Resin composition, method for producing resin composition, and resin molding

Abstract

To provide a resin composition that uses polybutylene terephthalate resin and recycled polycarbonate resin, and has low metal corrosion property.SOLUTION: A resin composition includes polybutylene terephthalate resin (A) and recycled polycarbonate resin (B), where an amount of halogenated aromatic organic solvent (S) contained in the resin composition which is measured by a headspace gas chromatography (150°C, heating for 1 hour) is 0.005 ppm or more and less than 0.5 ppm for the total amount of the resin composition.SELECTED DRAWING: None

Description

Technical Field

[0001] Embodiments of the present invention relate to a resin composition, a method for producing the resin composition, and a resin molded article.

Background Art

[0002] Polybutylene terephthalate resin (hereinafter, also referred to as "PBT resin") is excellent in various properties such as mechanical properties, electrical properties, heat resistance, chemical resistance, and solvent resistance. Therefore, as an engineering plastic, it is widely used in various applications such as automotive parts and electrical and electronic parts.

[0003] It is known that crystalline resins such as PBT resin cause molding shrinkage due to molecular orientation accompanying crystallization during the cooling and solidification process in a mold during molding, for example, in injection molding. And if there is variation in the magnitude of this molding shrinkage for each part of the molded article, deformation such as warping and twisting may also occur in the molded article.

[0004] As one of the causes of the above-mentioned shrinkage variation, for example, anisotropy of the shrinkage rate of the material itself caused by the orientation of the molecular chains of the resin can be cited. For such anisotropy derived from molecular orientation, a countermeasure of alloying with an amorphous resin such as polycarbonate resin (hereinafter, also referred to as "PC resin") is known in order to suppress the molecular orientation itself due to crystallization. In particular, PC resin has a high Tg among amorphous resins and is suitable for heat-resistant applications.

[0005] On the other hand, from the viewpoint of environmental consideration in recent years, the use of recycled resin has been attracting attention, and PC resin is no exception, and recycling methods and the like are being studied (Patent Documents 1 to 3).

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Patent Document 2

[0007] As a result of investigations by the present inventors, it has been found that when a resin composition containing a recycled polycarbonate resin is used for applications such as electronic products, there is a concern about metal corrosion. An embodiment of the present invention aims to provide a resin composition with low metal corrosiveness, using a polybutylene terephthalate resin and a recycled polycarbonate resin. [Means for Solving the Problems]

[0008] One embodiment of the present invention is a resin composition containing a polybutylene terephthalate resin (A) and a recycled polycarbonate resin (B), wherein the amount of the halogenated aromatic organic solvent (S) contained in the resin composition, measured by headspace gas chromatography (heating at 150°C for 1 hour), is 0.005 ppm or more and less than 0.5 ppm with respect to the total amount of the resin composition. Another embodiment of the present invention relates to a resin molded article obtained using the above-described resin composition. Another embodiment of the present invention is a method for producing a resin composition, which includes melt-kneading a polybutylene terephthalate resin (A) and a recycled polycarbonate resin (B), wherein the amount of the halogenated aromatic organic solvent (S) contained in the resin composition, measured by headspace gas chromatography (heating at 150°C for 1 hour), is 0.005 ppm or more and less than 0.5 ppm with respect to the total amount of the resin composition. [Advantages of the Invention]

[0009] According to an embodiment of the present invention, a resin composition with low metal corrosiveness can be provided by using a polybutylene terephthalate resin and a recycled polycarbonate resin.

Mode for Carrying Out the Invention

[0010] The preferred embodiments of the present invention will be described below, but the present invention is not limited to the following embodiments.

[0011] <Resin Composition> The resin composition of the present embodiment is a resin composition containing polybutylene terephthalate resin (PBT resin) (A) and recycled polycarbonate resin (recycled PC resin) (B), and the amount of the halogenated aromatic organic solvent (S) contained in the resin composition, measured by headspace gas chromatography (heating at 150°C for 1 hour), is 0.005 ppm or more and less than 0.5 ppm with respect to the total amount of the resin composition.

