Thermoplastic resin composition containing amorphous polymer and molded article

Abstract

To provide a thermoplastic resin composition having characteristics more excellent in Charpy impact strength than before extrusion by an extrusion process capable of improving physical properties of the thermoplastic resin composition containing an amorphous polymer.SOLUTION: A thermoplastic resin composition containing an amorphous polymer, wherein when a Charpy impact strength of a thermoplastic resin composition produced by melt-kneading the thermoplastic resin composition with an extruder is defined as (b) and a Charpy impact strength of the thermoplastic resin composition before melt-extruding the thermoplastic resin composition is defined as (a), a value of the Charpy impact strength (b) exceeds a value of the Charpy impact strength (a).SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a thermoplastic resin composition containing an amorphous polymer and a molded article thereof. More specifically, the present invention relates to a thermoplastic resin composition containing an amorphous polymer and a molded article thereof, which exhibits a Charpy impact strength exceeding the value before extrusion through an extrusion process that enables improvement of the physical properties of the thermoplastic resin composition. [Background technology]

[0002] Thermoplastic resins are often formulated to achieve desired physical properties by incorporating multiple inorganic and other polymeric components into the system depending on the application and purpose. However, it has been thought that physical properties such as elongation at break are reduced due to the presence of inorganic and other polymeric components in the system, which can cause breakage initiation points. Furthermore, the use of additives to improve interfacial adhesion between inorganic and other polymeric components and the matrix polymer in thermoplastic resins increases costs.

[0003] In recent years, social demand for environmental friendliness has increased, leading to a growing trend toward recycling petrochemical products, particularly resins. One method for recycling used resins is material recycling, in which recovered used molded products are crushed, washed with a cleaning solution, and then the crushed thermoplastic plastic is separated from the crushed mixture to obtain recycled resin. However, recycled resins have the problem of having lower mechanical properties than virgin resins. This deterioration in mechanical properties is believed to be due to degradation of the resin composition due to hydrolysis, exposure to ultraviolet light, and other factors. Because this phenomenon, known as molecular chain scission, makes recovery impossible, it has been thought impossible to restore the mechanical properties of recycled resins.

[0004] Meanwhile, it has been fundamentally clarified that the cause of the deterioration of the mechanical properties of recycled resins is due to mutations in the internal structure of the polymer, and findings on new molding methods that enable the restoration of physical properties have been proposed. For example, a resin composition molding machine having a resin reservoir section provided between the melt-kneading section and the discharge section has been disclosed, and crystalline polymers containing polyolefin-based resins derived from recycled resins as thermoplastic resins have been disclosed (Patent Documents 1 to 4).

[0005] Resin compositions containing polycarbonate resin, a type of amorphous polymer, are widely used industrially due to their excellent heat resistance, mechanical properties, and electrical characteristics. Furthermore, there is a growing demand, particularly in Europe and the United States, for the use of recycled resins in the exteriors and housings of vehicle parts and electronic devices. Therefore, polycarbonate resin compositions using recycled resins are required to have properties comparable to or superior to those of virgin resins. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Patent No. 6608306 [Patent Document 2] Patent No. 6333674 [Patent Document 3] Patent No. 6914541 [Patent Document 4] Japanese Patent Application Publication No. 2023-79184 Summary of the Invention [Problem to be solved by the invention]

[0007] The above Patent Documents 1 to 4 have the effect of improving the physical properties of resin compositions containing recycled polyolefins. However, they do not teach any knowledge regarding the impact resistance of resin compositions containing amorphous polymers. Therefore, the present inventors thought that there is room for further improvement, including resin compositions containing amorphous polymers.

[0008] An object of the present invention is to provide a thermoplastic resin composition containing an amorphous polymer, which has been subjected to an extrusion process that enables the physical properties of the composition to be improved, and which has superior Charpy impact strength compared to the composition before extrusion. [Means for solving the problem]

[0009] The present inventors have conducted extensive research to solve the above problems, and as a result have found that the following inventions meet the above object, and have completed the present invention. That is, the object of the present invention is achieved by the following (1) to (9).

[0010] (1) A thermoplastic resin composition containing an amorphous polymer, characterized in that, when the Charpy impact strength of a thermoplastic resin composition produced by melt-kneading the thermoplastic resin composition in an extruder is (b), and the Charpy impact strength of the thermoplastic resin composition before melt-extruding the thermoplastic resin composition is (a), the value of the Charpy impact strength (b) exceeds the value of the Charpy impact strength (a). (2) The thermoplastic resin composition according to the preceding paragraph (1), wherein the Charpy impact strength (b) is 1.5 times or more the Charpy impact strength (a). (3) The thermoplastic resin composition according to the preceding paragraph (1), wherein the value of the Charpy impact strength (b) is at least twice the value of the Charpy impact strength (a). (4) The thermoplastic resin composition according to the above item (1), wherein the amorphous polymer is a polycarbonate resin. (5) The thermoplastic resin composition according to the above item (4), wherein the polycarbonate resin contains recycled polycarbonate, and the recycled polycarbonate content in the polycarbonate resin component is 30% by weight or more. (6) The thermoplastic resin composition according to the above item (4), wherein the polycarbonate resin has a viscosity average molecular weight of 16,000 to 30,000. (7) The thermoplastic resin composition according to the above item (5), wherein the recycled polycarbonate has a viscosity average molecular weight of 17,000 to 25,000. (8) The thermoplastic resin composition according to the above item (1), wherein the thermoplastic resin composition before melt-extrusion is a pulverized product or pellets of a molded article. (9) A molded article obtained by molding the thermoplastic resin composition according to any one of the above items (1) to (8). [Effects of the Invention]

[0011] According to the present invention, the Charpy impact strength of a thermoplastic resin composition containing an amorphous polymer can be improved. DETAILED DESCRIPTION OF THE INVENTION

[0012] The present disclosure is not limited to the following embodiments, and various modifications can be made within the scope of the present invention.

[0013] [Thermoplastic resin composition] In the present invention, the thermoplastic resin composition may contain multiple thermoplastic resins, and the main component may be referred to as the first thermoplastic resin. The first thermoplastic resin used in the present invention is an amorphous polymer that softens and becomes moldable when heated. Examples of amorphous polymers include polycarbonate resin (PC), polystyrene (PS), acrylonitrile-styrene copolymer (AS resin), acrylonitrile-butadiene-styrene copolymer (ABS resin), acrylic resins such as PMMA, polyvinyl chloride (PVC), modified polyphenylene ether (mPPE), polyarylate (PAR), polysulfone (PSU), polyethersulfone (PES), polyetherimide (PEI), and polyamideimide (PAI). Among these, it is preferable to use a polycarbonate resin as the first thermoplastic resin.

