Polycarbonate resin composition molded article

Abstract

A polycarbonate resin composition exhibiting excellent tensile elongation, notched tensile strength, and flexural elasticity. [Solution] A molded polycarbonate resin composition comprising 100 parts by mass in total, consisting of 50 to 80 parts by mass of polycarbonate resin (A) and 20 to 50 parts by mass of thermoplastic polyester resin (B), and containing 5 to 20 parts by mass of wollastonite (C) having a volume-average fiber diameter of 1.0 to 6.0 μm, a volume-average fiber length of 10.0 to 20.0 μm, an aspect ratio of 3 or more, and surface-treated with an alkylsilane having 8 to 14 carbon atoms, A molded polycarbonate resin composition characterized in that the polycarbonate resin (A) phase forms a continuous phase, the polyester resin (B) phase is dispersed in the continuous phase of the polycarbonate resin (A), and wollastonite (C) has a morphology in which it is in contact with both the polycarbonate resin (A) phase and the polyester resin (B) phase.

Description

Technical Field

[0001] The present invention relates to a molded article of a polycarbonate resin composition, and more particularly to a molded article of a polycarbonate resin composition excellent in tensile elongation, notch tensile strength, and flexural elasticity.

Background Art

[0002] Conventionally, polycarbonate resins are excellent in transparency, impact resistance, heat resistance, etc., and moreover, the obtained molded products are also excellent in dimensional stability, etc., so they are used in a wide range of fields such as electrical and electronic equipment parts, OA equipment parts, mechanical parts, vehicle parts, etc. Furthermore, a polymer alloy composed of a polycarbonate resin and a thermoplastic polyester resin is a material in which the chemical resistance and molding processability, which are the drawbacks of aromatic polycarbonate resins, are improved while making use of the above excellent characteristics of polycarbonate resins, and is used in a wide range of fields such as vehicle interior and exterior parts, various housing members, and others. And, in order to improve the rigidity and dimensional stability of a polymer alloy composed of a polycarbonate resin and a thermoplastic polyester resin, it is often the case that flaky or plate-like inorganic fillers such as talc and mica are blended.

[0003] However, a molded article of a resin composition composed of a polycarbonate resin and a thermoplastic aromatic polyester resin blended with flaky or plate-like inorganic fillers such as talc and mica has a drawback that the mechanical properties deteriorate because the reinforcing effect is small. A method of blending wollastonite, which is a needle-like inorganic filler, as an inorganic filler is also known. In Patent Document 1, it is proposed that by blending wollastonite having an aspect ratio L / D of 3 to 50 into a resin composition composed of a polycarbonate resin and a thermoplastic aromatic polyester resin, a sufficient reinforcing effect (particularly rigidity and impact resistance) and chemical resistance are improved. However, a molded article obtained by simply blending wollastonite into a polymer alloy of a polycarbonate resin and a thermoplastic polyester resin has a problem that brittle fracture easily occurs in a tensile test and the toughness tends to be insufficient. [Prior art documents] [Patent Documents]

[0004] [Patent Document 1] Japanese Patent Publication No. 2001-187839 [Overview of the project] [Problems that the invention aims to solve]

[0005] The object (problem) of the present invention is to provide a polycarbonate resin composition molded article that is excellent in tensile elongation, notched tensile strength, and flexural elasticity, comprising a polycarbonate resin composition of a polycarbonate resin and a thermoplastic polyester resin. [Means for solving the problem]

[0006] As a result of diligent research to achieve the above objectives, the inventors have discovered that a polycarbonate resin composition molded article, comprising a polymer alloy of a polycarbonate resin and a thermoplastic polyester resin, containing a specific amount of wollastonite surface-treated with an alkylsilane of a specific number of carbon atoms, having a specific volume-average fiber diameter and volume-average fiber length, an aspect ratio of 3 or more, wherein the polycarbonate resin phase forms a continuous phase, the polyester resin phase is dispersed in the continuous phase of the polycarbonate resin phase (A), and the wollastonite is in contact with both the polycarbonate resin phase and the polyester resin phase, exhibits excellent tensile elongation, notched tensile strength, and flexural elasticity, leading to the present invention. This invention relates to the following polycarbonate resin composition molded articles.

[0007] 1. A molded polycarbonate resin composition comprising 100 parts by mass in total, consisting of 50 to 80 parts by mass of polycarbonate resin (A) and 20 to 50 parts by mass of thermoplastic polyester resin (B), and containing 5 to 20 parts by mass of wollastonite (C) having a volume-average fiber diameter of 1.0 to 6.0 μm, a volume-average fiber length of 10.0 to 20.0 μm, an aspect ratio of 3 or more, and surface-treated with an alkylsilane having 8 to 14 carbon atoms. A molded polycarbonate resin composition characterized in that the polycarbonate resin (A) phase forms a continuous phase, the polyester resin (B) phase is dispersed in the continuous phase of the polycarbonate resin (A), and wollastonite (C) has a morphology in which it is in contact with both the polycarbonate resin (A) phase and the polyester resin (B) phase. 2. A molded polycarbonate resin composition according to item 1, wherein the tensile fracture strain measured in accordance with ISO 527 is 70% or more. [Effects of the Invention]

[0008] The polycarbonate resin composition molded article of the present invention exhibits excellent tensile elongation, notched tensile strength, and flexural elasticity. The polycarbonate resin composition molded article of the present invention has a sea-island structure, and has a morphology having a sea-island structure in which the polycarbonate resin (A) phase forms the matrix phase and the thermoplastic polyester resin (B) phase exists in an island-like manner. Normally, wollastonite is embedded in the highly polar thermoplastic polyester resin (B) phase, but in the present invention, by using wollastonite (C) surface-treated with an alkylsilane having 8 to 14 carbon atoms as the wollastonite, the wollastonite (C) has a morphology in which it is in contact with both the polycarbonate resin (A) phase and the polyester resin (B) phase. Due to this morphology, wollastonite (C) is dispersed in contact with both the polycarbonate resin (A) phase and the polyester resin (B) phase. As a result, the interfacial resin in contact with wollastonite (C) consists of both polycarbonate resin (A) and polyester resin (B), enabling the molded article to exhibit excellent tensile elongation, notched tensile strength, and flexural elasticity. [Brief explanation of the drawing]

[0009] [Figure 1] This is an SEM image (magnification 10,000x) showing the morphology of the molded body obtained in Example 1. [Figure 2] This is an SEM image (magnification 30,000x) showing the morphology of the molded body obtained in Example 1. [Figure 3] This is an SEM image (magnification 10,000x) showing the morphology of the molded body obtained in Example 4. [Figure 4] This is an SEM image (magnification 30,000x) showing the morphology of the molded body obtained in Example 4. [Figure 5] This is an SEM image (magnification 10,000x) showing the morphology of the molded body obtained in Comparative Example 1. [Figure 6] This is an SEM image (magnification 30,000x) showing the morphology of the molded body obtained in Comparative Example 1. [Modes for carrying out the invention]

[0010] The present invention will be described in detail below with reference to embodiments and examples. In this specification, unless otherwise specified, "~" means that the numbers before and after it are included as the lower and upper limits.