[0012] As described above, through the studies of the present inventors, it has been found that when a resin composition containing recycled PC resin is used in applications such as electronic products, there is a concern about metal corrosion. The present inventors studied the cause and found that metal corrosion may occur when a halogenated aromatic organic solvent such as chlorobenzene is contained in a resin composition containing PBT resin and recycled PC resin. And it has been found that even when recycled PC resin is used, metal corrosion can be suppressed when the halogenated aromatic organic solvent in the resin composition is within a predetermined amount.

[0013] Each component of the resin composition of the present embodiment will be described below. The manufacturing method of this resin composition is not particularly limited, but for example, it can be manufactured by the manufacturing method of the resin composition described later.

[0014] [Polybutylene Terephthalate Resin (A)] The PBT resin (A) contains at least terephthalic acid or its ester-forming derivative (C 1-6It is a resin obtained by polycondensation of a dicarboxylic acid component containing an alkylene glycol (such as an alkyl ester or acid halide of 1,4-butanediol) and a glycol component containing an alkylene glycol having at least 4 carbon atoms (such as 1,4-butanediol) or its ester-forming derivative (such as an acetylated product). The PBT resin (A) is not limited to a homopolybutylene terephthalate resin, but may also be a copolymer containing 60 mol % or more (particularly 75 mol % to 95 mol %) of butylene terephthalate units. In this embodiment, 1,4-butanediol and terephthalic acid or terephthalic acid alkyl ester, which are raw materials for the PBT resin, may be derived from either fossil resources or biomass resources. The PBT resin (A) can be used alone or in combination of two or more.

[0015] From the viewpoint of hydrolysis resistance, the amount of terminal carboxyl groups in the PBT resin (A) is preferably 30 meq / kg or less, more preferably 25 meq / kg or less, and even more preferably 20 meq / kg or less. From the viewpoint of adhesion to an inorganic filler, the amount of terminal carboxyl groups in the PBT resin (A) is preferably 3 meq / kg or more, more preferably 5 meq / kg or more, and even more preferably 8 meq / kg or more. The amount of terminal carboxyl groups in the PBT resin (A) is, for example, preferably 3 to 30 meq / kg, more preferably 5 to 25 meq / kg, and even more preferably 8 to 20 meq / kg.

[0016] The intrinsic viscosity (IV) of the PBT resin (A) is preferably 0.60 dL / g or more and 1.10 dL / g or less, more preferably 0.65 dL / g or more and 0.90 dL / g or less, and even more preferably 0.70 dL / g or more and 0.85 dL / g or less. The intrinsic viscosity can also be adjusted by blending PBT resins with different intrinsic viscosities. For example, a PBT resin with an intrinsic viscosity of 0.80 dL / g can be prepared by blending a PBT resin with an intrinsic viscosity of 0.60 dL / g with a PBT resin with an intrinsic viscosity of 0.90 dL / g. The intrinsic viscosity (IV) of the PBT resin (A) can be measured, for example, in o-chlorophenol at 35°C.

[0017] In the PBT resin (A), examples of the dicarboxylic acid component (comonomer component) other than terephthalic acid and its ester-forming derivatives include aromatic dicarboxylic acids such as isophthalic acid, phthalic acid, 2,6-naphthalenedicarboxylic acid, 4,4'-dicarboxydiphenyl ether, etc. of C 8-14 ; alkane dicarboxylic acids such as succinic acid, adipic acid, azelaic acid, sebacic acid, etc. of C 4-16 ; cycloalkane dicarboxylic acids such as cyclohexanedicarboxylic acid of C 5-10 ; and ester-forming derivatives of these dicarboxylic acid components (alkyl ester derivatives of C 1-6 , acid halides, etc.). These dicarboxylic acid components can be used alone or in combination of two or more.

[0018] Among these dicarboxylic acid components, aromatic dicarboxylic acids of C 8-12 such as isophthalic acid, and alkane dicarboxylic acids of C 6-12 such as adipic acid, azelaic acid, and sebacic acid are more preferable.

