Polycarbonate resin composition

Abstract

A polycarbonate resin composition exhibiting excellent tensile and flexural strength, and improved Charpy impact strength. [Solution] A polycarbonate resin composition characterized by containing 5 to 60 parts by mass of an inorganic filler (B) surface-treated with urethane or silicone, with respect to 100 parts by mass of polycarbonate resin (A), which contains more than 0% by mass and 90% by mass or less of polycarbonate resin (A1) with a terminal OH content of 200 ppm or less, and 10% by mass or more and less than 100% by mass of polycarbonate resin (A2) with a terminal OH content of 400 ppm or more.

Description

[Technical Field]

[0001] The present invention relates to a polycarbonate resin composition, and more specifically, to a polycarbonate resin composition that exhibits excellent tensile strength and flexural strength, and improved Charpy impact strength. [Background technology]

[0002] Polycarbonate resin is a resin with excellent heat resistance, mechanical properties, and electrical properties, and is widely used as a material for manufacturing parts in various industrial fields, such as vehicle parts, electrical and electronic equipment components, housing components, and other industrial sectors. Furthermore, in recent years, there has been a trend towards higher performance, greater integration, and lighter / thinner construction of products, requiring polycarbonate resin materials to possess high strength.

[0003] While polycarbonate resin compositions reinforced with fillers possess excellent mechanical strength, their impact strength, tensile strength, and flexural strength are not necessarily sufficiently improved. [Overview of the project] [Problems that the invention aims to solve]

[0004] The present invention has been made in view of the above circumstances, and its objective (problem) is to provide a reinforced polycarbonate resin composition that has excellent tensile strength and flexural strength and improved Charpy impact strength by using two types of polycarbonate with different terminal OH content. [Means for solving the problem]

[0005] The inventors, after diligent research to achieve the above objectives, discovered that the above objectives could be solved by combining two specific types of polycarbonate resins and incorporating an inorganic filler that has undergone a specific surface treatment, thereby completing the present invention. This invention relates to the following polycarbonate resin compositions and molded articles.

[0006] 1. A polycarbonate resin composition characterized by containing 5 to 60 parts by mass of an inorganic filler (B) surface-treated with urethane or silicone, per 100 parts by mass of polycarbonate resin (A), which contains more than 0% by mass and 90% by mass or less of polycarbonate resin (A1) with a terminal OH content of 200 ppm or less, and 10% by mass or more and less than 100% by mass of polycarbonate resin (A2) with a terminal OH content of 400 ppm or more. 2. The polycarbonate resin composition according to item 1, wherein polycarbonate resin (A1) is 10 to 90% by mass and polycarbonate resin (A2) is 10 to 90% by mass. 3. The polycarbonate resin composition according to 1 or 2 above, wherein the polycarbonate resin (A) is a bisphenol A type polycarbonate resin. 4. A polycarbonate resin composition according to any one of 1 to 3 above, wherein the inorganic filler (B) is glass fiber. 5. Pellets of the polycarbonate resin composition described in any of items 1 to 4 above. 6. A molded article of the polycarbonate resin composition described in any of items 1 to 4 above. 7. Molded product of the pellets described in item 5 above. [Effects of the Invention]

[0007] The polycarbonate resin composition of the present invention exhibits improved Charpy impact strength and excellent tensile and flexural strength. [Modes for carrying out the invention]

[0008] 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.

[0009] The polycarbonate resin composition of the present invention is characterized by containing 5 to 60 parts by mass of an inorganic filler (B) surface-treated with urethane or silicone, with respect to 100 parts by mass of polycarbonate resin (A), which contains more than 0% by mass and 90% by mass or less of polycarbonate resin (A1) having a terminal OH content of 200 ppm or less, and 10% by mass or more and less than 100% by mass of polycarbonate resin (A2) having a terminal OH content of 400 ppm or more.

[0010] [Polycarbonate resin (A)] The polycarbonate resin (A) used in this invention is a polycarbonate resin (A1) with a terminal OH content of 200 ppm or less and a polycarbonate resin (A2) with a terminal OH content of 400 ppm or more. By combining such polycarbonate resins (A1) and (A2) with an inorganic filler (B) surface-treated with urethane or silicone, a polycarbonate resin composition can be obtained that exhibits excellent tensile strength and flexural strength, and in particular, improved Charpy impact strength.

[0011] The terminal hydroxyl group concentration is expressed in ppm as the mass of terminal hydroxyl groups relative to the mass of polycarbonate resin, and is measured, for example, by the titanium tetrachloride / acetic acid method colorimetric determination [Macromol. Chem. 88 215 (1965)].