[0011] The polycarbonate resin composition molded article of the present invention is a molded article of a polycarbonate resin composition comprising 100 parts by mass in total, consisting of 50 to 80 parts by mass of polycarbonate resin (A) and 20 to 50 parts by mass of thermoplastic polyester resin (B), and containing 5 to 20 parts by mass of wollastonite (C) having a volume-average fiber diameter of 1.0 to 6.0 μm, a volume-average fiber length of 10.0 to 20.0 μm, an aspect ratio of 3 or more, and surface-treated with an alkylsilane having 8 to 14 carbon atoms. The polycarbonate resin (A) phase forms a continuous phase, the polyester resin (B) phase is dispersed within the continuous phase of the polycarbonate resin (A), and the wollastonite (C) has a morphology in which it is in contact with both the polycarbonate resin (A) phase and the polyester resin (B) phase.

[0012] Figure 1 is an SEM image (magnification: 10,000x) showing the morphology of the resin composition molded body obtained in Example 1, and Figure 2 is an image with increased magnification to 30,000x. In Figure 2, the light gray phase A forming the matrix (sea) is polycarbonate resin (A) phase A. The dark gray phases existing as islands within the sea of ​​polycarbonate resin (A) phase A are thermoplastic polyester resin (B) phase B. In Figures 1 and 2, the relatively large shapes are wollastonite (C) (C in Figure 2). The black circular shapes in Figures 1 and 2 are elastomers. Figure 2 shows that the interface of wollastonite (C)C is in contact with both the thermoplastic polyester resin (B) phase B and the polycarbonate resin (A) phase A. Figures 3 and 4 show morphological images of the resin composition molded articles obtained in Example 4, and it can be confirmed that they have the same morphology as Figures 1 and 2. Figs. 5 and 6 are SEM images of the resin composition molded body obtained in Comparative Example 1 (Fig. 5: magnification 10,000 times, Fig. 6: magnification 30,000 times). As shown in the figures, it can be seen that wollastonite (C) is encapsulated in the phase of the thermoplastic polyester resin (B). The molded body having the morphology of the present invention can exhibit excellent tensile elongation, notched tensile strength, and flexural elasticity.

[0013] [Polycarbonate resin (A)] The polycarbonate resin (A) contained in the polycarbonate resin composition molded body of the present invention is not particularly limited, and various types can be used. Polycarbonate resins can be classified into aromatic polycarbonate resins in which the carbon directly bonded to the carbonate bond is aromatic carbon, and aliphatic polycarbonate resins in which the carbon is aliphatic carbon, and either can be used. Among them, as the polycarbonate resin (A), aromatic polycarbonate resins are preferable from the viewpoints of heat resistance, mechanical properties, electrical properties, etc.

[0014] Among the monomers used as raw materials for aromatic polycarbonate resins, examples of aromatic dihydroxy compounds include Dihydroxybenzenes such as 1,2-dihydroxybenzene, 1,3-dihydroxybenzene (i.e., resorcinol), 1,4-dihydroxybenzene; Dihydroxybiphenyls such as 2,5-dihydroxybiphenyl, 2,2'-dihydroxybiphenyl, 4,4'-dihydroxybiphenyl; Dihydroxynaphthalenes such as 2,2'-dihydroxy-1,1'-binaphthyl, 1,2-dihydroxynaphthalene, 1,3-dihydroxynaphthalene, 2,3-dihydroxynaphthalene, 1,6-dihydroxynaphthalene, 2,6-dihydroxynaphthalene, 1,7-dihydroxynaphthalene, 2,7-dihydroxynaphthalene;

[0015] Dihydroxydiaryl ethers such as 2,2'-dihydroxydiphenyl ether, 3,3'-dihydroxydiphenyl ether, 4,4'-dihydroxydiphenyl ether, 4,4'-dihydroxy-3,3'-dimethyldiphenyl ether, 1,4-bis(3-hydroxyphenoxy)benzene, and 1,3-bis(4-hydroxyphenoxy)benzene;

[0016] 2,2-bis(4-hydroxyphenyl)propane (i.e., bisphenol A), 1,1-Bis(4-hydroxyphenyl)propane, 2,2-Bis(3-methyl-4-hydroxyphenyl)propane (i.e., bisphenol C), 2,2-bis(3-methoxy-4-hydroxyphenyl)propane, 2-(4-hydroxyphenyl)-2-(3-methoxy-4-hydroxyphenyl)propane, 1,1-Bis(3-tert-butyl-4-hydroxyphenyl)propane, 2,2-bis(3,5-dimethyl-4-hydroxyphenyl)propane, 2,2-Bis(3-cyclohexyl-4-hydroxyphenyl)propane, 2-(4-hydroxyphenyl)-2-(3-cyclohexyl-4-hydroxyphenyl)propane, α,α'-bis(4-hydroxyphenyl)-1,4-diisopropylbenzene, 1,3-bis[2-(4-hydroxyphenyl)-2-propyl]benzene, Bis(4-hydroxyphenyl)methane, Bis(4-hydroxyphenyl)cyclohexylmethane, Bis(4-hydroxyphenyl)phenylmethane, Bis(4-hydroxyphenyl)(4-propenylphenyl)methane, Bis(4-hydroxyphenyl)diphenylmethane, Bis(4-hydroxyphenyl)naphthylmethane, 1,1-bis(4-hydroxyphenyl)ethane, 1,1-bis(4-hydroxyphenyl)-1-phenylethane, 1,1-bis(4-hydroxyphenyl)-1-naphthylethane, 1,1-Bis(4-hydroxyphenyl)butane, 2,2-bis(4-hydroxyphenyl)butane, 2,2-bis(4-hydroxyphenyl)pentane, 1,1-Bis(4-hydroxyphenyl)hexane, 2,2-bis(4-hydroxyphenyl)hexane, 1,1-bis(4-hydroxyphenyl)octane, 2,2-bis(4-hydroxyphenyl)octane, 4,4-bis(4-hydroxyphenyl)heptane, 2,2-bis(4-hydroxyphenyl)nonane, 1,1-bis(4-hydroxyphenyl)decane, 1,1-Bis(4-hydroxyphenyl)dodecane, Bis(hydroxyaryl)alkanes such as;