[0019] In the PBT resin (A), examples of the glycol component (comonomer component) other than 1,4-butanediol include alkylene glycols of C 2-10 such as ethylene glycol, propylene glycol, trimethylene glycol, 1,3-butylene glycol, hexamethylene glycol, neopentyl glycol, 1,3-octanediol, etc.; polyoxyalkylene glycols such as diethylene glycol, triethylene glycol, dipropylene glycol, etc.; alicyclic diols such as cyclohexanedimethanol, hydrogenated bisphenol A, etc.; aromatic diols such as bisphenol A, 4,4'-dihydroxybiphenyl, etc.; ethylene oxide 2-molar adducts of bisphenol A, propylene oxide 3-molar adducts of bisphenol A, etc., alkylene oxide adducts of bisphenol A of C 2-4 ; or ester-forming derivatives of these glycols (acetylates, etc.). These glycol components can be used alone or in combination of two or more.

[0020] Among these glycol components, C alkylene glycols such as ethylene glycol and trimethylene glycol, polyoxyalkylene glycols such as diethylene glycol, or alicyclic diols such as cyclohexanedimethanol are more preferable. As comonomer components that can be used in addition to the dicarboxylic acid component and the glycol component, for example, aromatic hydroxycarboxylic acids such as 4-hydroxybenzoic acid, 3-hydroxybenzoic acid, 6-hydroxy-2-naphthoic acid, and 4-carboxy-4'-hydroxybiphenyl; aliphatic hydroxycarboxylic acids such as glycolic acid and hydroxycaproic acid; C lactones such as propiolactone, butyrolactone, valerolactone, and caprolactone (ε-caprolactone, etc.); ester-forming derivatives of these comonomer components (alkyl ester derivatives, acid halides, acetylated products, etc.) can be mentioned. 2-6 ... 3-12 ... 1-6 ...

[0021] All of the polybutylene terephthalate copolymers copolymerized with the comonomer components described above can be suitably used as the PBT resin (A). Also, as the PBT resin (A), a homopolybutylene terephthalate polymer and a polybutylene terephthalate copolymer may be used in combination.

[0022] As the PBT resin (A), recycled products may be used. As recycled products, for example, market recovered products can be used (material recycling). Also, PBT resins produced by decomposing PBT resin waste to the monomer level such as 1,4-butanediol and terephthalic acid (chemical recycling) and polycondensing the obtained raw materials can be used.

[0023] The amount of PBT resin (A) may be 10% by mass or more, 15% by mass or more, or 20% by mass or more based on the total amount of the resin composition. On the other hand, the amount of PBT resin (A) may be 70% by mass or less, 60% by mass or less, or 50% by mass or less based on the total amount of the resin composition. The amount of PBT resin (A) may be, for example, 10 - 70% by mass, 15 - 60% by mass, or 20 - 50% by mass based on the total amount of the resin composition.

[0024] [Recycled polycarbonate resin (B)] Recycled PC resin (B) can be obtained by recycling. Recycled PC resin (B) may be, for example, obtained by material recycling, chemical recycling, etc. In material recycling, for example, recycled PC resin molded products, etc. can be pulverized, washed, etc. to obtain recycled PC resin (B). In chemical recycling, for example, recycled PC resin molded products, etc. can be chemically decomposed to the monomer level, etc., and polycondensed, etc. from the obtained raw materials to obtain recycled PC resin (B). Also, after dissolving the recycled PC resin molded products, etc. in hydrocarbons, halogenated hydrocarbons, etc., foreign substances can be removed, a poor solvent, etc. can be added for separation, and the crystallized product may be used.

[0025] PC resin can be produced by a solvent method, that is, by the reaction of a divalent phenol with a carbonate precursor such as phosgene or the transesterification reaction of a divalent phenol with a carbonate precursor such as diphenyl carbonate in the presence of a known acid acceptor and a molecular weight regulator in a solvent such as methylene chloride. Divalent phenols that can be preferably used here include bisphenols, and particularly 2,2-bis(4-hydroxyphenyl)propane, that is, bisphenol A is preferred. Also, a part or all of bisphenol A may be replaced with other divalent phenols.