[0012] [Polycarbonate resin with terminal OH content of 200 ppm or less (A1)] Polycarbonate resins can be classified into aromatic polycarbonate resins, in which the carbon atoms directly bonded to the carbonate bonds are aromatic carbon atoms, and aliphatic polycarbonate resins, in which the carbon atoms are aliphatic carbon atoms. However, aromatic polycarbonate resins are preferred as the polycarbonate resin (A1). Examples of aromatic dihydroxy compounds among the monomers that serve as raw materials for preferred aromatic polycarbonate resins (A1) are as follows:

[0013] 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;

[0014] Dihydronaphthalenes 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, 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 the above;

[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.

[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 (i.e., bisphenol A) and 2,2-bis(3-methyl-4-hydroxyphenyl)propane (i.e., bisphenol C) 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] As an example of a preferred carbonate precursor to be combined with the aromatic dihydroxy compound of the polycarbonate resin (A1), carbonyl halides are preferably used. Note that one carbonate precursor may be used, or two or more may be used in any combination and ratio. Examples of carbonyl halides include, specifically, phosgene; bischloroformates of dihydroxy compounds; monochloroformates of dihydroxy compounds; and other haloformates.

[0022] The method for producing the polycarbonate resin (A1) is not limited, but is preferably carried out by an interfacial polymerization method.

[0023] The following describes the production of polycarbonate resin (A1) by interfacial polymerization. In interfacial polymerization, a dihydroxy compound and a carbonate precursor (preferably phosgene) are reacted in the presence of an organic solvent inert to the reaction and an alkaline aqueous solution, usually maintaining a pH of 9 or higher. After this reaction, interfacial polymerization is carried out in the presence of a polymerization catalyst to obtain polycarbonate resin. A molecular weight modifier (end-terminating agent) may be added to the reaction system as needed, and an antioxidant may be added to prevent oxidation of the dihydroxy compound.

[0024] The dihydroxy compound and carbonate precursor are as described above. Among the carbonate precursors, phosgene is preferred.

[0025] Examples of organic solvents that are inert to the reaction include chlorinated hydrocarbons such as dichloromethane, 1,2-dichloroethane, chloroform, monochlorobenzene, and dichlorobenzene; and aromatic hydrocarbons such as benzene, toluene, and xylene. Note that one organic solvent may be used, or two or more may be used in any combination and ratio.

[0026] Examples of alkali compounds contained in the alkaline aqueous solution include alkali metal compounds such as sodium hydroxide, potassium hydroxide, lithium hydroxide, and sodium bicarbonate, as well as alkaline earth metal compounds, but sodium hydroxide and potassium hydroxide are preferred among them. Note that one alkali compound may be used, or two or more may be used in any combination and ratio.

[0027] There are no restrictions on the concentration of the alkali compound in the alkaline aqueous solution, but it is usually used at 5-10% by mass to control the pH of the alkaline aqueous solution in the reaction to 10-12. Furthermore, for example, when bubbling in phosgene, it is preferable to set the molar ratio of the bisphenol compound to the alkali compound to 1:1.9 or higher, more preferably 1:2.0 or higher, and more preferably 1:3.2 or lower, more preferably 1:2.5 or lower, in order to control the pH of the aqueous phase to 10-12, preferably 10-11.

[0028] Examples of polymerization catalysts include aliphatic tertiary amines such as trimethylamine, triethylamine, tributylamine, tripropylamine, and trihexylamine; alicyclic tertiary amines such as N,N'-dimethylcyclohexylamine and N,N'-diethylcyclohexylamine; aromatic tertiary amines such as N,N'-dimethylaniline and N,N'-diethylaniline; and quaternary ammonium salts such as trimethylbenzylammonium chloride, tetramethylammonium chloride, and triethylbenzylammonium chloride. Note that one polymerization catalyst may be used, or two or more may be used in any combination and ratio.

[0029] Examples of molecular weight modifiers include aromatic phenols having a monovalent phenolic hydroxyl group; aliphatic alcohols such as methanol and butanol; mercaptans; phthalimides, etc., but aromatic phenols are preferred among them. Specific examples of such aromatic phenols include alkyl-substituted phenols such as m-methylphenol, p-methylphenol, m-propylphenol, p-propylphenol, p-tert-butylphenol, and p-long-chain alkyl-substituted phenols; vinyl group-containing phenols such as isopropanylphenol; epoxy group-containing phenols; carboxyl group-containing phenols such as o-hydroxybenzoic acid and 2-methyl-6-hydroxyphenylacetic acid; and the like. Furthermore, one molecular weight adjusting agent may be used, or two or more may be used in any combination and ratio.

