparative example): Yellow (trade name) (manufactured by Toyo Chemical, IV: 0.57, recycled aromatic polyethylene terephthalate resin, amount of methyl vinyl ester of terephthalic acid 5.9%)

[0058] <Component C: Phosphorus Stabilizer> C-1: AX-71 (trade name) (manufactured by ADEKA, octadecyl phosphate) C-2: 6260PW (trade name) (manufactured by SNGWON, bis(2,4-di-tert-butylphenyl)pentaerythritol diphosphite) C-3: JC-224 (trade name) (manufactured by Johoku Chemical Industry, ethyldiethylphosphonoacetate) C-4: JP-518Zn (trade name) (manufactured by Johoku Chemical Industry, zinc salt of stearyl acid phosphate)

[0059] <Component D: Inorganic Filler> D-1: KGP-H40 (trade name) (manufactured by Kansai Mattech, average fiber length 6.5 μm, wollastonite) D-2: GM-6 (Trade Name) (manufactured by GreaMinerals, average fiber length 17 μm, mica) D-3: Victolite TK-RC (Trade Name) (manufactured by Kosei Kogyosho, average fiber length 7.5 μm, talc) <Other Components> (Impact Modifier) E-1: S2001 (Trade Name) (manufactured by Mitsubishi Chemical, silicon-acrylic impact modifier) E-2: S2030 (Trade Name) (manufactured by Mitsubishi Chemical, silicon-acrylic impact modifier) E-3: S2130 (Trade Name) (manufactured by Mitsubishi Chemical, silicon-acrylic impact modifier) (Release Agent) E-4: EW-400 (Trade Name) (manufactured by Riken Vitamin, special fatty acid ester) (Colorant) E-5: ROYAL BLACK 90003S (Trade Name) (manufactured by Kotani Kasei Kogyo, masterbatch composed of carbon black and PS resin)

[0060] (Manufacture of Resin Composition) (Examples 1 - 17, Comparative Examples 1 - 5) The components shown in Table 1 were premixed at the ratios shown in Table 1, and using a twin-screw extruder [TEX30α-31 manufactured by Nippon Steel Works], they were melt-kneaded at a screw rotation speed of 200 rpm, a discharge rate of 20 kg / h, and a vent vacuum degree of 0 kPa to obtain pellets. The extrusion temperature was carried out at 270°C from the first feed port to the die part.

[0061] (Evaluation Method) The obtained pellets were dried in a hot air circulation dryer at 120°C for 5 hours or more, and then judged by the following evaluation method. The results are shown in Table 1. 1. Thermal Stability Evaluation Using an injection molding machine [ROBOSHOT α―S100iA manufactured by Fanuc], a plate (thickness 2 mm, width 5 cm, length 9 cm) was molded by retaining it at a cylinder temperature of 280°C and a mold temperature of 80°C for 10 minutes, and the appearance at that time was observed with the naked eye and judged according to the following criteria. ○: The area where silver occurred is less than 10 cm 2 less than. ×: The area where silver has occurred is 10 cm 2 or more.

[0062] 2. Evaluation of Damp Heat Resistance Using a highly accelerated life test device [EHS-412MD, manufactured by ESPEC], the pellets were subjected to damp heat treatment at 110 °C × 100% RH × 24 hours. Next, the MVR of the pellets before and after the treatment was measured under the conditions of 280 °C × 1.2 Kgf, and the value of ΔMVR (MVR after treatment - MVR before treatment) was calculated and judged according to the following criteria. ○: ΔMVR is less than 20. ×: ΔMVR is 20 or more.

[0063] 3. Chemical Resistance Evaluation Using a three-point bending jig for chemical resistance testing and an injection molding machine [ROBOSHOT α-S100iA, manufactured by FANUC], a strain was applied to a 4-mm-thick test piece created at a cylinder temperature of 280 °C and a mold temperature of 80 °C. 2 mL of gasoline was applied to the center of the test piece, and a chemical resistance test was conducted under the conditions of 23 °C × 50% RH × 24 hours and judged according to the following criteria. ○: Cracks leading to test piece fracture do not occur at a strain of 1.8%. ×: Cracks leading to test piece fracture occur at a strain of 1.8%.

[0064] 4. Rigidity Evaluation In accordance with ISO 178, using an injection molding machine [ROBOSHOT α-S100iA, manufactured by FANUC], the flexural modulus was measured using a 4-mm-thick strip-shaped test piece created at a cylinder temperature of 280 °C and a mold temperature of 80 °C and judged according to the following criteria. ○: The flexural modulus is 3500 MPa or more. ×: The flexural modulus is less than 3500 MPa.

[0065]

Table 1

[0066] As shown in Table 1, according to the resin composition of the present invention, a polycarbonate resin composition excellent in thermal stability, heat and humidity resistance, rigidity, and chemical resistance can be provided.

Industrial Applicability

[0067] The resin composition and molded article of the present invention can be used for automotive exterior parts typified by housings, interior panels, roof spoilers, window garnishes, roof panels, etc. of electric, electronic, and OA equipment.

Claims

1. A polycarbonate resin composition comprising 100 parts by weight of a resin component composed of (A) an aromatic polycarbonate resin (component A) and (B) a recycled polyethylene terephthalate resin (component B), containing 0.002 to 0.28 parts by weight of (C) a phosphorus-based stabilizer (component C) and 5 to 30 parts by weight of (D) an inorganic filler (component D), wherein the content of methyl vinyl terephthalate in component B is less than 5.5% by weight.

2. The polycarbonate resin composition according to claim 1, wherein component D is a silicate mineral.

3. A molded article comprising the polycarbonate resin composition according to claim 1 or 2.

4. The molded article according to claim 3, which is an automotive exterior part.

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