[0026] Examples of dihydric phenols other than bisphenol A include compounds such as hydroquinone, 4,4-dihydroxydiphenyl, bis(4-hydroxyphenyl)alkane, bis(4-hydroxyphenyl)cycloalkane, bis(4-hydroxyphenyl)sulfide, bis(4-hydroxyphenyl)sulfone, bis(4-hydroxyphenyl)sulfoxide, bis(4-hydroxyphenyl)ether, or halogenated bisphenols such as bis(3,5-dibromo-4-hydroxyphenyl)propane and bis(3,5-dichloro-4-hydroxyphenyl)propane. These dihydric phenols may be homopolymers or copolymers of two or more types of dihydric phenols. Furthermore, the polycarbonate-based resin may be a thermoplastic random branched polycarbonate obtained by reacting a polyfunctional aromatic with a dihydric phenol and / or a carbonate precursor. From the viewpoint of hydrolysis resistance, a polycarbonate having a high viscosity is preferable, and the melt viscosity at 300 °C and 1000 sec−1 is preferably 0.20 kPa·s or more, more preferably 0.25 kPa·s or more, and most preferably 0.30 kPa·s or more.

[0027] Analysis by the present inventors has revealed that recycled PC resins may contain trace amounts of halogenated aromatic organic solvents. In the production of PC resins, halogenated organic solvents such as dichloromethane may be used during polymerization, but virgin PC resins generally contain little halogenated aromatic organic solvents such as chlorobenzene. It is presumed that in recycled PC resins, the organic solvents used in the recycling process may remain in the recycled PC resins. Note that this is an inference and does not limit the present invention in any way. In the resin composition of the embodiment, the recycled PC resin (B) may contain a halogenated aromatic organic solvent (S). Examples of the halogenated aromatic organic solvent (S) include chlorobenzene, dichlorobenzene, bromobenzene, dibromobenzene, chloronaphthalene, chlorotoluene, chloroxylene, chlorocumene, and the like. The recycled PC resin (B) may contain the halogenated aromatic organic solvent (S) alone or in combination of two or more.

[0028] The amount of the recycled PC resin (B) may be 10% by mass or more, 20% by mass or more, 25% by mass or more, or 30% by mass or more based on the total amount of the resin composition. On the other hand, the amount of the recycled PC resin (B) may be 90% by mass or less, 80% by mass or less, 60% by mass or less, or 50% by mass or less based on the total amount of the resin composition. The amount of the recycled PC resin (B) may be, for example, 10 to 90% by mass, 20 to 80% by mass, 25 to 60% by mass, or 30 to 50% by mass based on the total amount of the resin composition.

[0029] The resin composition may contain, as the PC resin, in addition to the recycled PC resin (B), a PC resin that is not a recycled PC resin (hereinafter also referred to as "virgin PC resin"). The total amount of the PC resin may be, for example, 10 to 90% by mass, 20 to 80% by mass, 25 to 60% by mass, or 30 to 50% by mass based on the total amount of the resin composition. The amount of the recycled PC resin (B) may be, for example, 50% by mass or more or 100% by mass based on the total amount of the PC resin in the resin composition. From the environmental perspective, the larger the amount of the recycled PC resin (B), the more preferable.

[0030] [Halogenated Aromatic Organic Solvent (S)] The resin composition can contain the halogenated aromatic organic solvent (S). The halogenated aromatic organic solvent (S) may be contained in the recycled PC resin (B) which is a material of the resin composition and blended into the resin composition. Examples of the halogenated aromatic organic solvent (S) include chlorobenzene, dichlorobenzene, bromobenzene, dibromobenzene, chloronaphthalene, chlorotoluene, chloroxylene, chlorocumene, and the like. The resin composition may contain the halogenated aromatic organic solvent (S) alone or in combination of two or more.

[0031] From the viewpoint of suppressing metal corrosion, the amount of the halogenated aromatic organic solvent (S) contained in the resin composition is preferably less than 0.5 ppm, more preferably 0.3 ppm or less, and still more preferably 0.2 ppm or less with respect to the total amount of the resin composition.

[0032] The amount of the halogenated aromatic organic solvent contained in the resin composition may be 0.005 ppm or more, 0.01 ppm or more, or 0.05 ppm or more with respect to the total amount of the resin composition. The amount of the halogenated aromatic organic solvent (S) contained in the resin composition is preferably 0.005 ppm or more and less than 0.5 ppm, more preferably 0.01 to 0.3 ppm, and still more preferably 0.05 to 0.2 ppm with respect to the total amount of the resin composition.