[0030] The amount of molecular weight adjuster used is usually 0.5 moles or more, preferably 1 mole or more, and usually 50 moles or less, preferably 30 moles or less, per 100 moles of the dihydroxy compound.

[0031] During the reaction, the order in which the reaction substrate, reaction medium, catalyst, additives, etc. are mixed is arbitrary as long as the desired polycarbonate resin is obtained, and any appropriate order can be set. For example, when phosgene is used as the carbonate precursor, the molecular weight adjuster can be mixed at any time between the reaction between the dihydroxy compound and phosgene (phosgenation) and the start of the polymerization reaction. The reaction temperature is typically between 0 and 40°C, and the reaction time is usually between a few minutes (e.g., 10 minutes) and several hours (e.g., 6 hours).

[0032] The terminal OH content of the polycarbonate resin (A1) is 200 ppm or less, preferably 180 ppm or less, more preferably 170 ppm or less, even more preferably 160 ppm or less, preferably 30 ppm or more, more preferably 50 ppm or more, and even more preferably 70 ppm or more.

[0033] The molecular weight of the polycarbonate resin (A1) is the viscosity-average molecular weight (Mv) calculated from the solution viscosity measured at 25°C using methylene chloride as the solvent, preferably 10,000 to 50,000, more preferably 11,000 to 40,000, and most preferably 12,000 to 35,000, with a particular preference of 13,000 to 30,000. By setting the viscosity-average molecular weight above the lower limit of the above range, the mechanical strength of the polycarbonate resin composition of the present invention can be further improved. By setting the viscosity-average molecular weight 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.

[0034] In this invention, the viscosity-average molecular weight [Mv] of the polycarbonate resin is determined by using methylene chloride as the solvent, and calculating the intrinsic viscosity [η] (unit dl / g) at a temperature of 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

[0035] [Polycarbonate resin with terminal OH content of 400 ppm or more (A2)] As the polycarbonate resin (A2) with a terminal OH content of 400 ppm or more, aromatic polycarbonate resins are preferred. The method for producing the polycarbonate resin (A2) is not limited, but is preferably by the melting method (also known as the transesterification method, hereinafter referred to as the "melting method").

[0036] To explain the process of producing polycarbonate resin (A2) by the melting method, for example, a transesterification reaction is carried out between a diester carbonate and a dihydroxy compound.

[0037] The dihydroxy compounds are as described above. On the other hand, examples of dialkyl carbonate compounds such as dimethyl carbonate, diethyl carbonate, and di-tert-butyl carbonate; diphenyl carbonate; and substituted diphenyl carbonates such as ditolyl carbonate. Among these, diphenyl carbonate and substituted diphenyl carbonates are preferred, and diphenyl carbonate is particularly preferred. Note that one type of diester carbonate may be used, or two or more types may be used in any combination and ratio.

[0038] The ratio of dihydroxy compound to diester carbonate is arbitrary as long as the desired polycarbonate resin can be obtained, but it is preferable to use an equimolar amount or more of diester carbonate per mole of dihydroxy compound, and more preferably 1.001 moles or more. The upper limit is usually 1.30 moles or less. By setting the range in this way, the amount of terminal OH groups can be adjusted to a suitable range. Furthermore, the number of terminal OH groups can be adjusted to the desired range by controlling factors such as the degree of reduced pressure during the transesterification reaction.

[0039] When manufacturing polycarbonate resin by melting, a transesterification catalyst is usually used. Any transesterification catalyst can be used. In particular, alkali metal compounds and / or alkaline earth metal compounds are preferred. Additionally, basic compounds such as basic boron compounds, basic phosphorus compounds, basic ammonium compounds, and amine compounds may be used in combination. One type of transesterification catalyst may be used, or two or more types may be used in any combination and ratio.

[0040] In the melting method, the reaction temperature is typically 100 to 320°C. The reaction pressure is usually reduced to 2 mmHg or less. Specifically, the melting polycondensation reaction is carried out under the aforementioned conditions while removing by-products such as aromatic hydroxy compounds.