[0014] The thermoplastic resin composition may also contain impurities typically found in thermoplastic resin compositions. The first thermoplastic resin contained in the thermoplastic resin composition is preferably 40% by mass or more, 50% by mass or more, 60% by mass or more, 70% by mass or more, 80% by mass or more, 90% by mass or more, or 95% by mass or more. The upper limit of the first thermoplastic resin contained in the thermoplastic resin composition need not be particularly specified, but since the thermoplastic resin may contain additives or trace impurities, an upper limit of 99.9% by mass or less, 99.5% by mass or less, 99% by mass or less, 98% by mass or less, or 95% by mass or less may be set. In the present invention, it is preferable that the thermoplastic resin composition before melt extrusion is a pulverized product or pellets, as this facilitates the development of the effects of the present invention.

[0015] [Polycarbonate resin component] In the present invention, the polycarbonate resin used may be a new or recycled polycarbonate resin obtained by the following production method.

[0016] The polycarbonate resin used in the present invention is obtained by reacting a dihydric phenol with a carbonate precursor, and examples of the reaction method include interfacial polymerization, melt transesterification, solid-phase transesterification of carbonate prepolymers, and ring-opening polymerization of cyclic carbonate compounds.

[0017] Representative examples of dihydric phenols used herein include hydroquinone, resorcinol, 4,4'-biphenol, 1,1-bis(4-hydroxyphenyl)ethane, 2,2-bis(4-hydroxyphenyl)propane (commonly known as bisphenol A or BPA), 2,2-bis(4-hydroxy-3-methylphenyl)propane, 2,2-bis(4-hydroxyphenyl)butane, 1,1-bis(4-hydroxyphenyl)-1-phenylethane, 1,1-bis(4-hydroxyphenyl)cyclohexane, 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, 2,2-bis(4-hydroxyphenyl)pentane, 4,4'-(p-phenylenediisopropylidene)diphenol, and the like. Examples of suitable dihydric phenols include phenol, 4,4'-(m-phenylenediisopropylidene)diphenol, 1,1-bis(4-hydroxyphenyl)-4-isopropylcyclohexane, bis(4-hydroxyphenyl)oxide, bis(4-hydroxyphenyl)sulfide, bis(4-hydroxyphenyl)sulfoxide, bis(4-hydroxyphenyl)sulfone, bis(4-hydroxyphenyl)ketone, bis(4-hydroxyphenyl)ester, bis(4-hydroxy-3-methylphenyl)sulfide, 9,9-bis(4-hydroxyphenyl)fluorene, 9,9-bis(4-hydroxy-3-methylphenyl)fluorene, and 9,9-bis[4-(2-hydroxyethoxy)phenyl]fluorene. Preferred dihydric phenols are bis(4-hydroxyphenyl)alkanes, and among these, bisphenol A is particularly preferred and widely used in terms of impact resistance.

[0018] In the present invention, in addition to bisphenol A-based polycarbonate resins, which are general-purpose polycarbonate resins, it is also possible to use special polycarbonate resins produced using other dihydric phenols as the polycarbonate resin component. For example, polycarbonate resins (homopolymers or copolymers) containing 4,4'-(m-phenylenediisopropylidene)diphenol (hereinafter sometimes abbreviated as "BPM"), 1,1-bis(4-hydroxyphenyl)cyclohexane, 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane (hereinafter sometimes abbreviated as "Bis-TMC"), 9,9-bis(4-hydroxyphenyl)fluorene, 9,9-bis(4-hydroxy-3-methylphenyl)fluorene (hereinafter sometimes abbreviated as "BCF"), and 9,9-bis[4-(2-hydroxyethoxy)phenyl]fluorene (hereinafter sometimes abbreviated as "BPEF") as part or all of the dihydric phenol components are suitable for applications requiring particularly strict resistance to dimensional change due to water absorption and dimensional stability. These dihydric phenols other than BPA are preferably used in an amount of 5 mol% or more, and especially 10 mol% or more, of the total dihydric phenol components constituting the polycarbonate resin. In particular, when high rigidity and better hydrolysis resistance are required, it is particularly preferable that the polycarbonate resin component constituting the resin composition is a copolymer polycarbonate resin of the following (1) to (3).

[0019] (1) A copolymer polycarbonate resin in which, based on 100 mol% of the dihydric phenol component constituting the polycarbonate resin, BPM accounts for 20 to 80 mol% (more preferably 40 to 75 mol%, and even more preferably 45 to 65 mol%) and BCF and / or BPEF accounts for 20 to 80 mol% (more preferably 25 to 60 mol%, and even more preferably 35 to 55 mol%).

[0020] (2) A copolymer polycarbonate resin in which, out of 100 mol% of the dihydric phenol components constituting the polycarbonate resin, BPA accounts for 10 to 95 mol% (more preferably 50 to 90 mol%, even more preferably 60 to 85 mol%) and BCF and / or BPEF accounts for 5 to 90 mol% (more preferably 10 to 50 mol%, even more preferably 15 to 40 mol%).

[0021] (3) A copolymer polycarbonate resin in which, based on 100 mol% of the dihydric phenol component constituting the polycarbonate resin, BPM accounts for 20 to 80 mol% (more preferably 40 to 75 mol%, and even more preferably 45 to 65 mol%) and Bis-TMC accounts for 20 to 80 mol% (more preferably 25 to 60 mol%, and even more preferably 35 to 55 mol%).

[0022] These special polycarbonate resins may be used alone or in a suitable mixture of two or more. They may also be used in a mixture with a commonly used bisphenol A polycarbonate resin. The production methods and properties of these special polycarbonate resins are described in detail in, for example, JP-A-6-172508, JP-A-8-27370, JP-A-2001-55435, and JP-A-2002-117580.

[0023] Among the various polycarbonate resins mentioned above, those having a water absorption rate and a glass transition temperature (Tg) within the following ranges by adjusting the copolymer composition and the like are particularly suitable in fields where dimensional stability is required, since the polymer itself has good hydrolysis resistance and exhibits significantly reduced warpage after molding: (i) a polycarbonate resin having a water absorption rate of 0.05 to 0.15%, preferably 0.06 to 0.13%, and a Tg of 120 to 180°C, or (ii) a polycarbonate resin having a Tg of 160 to 250°C, preferably 170 to 230°C, and a water absorption rate of 0.10 to 0.30%, preferably 0.13 to 0.30%, and more preferably 0.14 to 0.27%.

[0024] Here, the water absorption rate of polycarbonate is a value measured by using a disk-shaped test piece with a diameter of 45 mm and a thickness of 3.0 mm and immersing it in water at 23°C for 24 hours in accordance with ISO 62-1980. Furthermore, Tg (glass transition temperature) is a value determined by differential scanning calorimetry (DSC) measurement in accordance with JIS K7121.