[0033] The recycled PC resin (B) used in the resin composition may contain a halogenated aromatic organic solvent (S). From the viewpoint of suppressing metal corrosion, the amount of the halogenated aromatic organic solvent (S) contained in the recycled PC resin (B) is preferably less than 5 ppm, more preferably 3 ppm or less, and even more preferably 1 ppm or less, based on the recycled PC resin (B). On the other hand, the amount of the halogenated aromatic organic solvent (S) contained in the recycled PC resin (B) may be, for example, 0.1 ppm or more, 0.2 ppm or more, or 0.5 ppm or more, based on the recycled PC resin (B). The amount of the halogenated aromatic organic solvent (S) contained in the recycled PC resin (B) is preferably 0.1 ppm or more and less than 5 ppm, more preferably 0.2 to 3 ppm, and even more preferably 0.5 to 1 ppm. The halogenated aromatic organic solvent (S) may volatilize, for example, when heated at the stage of manufacturing the resin composition. In the present disclosure, the amount of the halogenated aromatic organic solvent (S) contained in the recycled PC resin (B) is the amount of the halogenated aromatic organic solvent (S) contained in the recycled PC resin (B) compounded in the manufacture of the resin composition. For example, in the manufacture of the resin composition, when melt-kneading a PBT resin or the like with a recycled PC resin or the like, the amount of the halogenated aromatic organic solvent (S) contained in the recycled PC resin (B) used for the melt-kneading can be within the above range.

[0034] In the present disclosure, the amount of the halogenated aromatic organic solvent (S) contained in the resin composition and the amount of the halogenated aromatic organic solvent (S) contained in the recycled PC resin (B) are both values measured by the headspace gas chromatography method (heating at 150°C for 1 hour). For the measurement of the amount of the halogenated aromatic organic solvent (S) contained in the resin composition, the resin composition is used as a sample, and for the measurement of the amount of the halogenated aromatic organic solvent (S) contained in the recycled PC resin (B), the recycled PC resin compounded in the production of the resin composition is used as a sample. Specifically, the amount of the halogenated aromatic organic solvent (S) contained in the resin composition and the amount of the halogenated aromatic organic solvent (S) contained in the recycled PC resin (B) can both be determined, for example, from the amount of gas generation derived from the halogenated aromatic organic solvent (S) by measuring the generated gas when the sample is heat-treated in the headspace by gas chromatography-mass spectrometry. In the case of pelletized resin compositions, pelletized recycled PC, etc., for example, they can be pulverized into samples as necessary. The amount of the halogenated aromatic organic solvent (S) contained in the resin composition and the amount of the halogenated aromatic organic solvent (S) contained in the recycled PC resin (B) can be measured more specifically, for example, by the method described in the examples.

[0035] [Other components] The resin composition can contain other components as necessary. Examples of other components include, but are not limited to, inorganic fillers, phosphorus-based stabilizers, antioxidants, weather stabilizers, molecular weight regulators, ultraviolet absorbers, antistatic agents, dyes, pigments, lubricants, crystallization accelerators, crystal nucleating agents, near-infrared absorbers, flame retardants, flame retardant aids, organic fillers, colorants, etc.

[0036] As for the shape of the inorganic filler, either fibrous inorganic filler or non-fibrous inorganic filler can be used, but fibrous inorganic filler is preferred.

[0037] Examples of the fibrous inorganic filler include glass fiber, carbon fiber, silica fiber, silica-alumina fiber, zirconia fiber, boron nitride fiber, silicon nitride fiber, boron fiber, potassium titanate fiber, metal fiber (for example, stainless steel, aluminum, titanium, copper, brass, etc.). Representative fibrous inorganic fillers include glass fiber and carbon fiber, and glass fiber is preferably used in terms of easy availability and cost. The type of glass used as the raw material for the glass fiber is not particularly limited, but E glass or corrosion-resistant glass containing zirconium element in the composition is preferably used in terms of quality.