[0041] The melt polycondensation reaction can be carried out in either a batch or continuous manner. In the batch method, the order in which the reaction substrate, reaction medium, catalyst, additives, etc. are mixed is arbitrary as long as the desired polycarbonate resin is obtained, and any appropriate order can be set. However, considering the stability of the polycarbonate resin and polycarbonate resin composition, it is preferable to carry out the melt polycondensation reaction in a continuous manner.

[0042] In the melting method, a catalyst deactivator may be used as needed. Any compound that neutralizes the transesterification catalyst can be used as the catalyst deactivator. Examples include sulfur-containing acidic compounds and their derivatives. Note that one catalyst deactivator may be used, or two or more may be used in any combination and ratio.

[0043] The amount of catalyst deactivator used is usually 0.5 equivalents or more, preferably 1 equivalent or more, and usually 10 equivalents or less, preferably 5 equivalents or less, relative to the alkali metal or alkaline earth metal contained in the transesterification catalyst. Furthermore, relative to the polycarbonate resin, it is usually 1 ppm or more, and usually 100 ppm or less, preferably 20 ppm or less.

[0044] The terminal OH content of the polycarbonate resin (A2) is 400 ppm or more, preferably 430 ppm or more, more preferably 450 ppm or more, even more preferably 460 ppm or more, preferably 1000 ppm or less, more preferably 800 ppm or less, even more preferably 750 ppm or less, and particularly preferably 700 ppm or less.

[0045] The viscosity-average molecular weight (Mv) of the polycarbonate resin (A2) is preferably 10,000 to 50,000, more preferably 11,000 to 40,000, and most preferably 12,000 to 35,000, with a particular preference of 13,000 to 30,000. By setting the viscosity-average molecular weight above the lower limit of the above range, the mechanical strength of the polycarbonate resin composition of the present invention can be further improved. By setting the viscosity-average molecular weight 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.

[0046] [Ratio of polycarbonate resin (A1) to polycarbonate resin (A2)] As mentioned above, the content ratio of polycarbonate resin (A1) and polycarbonate resin (A2) is greater than 0% by mass and 90% by mass or less for polycarbonate resin (A1), and 10% by mass or more and less than 100% by mass for polycarbonate resin (A2) (based on a total of 100% by mass for both). By combining polycarbonate resin (A2) in such amounts and including it together with an inorganic filler (B) surface-treated with urethane or silicone, the Charpy impact strength, tensile strength, and flexural strength are all well-balanced and excellent. Preferred blending ratios are 10% by mass or more for (A1), more preferably 15% by mass or more, 20% by mass or more, 25% by mass or more, and 30% by mass or more, and also 85% by mass or less, particularly 83% by mass or less, 75% by mass or less, 70% by mass or less, and 65% by mass or less. (A2) is preferably 15% by mass or more, more preferably 17% by mass or more, 25% by mass or more, and more preferably 30% by mass or more, and more preferably 95% by mass or less, among which 90% by mass or less, 80% by mass or less, 75% by mass or less, 70% by mass or less, and especially preferably 65% ​​by mass or less.

[0047] Furthermore, polycarbonate resins (A1) and (A2) may be made not only from virgin raw materials but also from polycarbonate resins recycled from used products (so-called material-recycled polycarbonate resins). It is also preferable to contain both virgin polycarbonate resin and recycled polycarbonate resin, or to consist solely of recycled polycarbonate resin. Recycled polycarbonate resin has a longer thermal history and undergoes more thermal decomposition than virgin polycarbonate resin, so it usually has a terminal OH content of 400 ppm or more. When using recycled polycarbonate resin, its terminal OH content is measured, and if the terminal OH content is 400 ppm or more, it is polycarbonate resin (A2), and if it is 200 ppm or less, it is polycarbonate resin (A1). When recycled polycarbonate resin is included, the proportion of recycled polycarbonate resin in polycarbonate resin (A) is preferably 10% by mass or more, and more preferably 20% by mass or more, 30% by mass or more, 40% by mass or more, and especially 50% by mass or more.

[0048] [Inorganic filler (B)] The polycarbonate resin composition of the present invention contains an inorganic filler (B) surface-treated with urethane or silicone in an amount of 5 to 60 parts by mass per 100 parts by mass of polycarbonate resin (A). By including it in this range, it is possible to improve Charpy impact strength while also achieving excellent tensile strength and flexural strength. The content of the inorganic filler (B) is preferably 8 parts by mass or more, preferably 55 parts by mass or less, more preferably 50 parts by mass or less, and even more preferably 45 parts by mass or less.