[0025] Carbonate precursors that can be used include carbonyl halides, carbonic acid diesters, and haloformates, and specific examples include phosgene, diphenyl carbonate, and dihaloformates of dihydric phenols.

[0026] When producing a polycarbonate resin by interfacial polymerization of the dihydric phenol and carbonate precursor, a catalyst, a terminal stopper, an antioxidant to prevent oxidation of the dihydric phenol, etc. may be used as needed. The polycarbonate resin of the present invention also includes branched polycarbonate resins copolymerized with a trifunctional or higher polyfunctional aromatic compound, polyester carbonate resins copolymerized with an aromatic or aliphatic (including alicyclic) bifunctional carboxylic acid, copolymerized polycarbonate resins copolymerized with a bifunctional alcohol (including alicyclic), and polyester carbonate resins copolymerized with such bifunctional carboxylic acid and bifunctional alcohol. A mixture of two or more of the obtained polycarbonate resins may also be used.

[0027] The branched polycarbonate resin can impart anti-drip properties to the resin composition of the present invention. Examples of trifunctional or higher polyfunctional aromatic compounds used in such branched polycarbonate resins include phloroglucin, phloroglucside, 4,6-dimethyl-2,4,6-tris(4-hydroxyphenyl)heptene-2,2,4,6-trimethyl-2,4,6-tris(4-hydroxyphenyl)heptane, 1,3,5-tris(4-hydroxyphenyl)benzene, 1,1,1-tris(4-hydroxyphenyl)ethane, 1,1,1-tris(3,5-dimethyl-4-hydroxyphenyl)ethane, 2,6-bis(2-hydroxy-5-methylbenzyl)-4-methylphenol, 4-[4-[1,1-bis(4- Examples of the 4-hydroxyphenyl ether include trisphenols such as {4-hydroxyphenyl)ethyl]benzene}-α,α-dimethylbenzylphenol, tetra(4-hydroxyphenyl)methane, bis(2,4-dihydroxyphenyl)ketone, 1,4-bis(4,4-dihydroxytriphenylmethyl)benzene, trimellitic acid, pyromellitic acid, benzophenonetetracarboxylic acid, and acid chlorides thereof. Among these, 1,1,1-tris(4-hydroxyphenyl)ethane and 1,1,1-tris(3,5-dimethyl-4-hydroxyphenyl)ethane are preferred, and 1,1,1-tris(4-hydroxyphenyl)ethane is particularly preferred.

[0028] The structural units derived from polyfunctional aromatic compounds in the branched polycarbonate are preferably 0.01 to 1 mol%, more preferably 0.05 to 0.9 mol%, and even more preferably 0.05 to 0.8 mol% out of the total 100 mol% of the structural units derived from dihydric phenols and the structural units derived from such polyfunctional aromatic compounds. In particular, in the case of the melt transesterification method, branched structural units may be generated as a side reaction, and the amount of such branched structural units is preferably 0.001 to 1 mol%, more preferably 0.005 to 0.9 mol%, and even more preferably 0.01 to 0.8 mol% out of the total 100 mol% of the structural units derived from dihydric phenols. The proportion of such branched structures is 1 It can be calculated by H-NMR measurement.

[0029] The aliphatic bifunctional carboxylic acid is preferably an α,ω-dicarboxylic acid. Preferred examples of the aliphatic bifunctional carboxylic acid include linear saturated aliphatic dicarboxylic acids such as sebacic acid (decanedioic acid), dodecanedioic acid, tetradecanedioic acid, octadecanedioic acid, and icosane diacid, as well as alicyclic dicarboxylic acids such as cyclohexanedicarboxylic acid. The bifunctional alcohol is more preferably an alicyclic diol, such as cyclohexanedimethanol, cyclohexanediol, and tricyclodecanedimethanol.

[0030] The reaction modes of the methods for producing the polycarbonate resin of the present invention, such as interfacial polymerization, melt transesterification, carbonate prepolymer solid-phase transesterification, and ring-opening polymerization of a cyclic carbonate compound, are well known in various literatures and patent publications.

[0031] The viscosity average molecular weight (M) of the polycarbonate resin component is not particularly limited, but is preferably 16,000 to 30,000, more preferably 17,000 to 25,000, and even more preferably 18,000 to 22,000.

[0032] Polycarbonate resin components with a viscosity-average molecular weight of less than 16,000 may not provide satisfactory improvements in mechanical properties (particularly Charpy impact strength), while polycarbonate resin components with a viscosity-average molecular weight of more than 30,000 may have poor fluidity during injection molding.

[0033] The polycarbonate resin component may be obtained by mixing components having a viscosity average molecular weight outside the above range. 4) or more, the entropy elasticity of the resin is improved. As a result, good molding processability is exhibited in gas-assisted molding and foam molding, which are sometimes used when molding reinforced resin materials into structural members. Such improvement in molding processability is even better than that of the branched polycarbonate. In a more preferred embodiment, the polycarbonate resin component has a viscosity average molecular weight of 2.5 x 10 4 5x10 or more 4 The following polycarbonate resin (A-1 component) and viscosity average molecular weight of 0.5 x 10 4 Over 2.5 x 10 4 The viscosity average molecular weight of the polycarbonate resin (A-2 component) is less than 1.6 × 10 4 ~2.4×10 4 A polycarbonate resin (polycarbonate resin component) (hereinafter, sometimes referred to as a "polycarbonate resin containing a high molecular weight component") can also be used.

[0034] The high-molecular-weight component-containing polycarbonate resin can be obtained by mixing the A-1 and A-2 components in various ratios and adjusting the ratio to satisfy a predetermined molecular weight range. Preferably, the A-1 component is 2 to 40% by weight, more preferably 3 to 30% by weight, even more preferably 4 to 20% by weight, and particularly preferably 5 to 20% by weight, of 100% by weight of the polycarbonate resin component.

[0035] The viscosity average molecular weight in the present invention is determined by first calculating the specific viscosity (η SP ) was measured using an Ostwald viscometer from a solution of 0.7 g of polycarbonate resin dissolved in 100 ml of methylene chloride at 20°C. Specific viscosity (η SP )=(t-t0) / t0 [t0 is the number of seconds that methylene chloride falls, and t is the number of seconds that the sample solution falls] The calculated specific viscosity (η SP ) and calculate the viscosity average molecular weight M using the following formula: η SP / c=[η]+0.45×[η] 2c (where [η] is the intrinsic viscosity) [η]=1.23×10 -4 M 0.83 c=0.7

[0036] After polycarbonate resin is produced by conventional methods, it is preferable to remove impurities and foreign matter, such as low-molecular-weight components and unreacted components, by filtering the solution or washing the granular raw material after granulation (desolventization) with a poor solvent such as acetone under heated conditions. Furthermore, during the extrusion process (pelletization) to obtain pelletized polycarbonate resin for injection molding, it is preferable to remove foreign matter by passing the molten resin through a sintered metal filter. To obtain a resin with a low level of foreign matter, particularly iron or iron-containing foreign matter, whose specific heat difference with the resin is 50 J / (kg·K) or more, it is particularly important to select raw materials with low levels of such foreign matter as polymerization raw materials and to use equipment that minimizes the generation of such foreign matter. Furthermore, after pelletization, it is also preferable to remove iron or iron-containing foreign matter using a magnetic separator. In any case, it is necessary to minimize the content of foreign matter, impurities, and solvents in the raw resin before injection molding. In the present invention, it is preferable that the polycarbonate resin composition before melt-extrusion is in the form of pulverized molded articles or pellets, as this makes it easier to exhibit the effects of the present invention.