[0038] The average fiber diameter of the fibrous inorganic filler is preferably, for example, 5 to 20 μm, more preferably 8 to 15 μm. The average fiber length of the fibrous inorganic filler is not particularly limited and is preferably, for example, 150 to 600 mm. The average fiber diameter and average fiber length of the fibrous filler are values calculated by weighted average by analyzing an image taken with a CCD camera for the fibrous filler before being blended into the resin composition. For example, it can be calculated using a dynamic image analysis method / particle (state) analyzer PITA-3 manufactured by Seishin Enterprise Co., Ltd.

[0039] The shape of the non-fibrous inorganic filler is not particularly limited, and examples include granular, ellipsoidal, spindle-shaped, plate-shaped, flaky, irregular-shaped, etc. Specific examples of the non-fibrous inorganic filler include silicates such as mica, talc, quartz, calcium silicate, aluminum silicate, kaolin, clay, diatomaceous earth, bentonite, etc.; carbon-based materials such as carbon black and graphite; metal carbonates such as calcium carbonate and magnesium carbonate; metal sulfates such as zinc sulfate, calcium sulfate, and barium sulfate; metal oxides such as zinc oxide, iron oxide, titanium oxide, antimony trioxide, and alumina; glass flakes, glass beads, milled glass fiber, glass balloons, glass powder, etc.; and others such as magnesium hydroxide, boehmite, spherical silica, ferrite, silicon carbide, silicon nitride, boron nitride, and various metal powders, but are not limited thereto.

[0040] The inorganic filler may be used alone or in combination of two or more. The amount of the inorganic filler may be, for example, 5 to 40% by mass, or 10 to 30% by mass based on the total amount of the resin composition.

[0041] Examples of the phosphorus-based stabilizer include phosphorus-based compounds such as organic phosphite compounds, phosphonite compounds, and metal phosphates. Specific examples include bis(2,4-di-t-butylphenyl)pentaerythritol diphosphite, bis(2,4-di-t-butylphenyl)pentaerythritol diphosphite, tetrakis(2,4-di-t-butylphenyl)-4,4'-biphenylene phosphonite, 3,9-bis(2,6-di-t-butyl-4-methylphenoxy)-2,4,8,10-tetraoxa-3,9-diphosphaspiro[5.5]undecane, and the like. Examples of the metal phosphate include alkaline earth metal phosphates such as calcium primary phosphate (calcium dihydrogen phosphate) and alkaline metal phosphates such as sodium primary phosphate (sodium dihydrogen phosphate). The metal phosphate may be, for example, an anhydride or a hydrate. The phosphorus-based stabilizer may be used alone or in combination of two or more. The amount of the phosphorus-based stabilizer may be, for example, 0.01 to 1.0% by mass, or 0.02 to 0.8% by mass based on the total amount of the resin composition.

[0042] [Method for producing resin composition] The method for producing the resin composition described above is not particularly limited. The resin composition can be produced by various methods known as methods for producing thermoplastic resin compositions.

[0043] As a preferred method for producing the resin composition, for example, a method of melt-kneading each component using a melt-kneading device such as a single-screw or twin-screw extruder to obtain extrusion pellets can be mentioned.

[0044] [Resin molded article] The resin molded article of this embodiment can be obtained using the resin composition described above.

[0045] As a method for producing a resin molded product using the above-described resin composition, there are no particular limitations, and known methods can be employed. For example, the materials of the resin composition are put into an extruder, melt-kneaded, and pelletized, and these pellets are put into an injection molding machine equipped with a predetermined mold and injection molded to produce the product.

[0046] The resin molded product of the present embodiment can be suitably used, for example, in applications such as automotive parts and electrical and electronic parts.

[0047] <Manufacturing method of resin composition> The manufacturing method of the resin composition of the embodiment is a manufacturing method of a resin composition including melt-kneading a PBT resin (A) and a recycled PC resin (B), and the amount of the halogenated aromatic organic solvent (S) contained in the resin composition is 0.005 ppm or more and less than 0.5 ppm with respect to the total amount of the resin composition.

[0048] As the PBT resin (A) and the recycled PC resin (B), for example, those described in the above-described resin composition can be used. The amounts of the PBT resin (A) and the recycled PC resin (B) may be, for example, the amounts within the ranges described in the above-described resin composition. The amount of the halogenated aromatic organic solvent (S) contained in the resin composition may be, for example, the amount within the range described as the amount of the halogenated aromatic organic solvent (S) contained in the above-described resin composition. By this manufacturing method, for example, the above-described resin composition can be manufactured. The recycled PC resin (B) may contain the halogenated aromatic organic solvent (S), but the amount of the halogenated aromatic organic solvent (S) contained in the recycled PC resin (B) is preferably, for example, 0.1 ppm or more and less than 5 ppm.