[0017] 1,1-Bis(4-hydroxyphenyl)cyclopentane, 1,1-Bis(4-hydroxyphenyl)cyclohexane, 1,1-bis(4-hydroxyphenyl)-3,3-dimethylcyclohexane, 1,1-bis(4-hydroxyphenyl)-3,4-dimethylcyclohexane, 1,1-bis(4-hydroxyphenyl)-3,5-dimethylcyclohexane, 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, 1,1-Bis(4-hydroxy-3,5-dimethylphenyl)-3,3,5-trimethylcyclohexane, 1,1-Bis(4-hydroxyphenyl)-3-propyl-5-methylcyclohexane, 1,1-Bis(4-hydroxyphenyl)-3-tert-butyl-cyclohexane, 1,1-Bis(4-hydroxyphenyl)-4-tert-butyl-cyclohexane, 1,1-bis(4-hydroxyphenyl)-3-phenylcyclohexane, 1,1-Bis(4-hydroxyphenyl)-4-phenylcyclohexane, Bis(hydroxyaryl)cycloalkanes such as;

[0018] 9,9-Bis(4-hydroxyphenyl)fluorene, Bisphenols containing cardo structures, such as 9,9-bis(4-hydroxy-3-methylphenyl)fluorene;

[0019] 4,4'-Dihydroxydiphenyl sulfide, Dihydroxydiaryl sulfides such as 4,4'-dihydroxy-3,3'-dimethyldiphenyl sulfide; Dihydroxydiaryl sulfoxides such as 4,4'-dihydroxydiphenyl sulfoxide and 4,4'-dihydroxy-3,3'-dimethyldiphenyl sulfoxide; 4,4'-Dihydroxydiphenylsulfone, Dihydroxydiarylsulfones such as 4,4'-dihydroxy-3,3'-dimethyldiphenylsulfone; These are some examples.

[0020] Among these, bis(hydroxyaryl)alkanes are preferred, and among them, bis(4-hydroxyphenyl)alkanes are preferred, and in particular, 2,2-bis(4-hydroxyphenyl)propane and 2,2-bis(3-methyl-4-hydroxyphenyl)propane are preferred from the viewpoint of impact resistance and heat resistance. Furthermore, one aromatic dihydroxy compound may be used, or two or more may be used in any combination and ratio.

[0021] Among the monomers used as raw materials for polycarbonate resin, examples of carbonate precursors include carbonyl halides and carbonate esters. Note that one type of carbonate precursor may be used, or two or more types may be used in any combination and ratio.

[0022] Examples of carbonyl halides include, specifically, phosgene; bischloroformates of dihydroxy compounds; monochloroformates of dihydroxy compounds; and other haloformates.

[0023] Examples of carbonate esters include diaryl carbonates such as diphenyl carbonate and dityl carbonate; dialkyl carbonates such as dimethyl carbonate and diethyl carbonate; and carbonates of dihydroxy compounds such as biscarbonates, monocarbonates, and cyclic carbonates of dihydroxy compounds.

[0024] The method for producing the polycarbonate resin (A) is not particularly limited, and any method can be used. Examples include interfacial polymerization, molten transesterification, pyridine method, ring-opening polymerization of cyclic carbonate compounds, and solid-phase transesterification of prepolymers. Among these, interfacial polymerization and molten transesterification are preferred because they offer a greater improvement in moisture and heat resistance, with interfacial polymerization being particularly preferred.

[0025] The molecular weight of the polycarbonate resin (A) is preferably 10,000 to 50,000 in viscosity-average molecular weight (Mv), more preferably 10,000 to 40,000, among which 10,000 to 30,000 and 10,000 to 26,000, even more preferably 10,500 or more, 11,000 or more, particularly 11,500 or more, most preferably 12,000 or more, even more preferably 24,000 or less, and particularly preferably 20,000 or less. By setting the viscosity-average molecular weight to be above the lower limit of the above range, the mechanical strength of the polycarbonate resin composition of the present invention can be further improved, and by setting the viscosity-average molecular weight to be below the upper limit of the above range, the decrease in fluidity of the polycarbonate resin composition of the present invention can be suppressed and improved, thereby enhancing moldability and facilitating molding. Furthermore, two or more polycarbonate resins with different viscosity-average molecular weights may be mixed and used. In this case, polycarbonate resins whose viscosity-average molecular weight is outside the preferred range described above may also be mixed.

[0026] The viscosity-average molecular weight (Mv) is calculated by using methylene chloride as the solvent, determining the intrinsic viscosity [η] (unit: dl / g) at 25°C using an Ubbelohde viscometer, and then using Schnell's viscosity formula, i.e., η = 1.23 × 10⁻⁶. -4 Mv 0.83 It refers to the value calculated from [the formula]. In addition, intrinsic viscosity [η] is the specific viscosity [η] at each solution concentration [C] (g / dl). sp This value was calculated by measuring [the value] and using the following formula.

number

[0027] Furthermore, the polycarbonate resin (A) may be not only virgin resin, but also polycarbonate resin recycled from used products (so-called material-recycled polycarbonate resin), or polycarbonate resin manufactured from polycarbonate resin that has been chemically decomposed back into raw materials (so-called chemical-recycled polycarbonate resin). It is also preferable to contain both virgin resin and recycled resin, and may consist solely of recycled polycarbonate resin. The proportion of recycled polycarbonate resin in polycarbonate resin (A) is preferably 40% or more, 50% or more, 60% or more, or 80% or more, and particularly preferably 100%.

[0028] Preferred used products include various sheet materials, optical recording media such as optical discs (CDs, DVDs), light guide plates, transparent vehicle components such as car windows, car headlamp lenses, and windshields, containers such as water bottles, various cover materials, eyeglass lenses, and building components such as soundproof walls, glass windows, and corrugated sheets. In addition, recycled polycarbonate resin can be made from crushed materials obtained from defective products during molding, sprues, or runners, or pelletized materials obtained by melting these materials.

[0029] [Thermoplastic polyester resin (B)] The thermoplastic polyester resin (B) is a polymer or copolymer obtained by a condensation reaction mainly consisting of a dicarboxylic acid component, which is composed of dicarboxylic acids or their reactive derivatives, and a diol component, which is composed of diols or their ester derivatives. Preferably, an aromatic dicarboxylic acid is used as the main acid component, and a thermoplastic polyester resin obtained by polycondensation reaction of this with an alcohol mainly composed of an aliphatic diol is used.

[0030] Examples of aromatic dicarboxylic acids include terephthalic acid, isophthalic acid, orthophthalic acid, 1,5-naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid, 4,4'-biphenyldicarboxylic acid, 4,4'-biphenyletherdicarboxylic acid, 4,4'-biphenylmethanedicarboxylic acid, 4,4'-biphenylsulfondicarboxylic acid, 4,4'-biphenylisopropylidenedicarboxylic acid, 1,2-bis(phenoxy)ethane-4,4'-dicarboxylic acid, 2,5-anthracenedicarboxylic acid, 2,6-anthracenedicarboxylic acid, 4,4'-p-ta-phenylenedicarboxylic acid, and 2,5-pyridinedicarboxylic acid. Substitutes of these (e.g., alkyl-substituted compounds such as 5-methylisophthalic acid) and reactive derivatives (e.g., alkyl ester derivatives such as dimethyl terephthalate and diethyl terephthalate) can also be used.