[0037] [Recycled polycarbonate] The polycarbonate resin component preferably contains recycled polycarbonate. Examples of recycled polycarbonate include recycled polycarbonate obtained by crushing recovered molded articles containing polycarbonate resin. The molded article may be a used product. Examples of used products include various glazing materials, such as soundproof walls, automobile windows, translucent roofing materials, and automobile sunroofs; transparent components, such as windshields and automobile headlamp lenses; containers, such as water bottles; light guide plates; eyeglass lenses; and optical recording media. Crushed material obtained from non-conforming products, sprues, runners, etc., or pellets obtained by melting these materials may also be used. Crushed material or pellets of molded articles are preferred as the recycled polycarbonate, and they can be in common shapes, such as cylindrical, prismatic, or spherical. The diameter of the cylinder or sphere or the length of the base of the prismatic prism is preferably 1 to 5 mm, more preferably 1.5 to 4 mm. The length (height) of the cylinder or prism is preferably 1 to 30 mm, more preferably 2 to 20 mm, and even more preferably 2.5 to 10 mm.

[0038] The polycarbonate resin component preferably contains recycled polycarbonate in an amount of 30% by weight or more, 40% by weight or more, 50% by weight or more, 60% by weight or more, 70% by weight or more, 80% by weight or more, 90% by weight or more, or 95% by weight or more.

[0039] The viscosity average molecular weight (M) of the recycled polycarbonate is not particularly limited, but is preferably 17,000 to 25,000, more preferably 18,000 to 23,000, and even more preferably 19,000 to 21,000.

[0040] Recycled polycarbonate with a viscosity-average molecular weight of less than 17,000 may not provide satisfactory improvements in mechanical properties (especially Charpy impact strength), while polycarbonate resin components with a viscosity-average molecular weight of more than 25,000 may have poor fluidity during injection molding.

[0041] [Polycarbonate resin composition] In the present invention, a polycarbonate resin composition in which various additives such as those described below are blended with the above polycarbonate resin component is preferably used.

[0042] [Additives] The polycarbonate resin composition of the present invention may contain various stabilizers, mold release agents, coloring agents, etc. for preventing a decrease in molecular weight during molding and for stabilizing color tone. (i) Phosphorus stabilizers, phenolic stabilizers, and other heat stabilizers The polycarbonate resin composition of the present invention preferably contains various heat stabilizers. Phosphorus-based stabilizers are suitable as such heat stabilizers. Examples of phosphorus-based stabilizers include phosphorous acid, phosphoric acid, phosphonous acid, phosphonic acid, and their esters, as well as tertiary phosphines. These phosphorus-based stabilizers can be used alone or in combination of two or more.

[0043] Examples of the phosphite compound include trialkyl phosphites such as tridecyl phosphite, dialkyl monoaryl phosphites such as didecyl monophenyl phosphite, monoalkyl diaryl phosphites such as monobutyl diphenyl phosphite, triaryl phosphites such as triphenyl phosphite and tris(2,4-di-tert-butylphenyl)phosphite, distearyl pentaerythritol diphosphite, bis(2,4-di-tert-butylphenyl)pentaerythritol, Examples include pentaerythritol phosphites such as bis(2,4-dicumylphenyl)pentaerythritol diphosphite, bis(2,6-di-tert-butyl-4-methylphenyl)pentaerythritol diphosphite, and cyclic phosphites such as 2,2-methylenebis(4,6-di-tert-butylphenyl)octyl phosphite and 2,2′-methylenebis(4,6-di-tert-butylphenyl)(2,4-di-tert-butylphenyl)phosphite.

[0044] Examples of the phosphate compound include tributyl phosphate, trimethyl phosphate, tricresyl phosphate, triphenyl phosphate, triethyl phosphate, diphenyl cresyl phosphate, diphenyl monoorthoxenyl phosphate, tributoxyethyl phosphate, and diisopropyl phosphate, and preferred are triphenyl phosphate and trimethyl phosphate.

[0045] Preferred examples of the phosphonite compound include tetrakis(di-tert-butylphenyl)-biphenylene diphosphonite and bis(di-tert-butylphenyl)-phenyl-phenyl phosphonite, with tetrakis(2,4-di-tert-butylphenyl)-biphenylene diphosphonite and bis(2,4-di-tert-butylphenyl)-phenyl-phenyl phosphonite being more preferred. Such phosphonite compounds can be used in combination with the above-mentioned phosphite compounds having an aryl group substituted with two or more alkyl groups, and are therefore preferred.

[0046] Examples of the phosphonate compound include dimethyl benzenephosphonate, diethyl benzenephosphonate, dipropyl benzenephosphonate, etc. Examples of the tertiary phosphine include triphenylphosphine. The content of such phosphorus-based stabilizer is preferably 0.001 to 3.0 parts by weight, more preferably 0.01 to 2.0 parts by weight, and even more preferably 0.05 to 1.0 part by weight, relative to 100 parts by weight of the polycarbonate resin component.