[0049] In the step of melt-kneading PBT resin (A) and recycled PC resin (B), other components may be melt-kneaded together with PBT resin (A) and recycled PC resin (B) as necessary. Examples of other components include those described in the resin composition above. The amount of other components may be, for example, within the range described in the resin composition above. Melt-kneading can be carried out, for example, using an extruder or the like. After melt-kneading, it may be extruded and pelletized. The temperature during melt-kneading (for example, the cylinder temperature) is preferably 250 to 300 °C, more preferably 260 to 280 °C.

[0050] Embodiments of the present invention include the following, but the present invention is not limited to the following embodiments. <1> A resin composition comprising polybutylene terephthalate resin (A) and recycled polycarbonate resin (B), wherein the amount of the halogenated aromatic organic solvent (S) contained in the resin composition, measured by headspace gas chromatography (heating at 150 °C for 1 hour), is 0.005 ppm or more and less than 0.5 ppm with respect to the total amount of the resin composition. <2> The recycled polycarbonate resin (B) contains the halogenated aromatic organic solvent (S), and the amount of the halogenated aromatic organic solvent (S) contained in the recycled polycarbonate resin (B), measured by headspace gas chromatography (heating at 150 °C for 1 hour), is 0.1 ppm or more and less than 5 ppm with respect to the total amount of the recycled polycarbonate resin (B). The resin composition according to <1>. <3> The resin composition according to <1> or <2>, wherein the halogenated aromatic organic solvent (S) contains chlorobenzene. <4> A resin molded article obtained using the resin composition according to any one of <1> to <3>. <5> A method for producing a resin composition, comprising melt-kneading a polybutylene terephthalate resin (A) and a recycled polycarbonate resin (B), wherein the amount of the halogenated aromatic organic solvent (S) contained in the resin composition, as measured by headspace gas chromatography (heating at 150 °C for 1 hour), is 0.005 ppm or more and less than 0.5 ppm with respect to the total amount of the resin composition. <6> The recycled polycarbonate resin (B) contains the halogenated aromatic organic solvent (S), and the amount of the halogenated aromatic organic solvent (S) contained in the recycled polycarbonate resin (B), as measured by headspace gas chromatography (heating at 150 °C for 1 hour), is 0.1 ppm or more and less than 5 ppm with respect to the total amount of the recycled polycarbonate resin (B). The method for producing a resin composition according to <5>.

Examples

[0051] Hereinafter, the present embodiment will be described in more detail with reference to examples, but the present embodiment is not limited to the following examples.

[0052] [Examples 1 to 10, Comparative Examples 1 to 6, Reference Examples] Each component described in Table 1 was melt-kneaded and extruded at a cylinder temperature of 260 °C and a screw rotation speed of 130 rpm using a 30 mmφ twin-screw extruder (manufactured by Japan Steel Works, Ltd., TEX30) at the ratios (mass %) shown in Table 1 to obtain pellets composed of the resin compositions of Examples 1 to 10, Comparative Examples 1 to 6, and Reference Examples, respectively. The details of each component shown in Table 1 are shown below.

[0053] A: Polybutylene terephthalate resin (intrinsic viscosity IV: 0.69 dL / g) manufactured by Polyplastics Co., Ltd.

[0054] B-1: Polycarbonate resin (amount of chlorobenzene: 0 ppm) B-2: Recycled polycarbonate resin (amount of chlorobenzene: 0.16 ppm) B-3: Recycled polycarbonate resin (amount of chlorobenzene: 0.75 ppm) B-4: Recycled polycarbonate resin (chlorobenzene content: 0.95 ppm) B-5: Recycled polycarbonate resin (chlorobenzene content: 5.50 ppm) B-6: Recycled polycarbonate resin (chlorobenzene content: 10.05 ppm)

[0055] C: Glass fiber, "ECS 03 T-187" manufactured by Nippon Electric Glass Co., Ltd. D: Phosphorus-based stabilizer, primary calcium phosphate, manufactured by Daihei Chemical Industry Co., Ltd. E: Lubricant, "Lichemal B-74" manufactured by Riken Vitamin Co., Ltd.