[0031] Of these, terephthalic acid, isophthalic acid, 2,6-naphthalenedicarboxylic acid and their alkyl ester derivatives are more preferred, and terephthalic acid, isophthalic acid, and their alkyl ester derivatives are particularly preferred. These aromatic dicarboxylic acids may be used individually or in combination of two or more, and it is also possible to use one or more aliphatic dicarboxylic acids such as adipic acid, azelaic acid, sebacic acid, and dodecanedioic acid, or alicyclic dicarboxylic acids such as cyclohexanedicarboxylic acid in combination with the aromatic dicarboxylic acid.

[0032] Examples of diols include aliphatic diols such as ethylene glycol, diethylene glycol, 1,2-propylene glycol, 1,3-propanediol, triethylene glycol, 1,4-butanediol, neopentyl glycol, 1,5-pentanediol, 1,6-hexanediol, decamethylene glycol, and 2,2-dimethyl-1,3-propanediol; alicyclic diols such as 1,4-cyclohexanedimethanol, 1,3-cyclohexanedimethanol, cyclohexanediol, and trans- or cis-2,2,4,4-tetramethyl-1,3-cyclobutanediol; and aromatic diols such as p-xylenediol, bisphenol A, tetrabromobisphenol A, and tetrabromobisphenol A-bis(2-hydroxyethyl ether). Substitutes of these diols can also be used.

[0033] Of these, aliphatic diols are preferred in terms of heat resistance and dimensional stability, ethylene glycol, 1,4-butanediol, and 1,4-cyclohexanedimethanol are more preferred, and ethylene glycol is particularly preferred.

[0034] Diols may be used alone or in combination of two or more. Furthermore, one or more long-chain diols with molecular weights of 400 to 6,000, such as polyethylene glycol, poly-1,3-propylene glycol, and polytetramethylene glycol, may be copolymerized in combination with the above-mentioned diols.

[0035] Furthermore, thermoplastic polyester resin (B) can be copolymerized with hydroxycarboxylic acids such as parahydroxybenzoic acid, other carboxylic acids, and alcohols other than the diols mentioned above, and such copolymerized resins can also be used in the present invention. However, it is preferable that such copolymerized components be present in small amounts, and it is preferable that 80% by mass or more, and more preferably 90% by mass or more, of the thermoplastic polyester resin (B) consists of components from aromatic dicarboxylic acids and aliphatic diols. It is also preferable that one type of compound accounts for 80 mol% or more, and more preferably 90 mol% or more, of each aromatic dicarboxylic acid and aliphatic diol.

[0036] Preferred examples of such thermoplastic polyester resins (B) include polybutylene terephthalate, polybutylene naphthalate, polycyclohexanedimethanol terephthalate, polyethylene terephthalate, and polyethylene naphthalate. These may contain copolymer components such as polybutylene terephthalate / isophthalate and polyethylene terephthalate / isophthalate. In the present invention, among these, polybutylene terephthalate (PBT), polybutylene terephthalate / isophthalate (PBT / I), polyethylene terephthalate (PET), and polyethylene terephthalate / isophthalate (PET / I) are preferred, and it is also preferable to use a combination of these. When using a combination, the ratio of PET (as the amount containing PET / I):PBT (as the amount containing PBT / I) = 8:1 to 1:8 (by mass ratio) is preferred.

[0037] Germanium compounds, antimony compounds, tin compounds, and titanium compounds are known polymerization catalysts for the production of polyethylene terephthalate, but in the present invention, it is preferable to use a polymerized product using a germanium compound as a catalyst. When polymerized products using other catalysts are used, the thermal stability and recyclability of the final composition with aromatic polycarbonate resin tend to decrease. Examples of germanium compounds to be used as catalysts include germanium oxides such as germanium dioxide, germanium alkoxides such as germanium tetraethoxide and germanium tetraisopropoxide, germanium hydroxide and its alkali metal salts, germanium glycolate, germanium chloride, and germanium acetate. These may be used individually or in combination of two or more. Among these, the use of germanium dioxide is preferred in terms of the solvent resistance and thermal stability of the resulting polyethylene terephthalate.

[0038] It is preferable to use a germanium catalyst in such a concentration of germanium atoms in the resulting polyethylene terephthalate that it reaches 15 ppm to 40 ppm. Below 15 ppm, the polymerization reaction proceeds slowly, and above 40 ppm, side reactions may occur due to germanium compounds remaining in the resin.

[0039] As for polybutylene terephthalate, it is preferable to use a polymerized product using a titanium compound as the main catalyst and a Group 1 or Group 2 metal compound as a co-catalyst. Examples of titanium compounds include inorganic titanium compounds such as titanium oxide and titanium tetrachloride; titanium alcoholates such as tetramethyl titanate, tetraisopropyl titanate, and tetrabutyl titanate; and titanium phenolates such as tetraphenyl titanate. Among these, the use of titanium alcoholates is preferred. The most preferred are tetraalkyl titanates, particularly tetrabutyl titanate.

[0040] It is preferable to use the titanium compound in the resulting polybutylene terephthalate at a concentration of 20 ppm to 50 ppm, particularly 30 to 40 ppm, in terms of titanium atoms. If too much titanium compound is used, the color and hydrolysis resistance of the resulting polybutylene terephthalate may decrease, and solution haze and an increase in impurities may occur due to deactivation of the titanium catalyst. Conversely, if too little is used, the polymerization properties of the polybutylene terephthalate tend to decrease.

[0041] The thermoplastic polyester resin (B) preferably has an intrinsic viscosity (IV) of 0.4 to 2.0 dl / g, measured at 30°C in a mixed solvent of phenol and tetrachloroethane (mass ratio = 50 / 50). If an intrinsic viscosity of less than 0.4 dl / g is used, the mechanical strength of the resin composition will be inferior, while if it exceeds 2.0 dl / g, the moldability tends to decrease. A more preferred intrinsic viscosity (IV) for thermoplastic polyester resin (B) is 0.6 to 1.8 dl / g, and even more preferably 0.6 to 1.6 dl / g.

[0042] Furthermore, the thermoplastic polyester resin (B) can be made from not only virgin products but also recycled materials, such as those made from used products, or material recycled materials. It can also be made from recycled materials, such as defective products, sprues, and runners, produced during molding. It is preferable to use such recycled materials for the thermoplastic polyester resin (B).

[0043] The content of polycarbonate resin (A) and thermoplastic polyester resin (B) is such that, based on a total of 100 parts by mass of polycarbonate resin (A) and thermoplastic polyester resin (B), polycarbonate resin (A) is 50 to 80 parts by mass and thermoplastic polyester resin (B) is 20 to 50 parts by mass. If the content of thermoplastic polyester resin (B) is less than 20 parts by mass, the effect of improving the chemical resistance and fluidity of polycarbonate resin (A) is not sufficiently obtained, and if it exceeds 50 parts by mass, the heat resistance, heat retention stability, and dimensional stability of polycarbonate resin (A) deteriorate. The content of thermoplastic polyester resin (B) is preferably less than 50 parts by mass, more preferably 45 parts by mass or less, and particularly preferably 40 parts by mass or less. Furthermore, it is preferably 15 parts by mass or more, even more preferably 20 parts by mass or more, and particularly preferably 25 parts by mass or more.