[0047] The hindered phenol compound may be any of various compounds that are usually incorporated into resins, such as α-tocopherol, butylhydroxytoluene, sinapyl alcohol, vitamin E, octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, 2-tert-butyl-6-(3'-tert-butyl-5'-methyl-2'-hydroxybenzyl)-4-methylphenylacrylate, 2,6-di-tert-butyl-4-(N,N-dimethylaminomethyl)phenol, and 3,5-di-tert-butyl-4-hydroxybenzyl. Phosphonate diethyl ester, 2,2'-methylenebis(4-methyl-6-tert-butylphenol), 2,2'-methylenebis(4-ethyl-6-tert-butylphenol), 4,4'-methylenebis(2,6-di-tert-butylphenol), 2,2'-methylenebis(4-methyl-6-cyclohexylphenol), 2,2'-dimethylene-bis(6-α-methyl-benzyl-p-cresol), 2,2'-ethylidene-bis(4,6-di-tert-butylphenol), 2,2'-butylidene-bis( 4-methyl-6-tert-butylphenol), 4,4'-butylidenebis(3-methyl-6-tert-butylphenol), triethylene glycol-N-bis-3-(3-tert-butyl-4-hydroxy-5-methylphenyl)propionate, 1,6-hexanediol bis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], bis[2-tert-butyl-4-methyl-6-(3-tert-butyl-5-methyl-2-hydroxybenzyl)phenyl]terephthalate, 3,9 -Bis{2-[3-(3-tert-butyl-4-hydroxy-5-methylphenyl)propionyloxy]-1,1-dimethylethyl}-2,4,8,10-tetraoxaspiro[5,5]undecane, 4,4'-thiobis(6-tert-butyl-m-cresol), 4,4'-thiobis(3-methyl-6-tert-butylphenol), 2,2'-thiobis(4-methyl-6-tert-butylphenol), bis(3,5-di-tert-butyl-4-hydroxybenzyl)sulfide, 4,4'-dithiobis(2,6-di-tert-butylphenol), 4,4'-tri-thiobis(2,6-di-tert-butylphenol), 2,2-thiodiethylene bis-[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], 2,4-bis(n-octylthio)-6-(4-hydroxy-3,5-di-tert-butylanilino)-1,3,5-triazine, N,N'-hexamethylenebis-(3,5-di-tert-butyl-4-hydroxyhydrocinnamide), N,N'-bis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate] hydroxyphenyl)propionyl]hydrazine, 1,1,3-tris(2-methyl-4-hydroxy-5-tert-butylphenyl)butane, 1,3,5-trimethyl-2,4,6-tris(3,5-di-tert-butyl-4-hydroxybenzyl)benzene, tris(3,5-di-tert-butyl-4-hydroxyphenyl)isocyanurate, tris(3,5-di-tert-butyl-4-hydroxybenzyl)isocyanurate, 1,3,5-tris(4-tert-butyl-3-hydroxy-2,6-dimethylbenzyl)isocyanurate nurate, 1,3,5-tris-2[3(3,5-di-tert-butyl-4-hydroxyphenyl)propionyloxy]ethyl isocyanurate, tetrakis[methylene-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate]methane, triethylene glycol-N-bis-3-(3-tert-butyl-4-hydroxy-5-methylphenyl)propionate, triethylene glycol-N-bis-3-(3-tert-butyl-4-hydroxy-5-methylphenyl)acetate, 3,9-bis[2-{3- Examples include {(3-tert-butyl-4-hydroxy-5-methylphenyl)acetyloxy}-1,1-dimethylethyl)-2,4,8,10-tetraoxaspiro[5,5]undecane, tetrakis[methylene-3-(3-tert-butyl-4-hydroxy-5-methylphenyl)propionate]methane, 1,3,5-trimethyl-2,4,6-tris(3-tert-butyl-4-hydroxy-5-methylbenzyl)benzene, and tris(3-tert-butyl-4-hydroxy-5-methylbenzyl)isocyanurate.

[0048] Among the above hindered phenol compounds, tetrakis[methylene-3-(3-tert-butyl-4-hydroxy-5-methylphenyl)propionate]methane, octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, and 3,9-bis[2-{3-(3-t-butyl-4-hydroxy-5-methylphenyl)propionyloxy}-1,1-dimethylethyl]-2,4,8,10-tetraoxaspiro[5,5]undecane are preferred in the present invention, with 3,9-bis[2-{3-(3-t-butyl-4-hydroxy-5-methylphenyl)propionyloxy}-1,1-dimethylethyl]-2,4,8,10-tetraoxaspiro[5,5]undecane being particularly preferred.

[0049] The above hindered phenol compounds can be used alone or in combination of two or more. The content of the hindered phenol compound is preferably 0.001 to 3.0 parts by weight, more preferably 0.01 to 2.0 parts by weight, and even more preferably 0.05 to 1.0 part by weight, per 100 parts by weight of the polycarbonate resin component.

[0050] The polycarbonate resin composition of the present invention can also contain heat stabilizers other than the phosphorus-based stabilizer and hindered phenol compound. Such other heat stabilizers are preferably used in combination with either one of these stabilizers or antioxidants, and particularly preferably in combination with both. Suitable examples of such other heat stabilizers include lactone-based stabilizers, such as the reaction product of 3-hydroxy-5,7-di-tert-butyl-furan-2-one and o-xylene (details of such stabilizers are described in JP-A-7-233160). This compound is commercially available under the trade name Irganox HP-136 (trademark, manufactured by CIBA SPECIALTY CHEMICALS), and this compound can be used. Furthermore, stabilizers containing this compound mixed with various phosphite compounds and hindered phenol compounds are commercially available. For example, Irganox HP-2921 manufactured by the same company is a suitable example. Such premixed stabilizers can also be used in the present invention.

[0051] The content of the lactone-based stabilizer is preferably 0.0005 to 0.05 parts by weight, and more preferably 0.001 to 0.03 parts by weight, based on 100 parts by weight of the polycarbonate resin component.

[0052] Other examples of stabilizers include sulfur-containing stabilizers such as pentaerythritol tetrakis(3-mercaptopropionate), pentaerythritol tetrakis(3-laurylthiopropionate), and glycerol-3-stearylthiopropionate. Such stabilizers are particularly effective when the resin composition is used for rotational molding. The content of such sulfur-containing stabilizer is preferably 0.001 to 0.1 part by weight, more preferably 0.01 to 0.08 part by weight, per 100 parts by weight of the polycarbonate resin component.

[0053] (ii) Mold release agent To further improve releasability from a mold during melt molding, the polycarbonate resin composition of the present invention may be blended with a mold release agent within the scope of the present invention. Known mold release agents can be used. Examples of such mold release agents include saturated fatty acid esters, unsaturated fatty acid esters, polyolefin waxes (polyethylene wax, 1-alkene polymers, etc.; those modified with functional group-containing compounds, such as acid-modified waxes, can also be used), silicone compounds, fluorine compounds (fluorine oils, such as polyfluoroalkyl ethers), paraffin wax, and beeswax.

[0054] Among these, fatty acid esters are preferred as release agents. Such fatty acid esters are esters of aliphatic alcohols and aliphatic carboxylic acids. Such aliphatic alcohols may be monohydric alcohols or polyhydric alcohols having dihydric or higher hydric groups. The carbon number of the alcohol is in the range of 3 to 32, more preferably 5 to 30. Examples of such monohydric alcohols include dodecanol, tetradecanol, hexadecanol, octadecanol, eicosanol, tetracosanol, ceryl alcohol, and triacontanol. Examples of such polyhydric alcohols include pentaerythritol, dipentaerythritol, tripentaerythritol, polyglycerols (triglycerol to hexaglycerol), ditrimethylolpropane, xylitol, sorbitol, and mannitol. Polyhydric alcohols are more preferred for the fatty acid esters of the present invention.