[0056] In the above-mentioned B-1 (PC resin) and B-2 to B-6 (recycled PC resins), the chlorobenzene content is the amount of chlorobenzene contained in each of B-1 to B-6. The amount of chlorobenzene contained in each of B-1 to B-6 and the amount of chlorobenzene contained in each resin composition described in the table are values measured by the headspace gas chromatography method (heating at 150°C for 1 hour). Specifically, for each of B-1 to B-6 and the resin composition, 3 g of pellets were taken, left in a 20 ml headspace at 150°C for 1 hour, and then, using an Agilent headspace autosampler 7697A and a column: FRONTIER UA-5 (30 mm × Φ0.25 mm × t0.1 mm), after holding at 50°C for 2 minutes, the temperature was raised at 10°C / min, and the gas generation amount and compound identification derived from halogenated aromatic compounds were carried out by gas chromatography-mass spectrometry. The identified compound was chlorobenzene.

[0057] [Evaluation] Using the pellets of Examples 1 to 10, Comparative Examples 1 to 6, and the Reference Example, the following corrosion test was carried out.

[0058] (Corrosion Test) 50 g of the pellets of the resin composition were placed together with a 1 cm × 1 cm silver plate in a 300 ml glass screw-capped bottle, the bottle was capped, and after standing still in a gear oven at 180°C for 300 hours, the surface of the silver plate was visually inspected. Those without corrosion were evaluated as A, and those with corrosion were evaluated as B. The results are shown in Table 1.

[0059] [Table 1]

[0060] From Table 1, it can be seen that in the resin compositions of Examples 1 to 10 in which recycled PC resin (B) was used and the amount of the halogenated aromatic organic solvent (S) was 0.005 ppm or more and less than 0.5 ppm based on the total amount of the resin composition, good evaluation results were obtained in the corrosion test, similar to the reference example in which virgin PC resin B-1 was used. On the other hand, in the resin compositions of Comparative Examples 1 to 6 in which recycled PC resin (B) was used and the amount of the halogenated aromatic organic solvent (S) was 0.5 ppm or more based on the total amount of the resin composition, corrosion was observed in all of them in the corrosion test.

Claims

1. A resin composition comprising a polybutylene terephthalate resin (A) and a recycled polycarbonate resin (B), wherein the amount of the halogenated aromatic organic solvent (S) contained in the resin composition, measured by headspace gas chromatography (heating at 150 °C for 1 hour), is 0.005 ppm or more and less than 0.5 ppm with respect to the total amount of the resin composition.

2. The recycled polycarbonate resin (B) contains the halogenated aromatic organic solvent (S), and the amount of the halogenated aromatic organic solvent (S) contained in the recycled polycarbonate resin (B), measured by headspace gas chromatography (heating at 150 °C for 1 hour), is 0.1 ppm or more and less than 5 ppm with respect to the total amount of the recycled polycarbonate resin (B). The resin composition according to Claim 1.

3. The resin composition according to Claim 1 or 2, wherein the halogenated aromatic organic solvent (S) contains chlorobenzene.

4. A resin molded article obtained by using the resin composition according to Claim 1 or 2.

5. A method for producing a resin composition, comprising melt-kneading a polybutylene terephthalate resin (A) and a recycled polycarbonate resin (B), wherein the amount of the halogenated aromatic organic solvent (S) contained in the resin composition, measured by headspace gas chromatography (heating at 150 °C for 1 hour), is 0.005 ppm or more and less than 0.5 ppm with respect to the total amount of the resin composition.

6. The recycled polycarbonate resin (B) contains the halogenated aromatic organic solvent (S), and the amount of the halogenated aromatic organic solvent (S) contained in the recycled polycarbonate resin (B), measured by headspace gas chromatography (heating at 150 °C for 1 hour), is 0.1 ppm or more and less than 5 ppm with respect to the total amount of the recycled polycarbonate resin (B). The method for producing a resin composition according to Claim 5.

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