[0044] [Wallastonite (C)] The polycarbonate resin composition molded article of the present invention contains wollastonite (C) surface-treated with an alkylsilane having 8 to 14 carbon atoms, having a volume-average fiber diameter of 1.0 to 6.0 μm, a volume-average fiber length of 10.0 to 20.0 μm, and an aspect ratio of 3 or more.

[0045] Wollastonite, represented as CaO·SiO2, is a naturally occurring white, acicular crystalline mineral, and may also be synthesized.

[0046] The initial volume-average fiber diameter of wollastonite (C) is 1.0 to 6.0 μm, preferably 1.5 μm or more, more preferably 2.0 μm or more, even more preferably 2.5 μm or more, particularly preferably 3.0 μm or more, preferably 5.5 μm or less, more preferably 5.0 μm or less, even more preferably 4.7 μm or less, and particularly preferably 4.5 μm or less. If the volume-average fiber diameter is less than 1.0 μm, it is prone to breakage during processing. If the volume-average fiber diameter exceeds 6.0 μm, the surface area of ​​a single wollastonite particle increases, and when interfacial delamination occurs due to external stress, a large delamination area is formed, making it prone to breakage, resulting in reduced elongation and a smaller toughness improvement effect. The initial volume-average fiber length of wollastonite (C) is 10.0 to 20.0 μm, preferably 11.0 μm or more, more preferably 12.0 μm or more, even more preferably 13.0 μm or more, particularly preferably 13.5 μm or more, preferably 18.0 μm or less, more preferably 17.0 μm or less, even more preferably 16.0 μm or less, and particularly preferably 15.5 μm or less. If the volume-average fiber length is less than 10.0 μm, the reinforcing effect tends to be small, and if it exceeds 20.0 μm, the toughness becomes poor and appearance defects are likely to occur.

[0047] Furthermore, the initial average aspect ratio of wollastonite (C) (the value obtained by dividing the initial volume-average fiber length by the initial volume-average fiber diameter) is 3 or greater, preferably 3.1 or greater, more preferably 3.2 or greater, preferably 6.0 or less, more preferably 5.0 or less, even more preferably 4.5 or less, most preferably 4.0 or less, and especially preferably 3.8 or less. If the initial average aspect ratio falls below 3, the reinforcing effect tends to be reduced. In this invention, the volume-average fiber diameter and volume-average fiber length of wollastonite(C) can be measured, for example, by using the particle shape image analysis device "PITA-04" manufactured by Seishin Corporation to photograph wollastonite(C) particles and processing the obtained images. The measurement is considered to end when the cumulative number of wollastonite(C) particles from the start of measurement reaches 10,000, and each measurement value is the volume-average fiber diameter D of 10,000 wollastonite(C) particles. 50and volume-average fiber length D 50 That is the case. The average aspect ratio is calculated by dividing the volume-average fiber length obtained above by the volume-average fiber diameter.

[0048] The wollastonite (C) has the aforementioned morphology in contact with both the polycarbonate resin (A) phase and the polyester resin (B) phase, but the proportion of wollastonite (C) in contact with both the polycarbonate resin (A) phase and the polyester resin (B) phase is preferably 90% or more on average in number, and more preferably 95% or more. The proportion of wollastonite (C) in contact with both phase (A) and phase (B) is determined by using a SEM cross-section preparation device to observe the core portion of the molded body cross-section (the central part of the cross-section, the cross-section parallel to the flow direction of the resin composition) under an accelerating voltage of 1kV to 10kV at a magnification of 3,000 to 30,000 times. From the obtained image, the resin phase in contact with 100 or more wollastonite particles is investigated, and the proportion of these particles is calculated.

[0049] Wollastonite (C) is wollastonite surface-treated with an alkylsilane having 8 to 14 carbon atoms. Various surface treatment agents are available, but in this invention, an alkylsilane having 8 to 14 carbon atoms is used. By including wollastonite (C) with a volume-average fiber diameter of 1.0 to 6.0 μm, a volume-average fiber length of 10.0 to 20.0 μm, and an aspect ratio of 3 or more, and surface-treated with an alkylsilane having 8 to 14 carbon atoms, the molded article forms the aforementioned morphology, resulting in ductile fracture, which in turn exhibits high toughness and can be made to have excellent tensile elongation, notched tensile strength, and flexural modulus. Surface-treated materials with alkylsilanes having 7 or fewer carbon atoms exhibit poor tensile elongation and are prone to brittle fracture, while surface-treated materials with alkylsilanes having 15 or more carbon atoms exhibit poor tensile elongation and are prone to reduced notched tensile strength.

[0050] C8-C14 alkylsilanes are silane compounds having an alkyl group having C8-C14, where the alkyl group may be linear or branched. Examples of silane compounds having an alkyl group having C8-C14 include alkyltriethoxysilane and alkyltrimethoxysilane. Examples of C8-C14 alkyl groups include octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, and tetradecyl groups. C8-C10 alkyl groups are more preferred, with octyl, nonyl, and decyl groups being preferred. Preferred alkylsilanes include octyltriethoxysilane, octyltrimethoxysilane, nonyltriethoxysilane, nonyltrimethoxysilane, decyltriethoxysilane, and decyltrimethoxysilane.

[0051] The amount of surface treatment with alkylsilane is preferably 0.1 to 5% by mass relative to wollastonite (C), more preferably 0.2% by mass or more, and more preferably 0.3% by mass or more, 0.4% by mass or more, and 0.5% by mass or more, and more preferably 3% by mass or less, and more preferably 2.5% by mass or less, 2% by mass or less, 1.5% by mass or less, 1.4% by mass or less, and 1.3% by mass or less.

[0052] The wollastonite (C) content in the polycarbonate resin composition is 5 to 20 parts by mass per 100 parts by mass of the total of the polycarbonate resin (A) and thermoplastic polyester resin (B). If the amount of wollastonite (C) is less than 5 parts by mass, the effect of improving mechanical strength is small, and if it exceeds 20 parts by mass, the surface smoothness of the molded product decreases, and the fluidity and appearance deteriorate, which is undesirable. The wollastonite (C) content is preferably 8 parts by mass or more, and preferably 15 parts by mass or less.

[0053] [Elastomer] The polycarbonate resin composition preferably contains an elastomer. As the elastomer, a copolymer obtained by graft copolymerizing a rubber component with a monomer component copolymerizable thereto is preferred. The method for producing such a graft copolymer may be any of the following methods: bulk polymerization, solution polymerization, suspension polymerization, emulsion polymerization, etc., and the copolymerization method may be single-stage grafting or multi-stage grafting.