[0055] On the other hand, the aliphatic carboxylic acid preferably has 3 to 32 carbon atoms, and particularly preferably has 10 to 22 carbon atoms. Examples of the aliphatic carboxylic acid include saturated aliphatic carboxylic acids such as decanoic acid, undecanoic acid, dodecanoic acid, tridecanoic acid, tetradecanoic acid, pentadecanoic acid, hexadecanoic acid (palmitic acid), heptadecanoic acid, octadecanoic acid (stearic acid), nonadecanoic acid, behenic acid, icosanoic acid, and docosanoic acid, as well as unsaturated aliphatic carboxylic acids such as palmitoleic acid, oleic acid, linoleic acid, linolenic acid, eicosenoic acid, eicosapentaenoic acid, and cetoleic acid. Among the above, aliphatic carboxylic acids having 14 to 20 carbon atoms are preferred. Among these, saturated aliphatic carboxylic acids are preferred. Stearic acid and palmitic acid are particularly preferred. The above-mentioned aliphatic carboxylic acids, such as stearic acid and palmitic acid, are usually produced from natural fats and oils, such as animal fats and oils typified by beef tallow and lard, and vegetable fats and oils typified by palm oil and sunflower oil, and therefore these aliphatic carboxylic acids are usually mixtures containing other carboxylic acid components with different numbers of carbon atoms. Therefore, in the production of the fatty acid ester of the present invention, aliphatic carboxylic acids, particularly stearic acid and palmitic acid, which are produced from such natural fats and oils and are in the form of a mixture containing other carboxylic acid components are preferably used.

[0056] The fatty acid ester may be either a partial ester or a full ester (full ester). However, partial esters usually have a high hydroxyl value, which can easily induce decomposition of the resin at high temperatures, so full esters are more preferred. The acid value of the fatty acid ester of the present invention is preferably 20 or less, more preferably in the range of 4 to 20, and even more preferably in the range of 4 to 12, from the viewpoint of thermal stability. The acid value can be substantially 0. The hydroxyl value of the fatty acid ester is more preferably in the range of 0.1 to 30. The iodine value is preferably 10 or less. The iodine value can be substantially 0. These properties can be determined by the method specified in JIS K0070. The amount of such a release agent to be added is preferably 0.01 to 5 parts by weight per 100 parts by weight of the polycarbonate resin component.

[0057] (iii) UV absorber The polycarbonate resin composition of the present invention may contain an ultraviolet absorber. Examples of benzophenone-based ultraviolet absorbers include 2,4-dihydroxybenzophenone, 2-hydroxy-4-methoxybenzophenone, 2-hydroxy-4-octoxybenzophenone, 2-hydroxy-4-benzyloxybenzophenone, 2-hydroxy-4-methoxy-5-sulfoxybenzophenone, 2-hydroxy-4-methoxy-5-sulfoxytrihydridobenzophenone, 2,2'-dihydroxy-4-methoxybenzophenone, 2,2',4,4'-tetrahydroxybenzophenone, 2,2'-dihydroxy-4,4'-dimethoxybenzophenone, 2,2'-dihydroxy-4,4'-dimethoxy-5-sodium sulfoxybenzophenone, bis(5-benzoyl-4-hydroxy-2-methoxyphenyl)methane, 2-hydroxy-4-n-dodecyloxybenzophenone, and 2-hydroxy-4-methoxy-2'-carboxybenzophenone.

[0058] Benzotriazoles include, for example, 2-(2-hydroxy-5-methylphenyl)benzotriazole, 2-(2-hydroxy-5-tert-octylphenyl)benzotriazole, 2-(2-hydroxy-3,5-dicumylphenyl)phenylbenzotriazole, 2-(2-hydroxy-3-tert-butyl-5-methylphenyl)-5-chlorobenzotriazole, 2,2'-methylenebis[4-(1,1,3,3-tetramethylbutyl)-6-(2H-benzotriazol-2-yl)phenol], 2-(2-hydroxy-3,5-di-tert-butylphenyl)benzotriazole, 2-(2-hydroxy-3,5-di-tert-butylphenyl)-5-chlorobenzotriazole, 2-(2-hydroxy-3,5-di-tert-amylphenyl)benzotriazole, 2-(2-hydroxy-5-tert-octylphenyl)benzotriazole, Examples include polymers having a 2-hydroxyphenyl-2H-benzotriazole skeleton, such as azole, 2-(2-hydroxy-5-tert-butylphenyl)benzotriazole, 2-(2-hydroxy-4-octoxyphenyl)benzotriazole, 2,2'-methylenebis(4-cumyl-6-benzotriazolephenyl), 2,2'-p-phenylenebis(1,3-benzoxazin-4-one), and 2-[2-hydroxy-3-(3,4,5,6-tetrahydrophthalimidomethyl)-5-methylphenyl]benzotriazole, as well as copolymers of 2-(2'-hydroxy-5-methacryloxyethylphenyl)-2H-benzotriazole and a vinyl monomer copolymerizable with the monomer, and copolymers of 2-(2'-hydroxy-5-acryloxyethylphenyl)-2H-benzotriazole and a vinyl monomer copolymerizable with the monomer.

[0059] Examples of hydroxyphenyltriazines include 2-(4,6-diphenyl-1,3,5-triazin-2-yl)-5-hexyloxyphenol, 2-(4,6-diphenyl-1,3,5-triazin-2-yl)-5-methyloxyphenol, 2-(4,6-diphenyl-1,3,5-triazin-2-yl)-5-ethyloxyphenol, 2-(4,6-diphenyl-1,3,5-triazin-2-yl)-5-propyloxyphenol, and 2-(4,6-diphenyl-1,3,5-triazin-2-yl)-5-butyloxyphenol. Further examples include compounds in which the phenyl group of the above-mentioned compounds is replaced with a 2,4-dimethylphenyl group, such as 2-(4,6-bis(2,4-dimethylphenyl)-1,3,5-triazin-2-yl)-5-hexyloxyphenol.

[0060] Examples of cyclic iminoesters include 2,2'-p-phenylenebis(3,1-benzoxazin-4-one), 2,2'-(4,4'-diphenylene)bis(3,1-benzoxazin-4-one), and 2,2'-(2,6-naphthalene)bis(3,1-benzoxazin-4-one).

[0061] Examples of cyanoacrylates include 1,3-bis-[(2'-cyano-3',3'-diphenylacryloyl)oxy]-2,2-bis[(2-cyano-3,3-diphenylacryloyl)oxy]methyl)propane and 1,3-bis-[(2-cyano-3,3-diphenylacryloyl)oxy]benzene.