[0049] In this invention, inorganic filler refers to a material that is incorporated into a resin component to improve its strength and rigidity, and is also called a reinforcing filler. The inorganic filler (B) may be in any form, such as fibrous, plate-like, granular, or amorphous. The inorganic filler (B) may be one type or a mixture of two types. When the inorganic filler is in the form of fibers, examples include inorganic fibers such as glass fibers, carbon fibers, silica-alumina fibers, zirconia fibers, boron fibers, boron nitride fibers, potassium silicon titanate fibers, metal fibers, and wollastonite. When the inorganic filler is in the form of fibers, glass fibers are particularly preferred.

[0050] Examples of glass fibers include those made from glass compositions such as A glass, C glass, D glass, E glass, and S glass, with fibers made from the glass composition of E glass (alkali-free glass) being particularly preferred. The glass fibers may be single fibers or multiple single fibers twisted together. The form of the glass fibers may be, for example, glass roving made by continuously winding single fibers or multiple twisted fibers, chopped strands cut to a length of 1 to 10 mm, or milled fibers crushed to a length of approximately 10 to 500 μm.

[0051] When the inorganic filler is fibrous, its average fiber diameter, average fiber length, and cross-sectional shape are not particularly limited, but the average fiber diameter is preferably selected in the range of 1 to 100 μm, and the average fiber length is preferably selected in the range of 0.1 to 20 mm. The average fiber diameter is more preferably 1 to 50 μm, and more preferably 5 to 20 μm. The average fiber length is preferably 0.12 to 10 mm. Furthermore, when the fiber cross-section is a flattened shape such as oval, elliptical, or cocoon-shaped, the flattening ratio (ratio of major axis to minor axis) is preferably 1.4 to 10, more preferably 2 to 6, and even more preferably 2.5 to 5. Using glass fibers with such irregular cross-sections is preferable because it easily improves the dimensional stability of the molded article, such as warping and anisotropy of shrinkage.

[0052] The material may also contain other inorganic fillers in the form of plates, granules, or amorphous materials. Plate-shaped inorganic fillers have the function of reducing anisotropy and warping, and examples include glass flakes, talc, mica, kaolin, and metal foil. Among the plate-shaped inorganic fillers, glass flakes or talc are preferred.

[0053] Other granular or amorphous inorganic fillers include ceramic beads, asbestos, clay, zeolite, potassium titanate, barium sulfate, titanium dioxide, silicon dioxide, aluminum oxide, and magnesium hydroxide.

[0054] By using an inorganic filler (B) surface-treated with urethane or silicone as the inorganic filler, the degree of reaction at the interface between the polycarbonate resins (A1) and (A2), which retain terminal OH groups, and the inorganic filler (B) is improved, thereby improving the Charpy impact strength, tensile strength, and flexural strength of the polycarbonate resin composition. For example, if an inorganic filler surface-treated with epoxy resin is used, the terminal OH groups of the polycarbonate resin (A2) act on the interface between the polycarbonate resin (A2) and the inorganic filler, resulting in excessive adhesion. Consequently, no improvement in the Charpy impact strength, tensile strength, and flexural strength of the polycarbonate resin (A2) is observed.

[0055] Surface treatment of inorganic fillers with urethane involves coating part or all of the surface of the inorganic filler with an uncured or cured urethane resin. The urethane-based surface treatment agent includes, for example, a urethane resin derived from a high-molecular-weight polyol, an organic diisocyanate, and, if necessary, a chain extender and / or crosslinking agent. Examples of polymeric polyols include polyester polyols such as polyethylene adipate diol, polybutylene adipate diol, polyethylene butylene adipate diol, polyneopentyl adipate diol, polyneopentyl terephthalate diol, polycaprolactone diol, and polyvalerolactone diol; and polyether polyols such as polyethylene glycol, polypropylene glycol, polyoxyethylene oxypropylene glycol, polyoxytetramethylene glycol, and alkylene oxide adducts of bisphenols having 2 to 4 carbon atoms. One or more polymeric polyols can be used.

[0056] Examples of organic diisocyanates include aromatic diisocyanates such as 2,4'- or 4,4'-diphenylmethane diisocyanate (MDI), 2,4- or 2,6-tolylene diisocyanate (TDI), 4,4'-dibenzyle diisocyanate, 1,3- or 1,4-phenylene diisocyanate, 1,5-naphthylene diisocyanate, and xylylene diisocyanate; aliphatic diisocyanates such as ethylene diisocyanate, hexamethylene diisocyanate (HDI), and lysine diisocyanate; and alicyclic diisocyanates such as isophorone diisocyanate (IPDI) and 4,4'-dicyclohexylmethane diisocyanate. One or more organic diisocyanates can be used.