[0054] The above rubber components typically have a glass transition temperature of 0°C or lower, preferably -20°C or lower, and more preferably -30°C or lower. Specific examples of rubber components include polybutadiene rubber, polyisoprene rubber or its hydrogenated derivatives, butadiene-acrylic composite rubber, styrene-butadiene rubber, ethylene-α-olefin rubbers such as ethylene-propylene rubber, ethylene-butene rubber, and ethylene-octene rubber, and ethylene-acrylic rubber. These may be used individually or in mixtures of two or more. Among these, polybutadiene rubber, polyisoprene rubber and its hydrogenated derivatives, and styrene-butadiene rubber are preferred. Rubber components such as polyalkyl acrylate rubbers like polybutyl acrylate, poly(2-ethylhexyl acrylate), or butyl acrylate-2-ethylhexyl acrylate copolymers, or silicone-based rubbers like organopolysiloxane rubber, are undesirable because they tend to increase the dielectric loss tangent.

[0055] Specific examples of monomer components that can be graft copolymerized with rubber components include aromatic vinyl compounds, vinyl cyanide compounds, (meth)acrylic acid ester compounds, epoxy group-containing (meth)acrylic acid ester compounds such as glycidyl (meth)acrylate; maleimide compounds such as maleimide, N-methylmaleimide, and N-phenylmaleimide; and α,β-unsaturated carboxylic acid compounds such as maleic acid, phthalic acid, and itaconic acid, and their anhydrides (e.g., maleic anhydride). These monomer components may be used individually or in combination of two or more. Among these, aromatic vinyl compounds and (meth)acrylic acid ester compounds are preferred, and styrene, methyl (meth)acrylate, ethyl (meth)acrylate, butyl (meth)acrylate, cyclohexyl (meth)acrylate, and octyl (meth)acrylate are particularly preferred.

[0056] The elastomer is preferably of the core / shell type graft copolymer type. In particular, a core / shell type graft copolymer is preferred, which consists of a core layer made of at least one rubber component selected from polybutadiene-containing rubber, ethylene / butylene rubber, and polybutyl acrylate-containing rubber, and a shell layer formed by copolymerizing (meth)acrylic acid ester around it, and a core / shell type elastomer with butadiene-based rubber as the core is especially preferred. In the above core / shell type graft copolymer, it is preferable that the rubber component is contained in 40% by mass or more, and more preferably 60% by mass or more. Furthermore, it is preferable that the (meth)acrylic acid component is contained in 10% by mass or more.

[0057] Preferred specific examples of these core / shell type graft copolymers include butadiene / methyl (meth)acrylate copolymer (MB), butadiene / methyl (meth)acrylate / styrene copolymer (MBS), and styrene / ethylene / butylene / styrene copolymer (SEBS), with butadiene / methyl (meth)acrylate copolymer (MB), butadiene / methyl (meth)acrylate / styrene copolymer (MBS), and styrene / ethylene / butylene / styrene copolymer (SEBS) being more preferred.

[0058] The preferred elastomer content is 2 to 10 parts by mass per 100 parts by mass of the total of the polycarbonate resin (A) and thermoplastic polyester resin (B). Including it in this amount can further improve the impact resistance of the polycarbonate resin composition molded article. The elastomer content is more preferably 2.5 parts by mass or more, even more preferably 3.0 parts by mass or more, particularly preferably 3.3 parts by mass or more, more preferably 8 parts by mass or less, and among these, 7 parts by mass or less, 6 parts by mass or less, and particularly preferably 4 parts by mass or less. In the molded article of the present invention, if an elastomer is included, the elastomer exists as an island-like phase in the polycarbonate resin (A) phase matrix, appearing as dark black circular island-like structures in Figure 1-4.

[0059] [Stabilizer] The polycarbonate resin composition preferably contains a stabilizer, and phosphorus-based stabilizers or phenol-based stabilizers are preferred.

[0060] Any known phosphorus-based stabilizer can be used. Specific examples include phosphoric acid, phosphonic acid, phosphorous acid, phosphinic acid, polyphosphate and other phosphorus oxoacids; acidic pyrophosphate metal salts such as sodium acidic pyrophosphate, potassium acidic pyrophosphate, and calcium acidic pyrophosphate; phosphates of Group 1 or Group 2 metals such as potassium phosphate, sodium phosphate, cesium phosphate, and zinc phosphate; and organic phosphate compounds, organic phosphite compounds, and organic phosphonite compounds, with organic phosphite compounds being particularly preferred.

[0061] Examples of organic phosphite compounds include triphenyl phosphite, tris(mononylphenyl) phosphite, tris(mononyl / dinonylphenyl) phosphite, tris(2,4-di-tert-butylphenyl) phosphite, monooctyldiphenyl phosphite, dioctylmonophenyl phosphite, monodecyldiphenyl phosphite, didecylmonophenyl phosphite, tridecyl phosphite, trilauryl phosphite, tristearyl phosphite, and 2,2-methylenebis(4,6-di-tert-butylphenyl)octyl phosphite. Examples of such organic phosphite compounds include "ADEKA Stab 1178," "ADEKA Stab 2112," and "ADEKA Stab HP-10" from ADEKA Corporation, "JP-351," "JP-360," and "JP-3CP" from Johoku Chemical Industry Co., Ltd., and "Irgaphos 168" from BASF. Furthermore, the product may contain one type of phosphorus-based stabilizer, or two or more types in any combination and ratio.

[0062] The phosphorus-based stabilizer content is typically 0.001 parts by mass or more, preferably 0.01 parts by mass or more, and more preferably 0.03 parts by mass or more, per 100 parts by mass of the total of the polycarbonate resin (A) and the thermoplastic polyester resin (B), and is also typically 1 part by mass or less, preferably 0.7 parts by mass or less, and more preferably 0.5 parts by mass or less. If the phosphorus-based stabilizer content is below the lower limit of the above range, the thermal stabilization effect may be insufficient, and if the phosphorus-based stabilizer content exceeds the upper limit of the above range, the effect may plateau and become uneconomical.

[0063] Examples of phenolic stabilizers include hindered phenolic antioxidants. Specific examples include pentaerythritol tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, thiodiethylenebis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], N,N'-hexane-1,6-diylbis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionamide], 2,4-dimethyl-6-(1-methylpentadecyl)phenol, diethyl[[3,5-bis(1,1-dimethylethyl)-4-hydroxyphenyl]methyl]phosphoate, 3,3',3”,5,5',5”-hexa-tert-butyl-a,a',a”-(mesitylene-2,4,6- Examples include triyl)tri-p-cresol, 4,6-bis(octylthiomethyl)-o-cresol, ethylenebis(oxyethylene)bis[3-(5-tert-butyl-4-hydroxy-m-tolyl)propionate], hexamethylenebis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], 1,3,5-tris(3,5-di-tert-butyl-4-hydroxybenzyl)-1,3,5-triazine-2,4,6(1H,3H,5H)-trione, 2,6-di-tert-butyl-4-(4,6-bis(octylthio)-1,3,5-triazine-2-ylamino)phenol, and 2-[1-(2-hydroxy-3,5-di-tert-pentylphenyl)ethyl]-4,6-di-tert-pentylphenyl acrylate.