[0062] Furthermore, the ultraviolet absorber may be a polymeric ultraviolet absorber obtained by copolymerizing such an ultraviolet absorbing monomer and / or a photostable monomer having a hindered amine structure with a monomer such as alkyl (meth)acrylate by adopting a structure of a radically polymerizable monomer compound. Suitable examples of the ultraviolet absorbing monomer include compounds containing a benzotriazole skeleton, a benzophenone skeleton, a triazine skeleton, a cyclic imino ester skeleton, and a cyanoacrylate skeleton in the ester substituent of a (meth)acrylic acid ester.

[0063] The content of the ultraviolet absorber is preferably 0.01 to 2.0 parts by weight, more preferably 0.02 to 1.5 parts by weight, and even more preferably 0.03 to 1.0 part by weight, relative to 100 parts by weight of the polycarbonate resin component.

[0064] (iv) Dyes and pigments The polycarbonate resin composition of the present invention can further contain various dyes and pigments to provide molded articles with a variety of designs. By blending a fluorescent brightening agent or other fluorescent dye that emits light, it is possible to impart even better design effects by taking advantage of the emitted color. It is also possible to provide a flame-retardant polycarbonate resin composition that is colored with a very small amount of dyes and pigments and has vivid color development.

[0065] Examples of fluorescent dyes (including fluorescent whitening 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, thioxanthone-based fluorescent dyes, thiazine-based fluorescent dyes, and diaminostilbene-based fluorescent dyes. Among these, coumarin-based fluorescent dyes, benzopyran-based fluorescent dyes, and perylene-based fluorescent dyes are preferred because they have good heat resistance and are less susceptible to deterioration during molding and processing of polycarbonate resins.

[0066] Examples of dyes other than the bluing agents and fluorescent dyes include perylene dyes, coumarin dyes, thioindigo dyes, anthraquinone dyes, thioxanthone dyes, ferrocyanides such as Prussian blue, perinone dyes, quinoline dyes, quinacridone dyes, dioxazine dyes, isoindolinone dyes, and phthalocyanine dyes. Furthermore, the resin composition of the present invention can be blended with a metallic pigment to obtain a better metallic color. Suitable metallic pigments include those having a metal coating or a metal oxide coating on various plate-like fillers. The content of such dyes and pigments is preferably 0.00001 to 1 part by weight, and more preferably 0.00005 to 0.5 parts by weight, relative to 100 parts by weight of the polycarbonate resin component.

[0067] (v) Flame retardants The resin composition of the present invention can contain various compounds conventionally known as flame retardants for thermoplastic resins, particularly polycarbonate resins. Among these, preferred are (i) halogen-based flame retardants (e.g., brominated polycarbonate compounds), (ii) phosphorus-based flame retardants (e.g., monophosphate compounds, phosphate oligomer compounds, phosphonate oligomer compounds, phosphonitrile oligomer compounds, phosphonic acid amide compounds, and phosphazene compounds), (iii) metal salt-based flame retardants (e.g., alkali (earth) metal organic sulfonates, borate-based flame retardants, and stannate-based flame retardants), and (iv) silicone-based flame retardants consisting of silicone compounds. The incorporation of the compounds used as flame retardants not only improves flame retardancy, but also, depending on the properties of each compound, improves antistatic properties, fluidity, rigidity, and thermal stability, among other things.

[0068] Among the above-mentioned flame retardants, compounds that do not contain chlorine atoms or bromine atoms are more suitable as flame retardants from the viewpoint of reducing the environmental load, since they reduce factors that are considered undesirable when incinerating or thermally recycling the compounds.

[0069] When a flame retardant is added, the amount is preferably in the range of 0.05 to 50 parts by weight per 100 parts by weight of the polycarbonate resin component. At 0.05 part by weight or more, sufficient flame retardancy is likely to be exhibited, and at 50 parts by weight or less, the strength and heat resistance of the molded product are excellent.

[0070] [Production of Thermoplastic Resin Composition] The method for producing a thermoplastic resin composition according to the present invention includes an extrusion step in which the above-described components are fed simultaneously or in any order into a feed port of a kneader, the thermoplastic resin composition fed from the feed port is extruded while being melted in a melt-kneading section, and the thermoplastic resin composition is discharged from a discharge section. The extruded resin as described above is either directly cut into pellets, or formed into strands, which are then cut into pellets using a pelletizer. If it is necessary to reduce the influence of external dust during pelletization, it is preferable to purify the atmosphere around the extruder. The resulting pellets may have common shapes such as cylinders, prisms, and spheres, but are preferably cylinders. The diameter of the cylinders is preferably 1 to 5 mm, more preferably 1.5 to 4 mm, and even more preferably 2 to 3.5 mm. The length of the cylinders is preferably 1 to 30 mm, more preferably 2 to 5 mm, and even more preferably 2.5 to 4 mm. As described above, if the thermoplastic resin composition is in the form of pellets before melt extrusion, the shape of the pellets is preferably the same as that of the melt-extruded pellets.

[0071] The extruder is preferably configured to control the extrusion rate per unit time within a predetermined range depending on the type of thermoplastic resin composition, the extrusion pressure of the extruder, etc. It is also preferable to provide a vent port that is open to reduced pressure or the atmosphere. While either a single-screw extruder or a twin-screw extruder can be used as the extruder, a twin-screw extruder is preferred, as it exhibits the effects of the present invention more remarkably.

[0072] [Regarding molded articles produced by injection molding from the thermoplastic resin composition of the present invention] The thermoplastic resin composition of the present invention can be injection-molded into various products using pellets obtained by the above-described method. Injection molding can be performed using not only conventional molding methods but also injection compression molding, injection press molding, gas-assisted injection molding, foam molding (including supercritical fluid injection), insert molding, in-mold coating molding, adiabatic mold molding, rapid heating and cooling mold molding, two-color molding, sandwich molding, and ultra-high-speed injection molding, depending on the purpose. The advantages of these molding methods are widely known. Molding can be performed using either a cold runner or hot runner system. Considering the objectives of the present invention, it is preferable to maintain the molding process in an environment as clean as possible. It is also important to thoroughly dry the material to be molded to remove moisture and to avoid retention that could lead to decomposition of the molten resin. Furthermore, injection molding is preferably performed under conditions of a cylinder temperature of 250 to 350°C and a mold temperature of 60 to 120°C.

[0073] [Impact strength] The thermoplastic resin composition of the present invention has a notched Charpy impact strength of 20 kJ / m or more at 23°C measured in accordance with ISO 179. 2 More than 23kJ / m 2 More than 25kJ / m 2 More than 30kJ / m 2 More than 35kJ / m 2 More than 40kJ / m 2 More than 45kJ / m 2 More than 50kJ / m 2 More than 55kJ / m 2 More than 60kJ / m 2 More than 65kJ / m 2 More than 70kJ / m 2 If the measured value of the notched Charpy impact strength is below the appropriate range, it is difficult to apply it to various applications. The upper limit is not particularly limited, but it is 100 kJ / m 2 The following performs satisfactorily.