[0064] Among these, pentaerythritol tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate] and octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate are preferred. Specific examples of such hindered phenol antioxidants include, for example, BASF's "Irganox 1010" and "Irganox 1076," and ADEKA's "ADEKA Stab AO-50" and "ADEKA Stab AO-60." Furthermore, the product may contain one type of phenolic stabilizer, or two or more types in any combination and ratio.

[0065] The content of the phenolic stabilizer is usually 0.001 parts by mass or more, preferably 0.01 parts by mass or more, and usually 1 part by mass or less, preferably 0.5 parts by mass or less, per 100 parts by mass of the total of the polycarbonate resin (A) and the thermoplastic polyester resin (B). By setting the content of the phenolic stabilizer above the lower limit of the above range, the effect of the phenolic stabilizer can be sufficiently obtained, and by setting it below the upper limit of the above range, the effect does not plateau, making it economical.

[0066] [Release agent] The polycarbonate resin composition may also preferably contain a mold release agent. Examples of release agents include aliphatic carboxylic acids, esters of aliphatic carboxylic acids and alcohols, aliphatic hydrocarbon compounds with a number average molecular weight of 200 to 15,000, and polysiloxane-based silicone oils.

[0067] Examples of aliphatic carboxylic acids include saturated or unsaturated aliphatic monovalent, divalent, or trivalent carboxylic acids. Here, aliphatic carboxylic acids also include alicyclic carboxylic acids. Among these, preferred aliphatic carboxylic acids are monovalent or divalent carboxylic acids having 6 to 36 carbon atoms, and more preferably aliphatic saturated monovalent carboxylic acids having 6 to 36 carbon atoms. Specific examples of such aliphatic carboxylic acids include palmitic acid, stearic acid, caproic acid, capric acid, lauric acid, arachidic acid, behenic acid, lignoceric acid, cerotic acid, melissic acid, tetrariacontanoic acid, montanic acid, adipic acid, and azelaic acid.

[0068] As the aliphatic carboxylic acid in the ester of an aliphatic carboxylic acid and an alcohol, for example, the same aliphatic carboxylic acid as described above can be used. On the other hand, as the alcohol, for example, saturated or unsaturated monohydric or polyhydric alcohols can be used. These alcohols may have substituents such as fluorine atoms or aryl groups. Among these, monohydric or polyhydric saturated alcohols having 30 or fewer carbon atoms are preferred, and aliphatic saturated monohydric alcohols or aliphatic saturated polyhydric alcohols having 30 or fewer carbon atoms are more preferred. Here, "aliphatic" is used as a term that also includes alicyclic compounds.

[0069] Specific examples of such alcohols include octanol, decanol, dodecanol, stearyl alcohol, behenyl alcohol, ethylene glycol, diethylene glycol, glycerin, pentaerythritol, 2,2-dihydroxyperfluoropropanol, neopentylene glycol, ditrimethylolpropane, and dipentaerythritol.

[0070] Furthermore, the above-mentioned esters may contain aliphatic carboxylic acids and / or alcohols as impurities. Also, the above-mentioned esters may be pure substances or mixtures of multiple compounds. Moreover, the aliphatic carboxylic acids and alcohols that combine to form a single ester may be used individually, or two or more may be used in any combination and ratio.

[0071] Specific examples of esters of aliphatic carboxylic acids and alcohols include beeswax (a mixture mainly composed of myricyl palmitate), stearyl stearate, behenyl behenate, stearyl behenate, glycerin monopalmitate, glycerin monostearate, glycerin distearate, glycerin tristearate, pentaerythritol monopalmitate, pentaerythritol monostearate, pentaerythritol distearate, pentaerythritol tristearate, and pentaerythritol tetrastearate.

[0072] Examples of aliphatic hydrocarbons with a number-average molecular weight of 200 to 15,000 include liquid paraffin, paraffin wax, microwax, polyethylene wax, Fischer-Tropsch wax, and α-olefin oligomers having 3 to 12 carbon atoms. Note that alicyclic hydrocarbons are also included in the definition of aliphatic hydrocarbons. Furthermore, these hydrocarbons may be partially oxidized. Among these, paraffin wax, polyethylene wax, or partially oxided polyethylene wax are preferred, and paraffin wax and polyethylene wax are more preferred. Furthermore, the number-average molecular weight of the aliphatic hydrocarbon is preferably 5,000 or less. Furthermore, while aliphatic hydrocarbons may be single substances, mixtures of substances with varying constituent components and molecular weights can also be used as long as the main component falls within the above-mentioned range.

[0073] Examples of polysiloxane-based silicone oils include dimethyl silicone oil, methylphenyl silicone oil, diphenyl silicone oil, and fluorinated alkyl silicone.

[0074] Furthermore, the above-mentioned release agent may contain one type, or two or more types in any combination and ratio. The release agent content is typically 0.001 parts by mass or more, preferably 0.01 parts by mass or more, and typically 2 parts by mass or less, preferably 1 part by mass or less, and more preferably 0.5 parts by mass or less, per 100 parts by mass of the total of the polycarbonate resin (A) and thermoplastic polyester resin (B). If the release agent content is below the lower limit of the above range, the release effect may not be sufficient, and if the release agent content exceeds the upper limit of the above range, a decrease in hydrolysis resistance and mold contamination during injection molding may occur.

[0075] [Additives, etc.] The polycarbonate resin composition may contain other additives besides those mentioned above, such as fluorescent whitening agents, pigments (including carbon black), dyes, flame retardants, ultraviolet absorbers, impact modifiers, plasticizers, and compatibilizers. These additives may be present in one or more quantities.

[0076] Furthermore, the material may contain other resins besides polycarbonate resin (A) and thermoplastic polyester resin (B). Examples of other resins include styrene-based resins such as polystyrene resin, high-impact polystyrene resin (HIPS), acrylonitrile-styrene copolymer (AS resin), and acrylonitrile-butadiene-styrene copolymer (ABS resin); polyolefin resins such as polyethylene resin and polypropylene resin; polyamide resin; polyimide resin; polyetherimide resin; polyurethane resin; polyphenylene ether resin; polyphenylene sulfide resin; polysulfone resin; and polymethacrylate resin. Furthermore, other resins do not necessarily have to be included, and if they are included, it is preferable that the amount be 45 parts by mass or less per 100 parts by mass of the total of polycarbonate resin (A) and thermoplastic polyester resin (B), and in particular, 40 parts by mass or less, 30 parts by mass or less, 20 parts by mass or less, 10 parts by mass or less, 5 parts by mass or less, 3 parts by mass or less, 2 parts by mass or less, and especially 1 part by mass or less.

[0077] [Method for manufacturing a polycarbonate resin composition molded article] When manufacturing a polycarbonate resin composition, it is preferable to melt-mix the wollastonite (C) separately from the other components. In particular, when melt-mixing using an extruder, it is preferable to side-feed the wollastonite (C) and melt-mix it from the middle of the extruder into a molten mixture in which the polycarbonate resin and other components have been sufficiently melt-mixed. It is preferable to melt and knead the material in a twin-screw extruder because it facilitates the formation of the morphological structure of the present invention. The melting and kneading temperature is preferably in the range of 240 to 320°C, and more preferably 260 to 300°C.

[0078] The method for forming a molded article using a polycarbonate resin composition is not particularly limited, and conventionally known molding methods can be employed. Examples include injection molding, injection compression molding, extrusion molding, shape extrusion, transfer molding, hollow molding, gas-assisted hollow molding, blow molding, extrusion blow molding, IMC (in-mold coating) molding, rotational molding, multilayer molding, two-color molding, insert molding, sandwich molding, foam molding, and pressure molding. Among these, injection molding is particularly preferred.

[0079] As described above, the resulting polycarbonate resin composition molded article has a morphology in which the polycarbonate resin (A) phase forms a continuous phase, the polyester resin (B) phase is dispersed in the continuous phase of the polycarbonate resin phase (A), and the wollastonite (C) is in contact with both the polycarbonate resin (A) phase and the polyester resin (B) phase.

[0080] The polycarbonate resin composition molded article of the present invention preferably has a tensile fracture strain of 70% or more, as measured according to ISO 527. Furthermore, the notched tensile strength measured according to ISO 527 is preferably 65 MPa or higher. In addition, the flexural modulus measured according to ISO 178 is preferably 3000 MPa or higher. The details of the measurement methods for the tensile fracture nominal strain, notched tensile strength, and flexural modulus are as described in the examples.

[0081] There are no particular restrictions on the shape of the molded body, and it can be appropriately selected according to the application and purpose of the molded body. Examples include housings, plate-shaped, rod-shaped, sheet-shaped, film-shaped, cylindrical, annular, circular, elliptical, polygonal, irregularly shaped, hollow, frame-shaped, box-shaped, and panel-shaped products. [Examples]

[0082] The present invention will be described in more detail below with reference to examples. However, the present invention is not limited to the following examples. The components used in the examples and comparative examples are shown in Table 1 below.

[0083] [Table 1]

[0084] (Examples 1-5, Comparative Examples 1-7) Of the components listed above, all components except wollastonite were blended in the proportions (parts by mass) shown in Table 2 below. After mixing in a tumbler for 20 minutes, the wollastonite was side-fed, and the mixture was melt-kneaded at a cylinder temperature of 280°C using a twin-screw extruder with a screw diameter of 25 mm (TEX-25αIII manufactured by Japan Steel Works), and pellets were obtained by strand cutting.

[0085] <Tensile fracture strain (unit: %)> After drying the pellets obtained by the method described above at 100°C for 5 hours, injection molding was performed using a NEX80III injection molding machine manufactured by Nissei Plastic Industrial Co., Ltd. under the conditions of cylinder temperature 260°C, mold temperature 80°C, and molding cycle of 50 seconds to form ISO multipurpose test specimens (4 mm thick). Using the obtained test specimens, the tensile fracture strain (in %) was measured in accordance with the ISO 527 standard.

[0086] <Tensile strength with notches (unit: MPa)> The tensile strength (in MPa) of a notched specimen (notch R=0.5) with a width of 1 / 8 inch, conforming to ASTM D256, was measured during a tensile test at a -30°C environment. The surface of the test specimen was observed visually after measurement. In the table, specimens where the entire fracture surface was whitened and necking occurred, indicating ductile fracture, are labeled "ductile." Specimens where whitening was observed only around the notch of the specimen, indicating brittle fracture, are labeled "brittle."

[0087] <Flexural modulus (unit: MPa)> Using the above ISO multipurpose test specimen (4 mm thick), the flexural modulus (unit: MPa) was measured at 23°C in accordance with ISO 178.

[0088] <Morphological observation> From a cross-section parallel to the flow direction during molding of the ISO multipurpose test specimen (4 mm thick) obtained above, a block-shaped sample with an observation surface of 500 μm x 500 μm and a thickness of approximately 1 cm was cut using a Leica "UC7" diamond knife. The observation surface of the obtained sample was stained with ruthenium tetroxide in the gas phase at room temperature for 90 minutes. Then, using a scanning electron microscope (Hitachi High-Tech Corporation, "SU8020"), SEM images at magnifications of 10,000x and 30,000x were acquired under the conditions of acceleration voltage of 1 kV, signal LA100 (U), emission current of 10 μA, and probe current: High. From the obtained SEM images, we investigated whether wollastonite (C) was in contact with both the polycarbonate resin (A) phase and the polyester resin (B) phase, examining the resin phases in contact with more than 100 wollastonite particles and calculating the proportion of each particle. Samples in which the proportion of wollastonite (C) in contact with both phases was 90% or more on average in terms of the number of wollastonite (C) particles were marked with "○", samples in which the proportion was between 80% and 90% were marked with "△", and samples in which the proportion was less than 80% were marked with "×". Morphological images of Example 1, Example 4, and Comparative Example 1 (at magnifications of 10,000x and 30,000x) are shown in Figures 1 to 6, respectively. The morphological explanation for each figure is as described above.

[0089] The evaluation results are shown in Table 2 below.

[0090] [Table 2] [Industrial applicability]

[0091] The polycarbonate resin composition molded articles of the present invention exhibit excellent tensile elongation, notched tensile strength, and flexural elasticity, making them suitable for use in various molded products such as automotive exterior parts. [Explanation of Symbols]

[0092] A: Polycarbonate resin (A) phase B: Thermoplastic polyester resin (B phase) C: Wollastonite (C)

Claims

1. A molded polycarbonate resin composition comprising 100 parts by mass in total, consisting of 50 to 80 parts by mass of polycarbonate resin (A) and 20 to 50 parts by mass of thermoplastic polyester resin (B), and containing 5 to 20 parts by mass of wollastonite (C) having a volume-average fiber diameter of 1.0 to 6.0 μm, a volume-average fiber length of 10.0 to 20.0 μm, an aspect ratio of 3 or more, and surface-treated with an alkylsilane having 8 to 14 carbon atoms, A molded polycarbonate resin composition characterized in that the polycarbonate resin (A) phase forms a continuous phase, the polyester resin (B) phase is dispersed in the continuous phase of the polycarbonate resin phase (A), and wollastonite (C) has a morphology in which it is in contact with both the polycarbonate resin (A) phase and the polyester resin (B) phase.

2. A molded polycarbonate resin composition according to claim 1, wherein the tensile fracture strain measured in accordance with ISO 527 is 70% or more.

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