[0074] In the present invention, when the Charpy impact strength of the thermoplastic resin composition produced by melt-kneading the thermoplastic resin composition in an extruder is (b) and the Charpy impact strength of the thermoplastic resin composition before extrusion is (a), the value of Charpy impact strength (b) exceeds the value of Charpy impact strength (a). Furthermore, the value of Charpy impact strength (b) is preferably 1.5 times or more, more preferably 2 times or more, even more preferably 3 times or more, particularly preferably 4 times or more, and most preferably 5 times or more of the value of Charpy impact strength (a). [Example]

[0075] The embodiments for carrying out the present invention summarize the preferred ranges of each of the above-mentioned requirements, and representative examples are described in the following examples. Of course, the present invention is not limited to these embodiments. Furthermore, unless otherwise specified, parts in the examples are parts by weight and % is % by weight. Evaluations were carried out using the following methods.

[0076] [Evaluation of Resin Composition] (i) Charpy impact strength Using an ISO bending test piece having a thickness of 4 mm obtained by the method described below, the notched Charpy impact strength was measured in an atmosphere of 23°C in accordance with ISO179. (ii) Viscosity average molecular weight The specific viscosity (η SP ) was determined using an Oswald viscometer from a solution prepared by dissolving 0.7 g of the thermoplastic resin composition in 100 mL of methylene chloride at 20°C. Specific viscosity (η SP )=(t-t0) / t0 [t0 is the number of seconds that methylene chloride falls, and t is the number of seconds that the sample solution falls] The calculated specific viscosity (η SP ) and the viscosity average molecular weight Mv was calculated using the following formula: η SP / c=[η]+0.45×[η] 2 c (where [η] is the intrinsic viscosity) [η]=1.23×10-4 Mv 0.83 c=0.7 The raw materials used in the examples and comparative examples are as follows: A1: Recycled polycarbonate (recycled polycarbonate resin pellets recycled from polycarbonate resin sheets, viscosity average molecular weight 20,500) A2: Recycled polycarbonate (recycled polycarbonate resin pellets recycled from used water bottles shipped to the market, viscosity average molecular weight 20,400) A3: Recycled polycarbonate (recycled polycarbonate resin pellets recycled from used headlamps shipped to the market, viscosity average molecular weight 20,300) A4: Recycled polycarbonate (recycled polycarbonate resin pellets recycled from used headlamps shipped to the market, viscosity average molecular weight 20,500) A5: Recycled polycarbonate (recycled polycarbonate resin pellets recycled from used discs shipped to the market, viscosity average molecular weight 15,200)

[0077] [Examples 1 to 11] For Example 1, A1 was used in a twin-screw extruder (manufactured by The Japan Steel Works, Ltd., model TEX30α-38.5BW-3V) with a screw diameter of 30 mm, and melt-kneaded to obtain pellets under the extrusion conditions shown in Table 1. The obtained pellets were dried in a hot air circulation dryer at 120°C for 6 hours, and then molded into ISO bending test pieces (ISO179) using an injection molding machine at a cylinder temperature of 280°C and a mold temperature of 80°C. Examples 2 to 11 were also molded and evaluated in the same manner using the raw materials and extrusion conditions shown in Table 1.

[0078] [Examples 12 and 13] A1 was used in a single-screw extruder (Isuzu Chemical Engineering Co., Ltd., Model EXT40) with a screw diameter of 40 mm to obtain pellets by melt-kneading under the extrusion conditions shown in Table 1. The obtained pellets were dried in a hot air circulation dryer at 120°C for 6 hours, and then molded into ISO bending test pieces (ISO179) using an injection molding machine at a cylinder temperature of 280°C and a mold temperature of 80°C.

[0079] [Reference example 1] A1 was dried in a hot air circulation dryer at 120°C for 6 hours, and then molded into an ISO bending test piece (ISO179) using an injection molding machine at a cylinder temperature of 280°C and a mold temperature of 80°C. [Reference example 2] A2 was dried in a hot air circulation dryer at 120°C for 6 hours, and then molded into an ISO bending test piece (ISO179) using an injection molding machine at a cylinder temperature of 280°C and a mold temperature of 80°C. [Reference example 3] A3 was dried in a hot air circulation dryer at 120°C for 6 hours, and then molded into an ISO bending test piece (ISO179) using an injection molding machine at a cylinder temperature of 280°C and a mold temperature of 80°C. [Reference example 4] After drying the A4 size in a hot air circulation dryer at 120°C for 6 hours, an ISO bending test piece (ISO179) was molded using an injection molding machine at a cylinder temperature of 280°C and a mold temperature of 80°C. [Reference example 5] A5 was dried in a hot air circulation dryer at 120°C for 6 hours, and then molded into an ISO bending test piece (ISO179) using an injection molding machine at a cylinder temperature of 280°C and a mold temperature of 80°C. [Reference example 6] Pellets were produced in the same manner as in Example 1, except that A1 was changed to A5, and an ISO bending test piece (ISO179) was molded.

[0080] [Table 1] [Industrial Applicability]

[0081] The present invention relates to a thermoplastic resin composition containing an amorphous polymer, which has a high level of impact strength and is therefore useful in a wide range of applications, including housing equipment, building materials, daily necessities, infrastructure equipment, automobiles, office equipment, and other fields.

Claims

1. A thermoplastic resin composition containing an amorphous polymer, characterized in that, when the Charpy impact strength of a thermoplastic resin composition produced by melt-kneading the thermoplastic resin composition in an extruder is (b), and the Charpy impact strength of the thermoplastic resin composition before melt-extruding the thermoplastic resin composition is (a), the value of the Charpy impact strength (b) exceeds the value of the Charpy impact strength (a).

2. 2. The thermoplastic resin composition according to claim 1, wherein the Charpy impact strength (b) is at least 1.5 times the Charpy impact strength (a).

3. 2. The thermoplastic resin composition according to claim 1, wherein the Charpy impact strength (b) is at least twice the Charpy impact strength (a).

4. 2. The thermoplastic resin composition according to claim 1, wherein the amorphous polymer is a polycarbonate resin.

5. 5. The thermoplastic resin composition according to claim 4, wherein the polycarbonate resin contains recycled polycarbonate in an amount of 30% by weight or more of the polycarbonate resin component.

6. 5. The thermoplastic resin composition according to claim 4, wherein the polycarbonate resin has a viscosity average molecular weight of 16,000 to 30,000.

7. 6. The thermoplastic resin composition according to claim 5, wherein the recycled polycarbonate has a viscosity average molecular weight of 17,000 to 25,000.

8. 2. The thermoplastic resin composition according to claim 1, wherein the thermoplastic resin composition before being melt-extruded is in the form of pulverized or pelletized molded articles.

9. A molded article obtained by molding the thermoplastic resin composition according to any one of claims 1 to 8.

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