[0057] Examples of chain elongators and crosslinking agents include active hydrogen-containing compounds with a number-average molecular weight of 60 to 500, such as polyhydric alcohols, polyhydric phenols, and polyamines. Examples of polyhydric alcohols include dihydric alcohols such as ethylene glycol, propylene glycol, 1,3-butylene glycol, 1,4-butanediol, 1,6-hexanediol, 3-methylpentanediol, diethylene glycol, neopentyl glycol, 1,4-bis(hydroxymethyl)cyclohexane, 1,4-bis(hydroxyethyl)benzene, and 2,2-bis(4,4'-hydroxycyclohexyl)propane; trihydric alcohols such as glycerin and trimethylolpropane; and tetrahydric to octahydric alcohols such as pentaerythritol, diglycerin, α-methylglucoside, sorbitol, xylitol, mannitol, dipentaerythritol, glucose, fructose, and sucrose. Examples of polyhydric phenols include polyhydric phenols such as pyrogallol, catechol, and hydroquinone; and bisphenols such as bisphenol A, bisphenol F, and bisphenol S. Examples of polyamines include aliphatic polyamines such as ethylenediamine, hexamethylenediamine, and diethylenetriamine; alicyclic polyamines such as isophoronediamine and 4,4'-dicyclohexylmethanediamine; aromatic polyamines such as 4,4'-diaminodiphenylmethane; aromatic ring-containing aliphatic polyamines such as xylylenediamine; and hydrazines and their derivatives. One or more chain extenders and crosslinking agents can be used.

[0058] Surface treatment with silicone is carried out using organosilicon-based surface treatment agents, preferably organopolysiloxane-based surface treatment agents. Specific examples of organopolysiloxanes include, for example, methylhydrogen polysiloxane or copolymers in which methylhydrogen siloxane is an essential structural unit. A preferred copolymer in which methylhydrogen siloxane is an essential structural unit is, for example, a copolymer of dimethylsiloxane and methylhydrogen siloxane. Note that the organopolysiloxane may be one type or two or more types.

[0059] When surface-treating with urethane or silicone, the amount of urethane or silicone surface treatment agent applied is preferably 0.1 to 30% by mass of the inorganic filler (B), more preferably 1 to 10% by mass, and even more preferably 1 to 5% by mass.

[0060] The substrate of the inorganic filler to be surface-treated with urethane or silicone is preferably surface-treated with a silane-based coupling agent beforehand. Examples of silane-based coupling agents include γ-methacrylateoxypropyltrimethoxysilane, γ-glycidoxypropyltrimethoxysilane, and γ-aminopropyltriethoxysilane. The amount of silane-based coupling agent attached is preferably 0.01 to 1% by mass of the inorganic filler (B).

[0061] [Flame retardant] The polycarbonate resin composition of the present invention may also preferably contain a flame retardant. As for flame retardants, organic flame retardants are preferred, such as organometallic salt flame retardants, phosphorus-based flame retardants, and siloxane-based flame retardants. Organometallic salt flame retardants and phosphorus-based flame retardants are preferred, and phosphorus-based flame retardants are compounds containing phosphorus in their molecule, which may be low molecular weight compounds, oligomers, or polymers. However, from the viewpoint of thermal stability, condensed phosphate ester flame retardants and phosphazene-based flame retardants are particularly preferred.

[0062] As for organometallic salt-based flame retardants, organoalkali metal salt compounds are preferred. Examples of organometallic salt-based flame retardants include metal sulfonic acid salts, metal carboxylate salts, metal borate salts, and metal phosphate salts, but from the viewpoint of thermal stability, metal sulfonic acid salts are preferred.

[0063] Examples of alkali metal salts include lithium (Li), sodium (Na), potassium (K), rubidium (Rb), and cesium (Cs). Among these, sodium, potassium, and cesium are preferred, sodium and potassium are more preferred, and potassium is preferred from the viewpoint of flame retardancy and hydrolysis resistance.

[0064] Examples of preferred alkali metal salts of organic sulfonic acids include alkali metal salts of fluorine-containing aliphatic sulfonic acids or aromatic sulfonic acids. Specific examples of preferred examples include alkali metal salts of fluorine-containing aliphatic sulfonic acids having at least one CF bond in the molecule, such as potassium perfluorobutanesulfonate, lithium perfluorobutanesulfonate, sodium perfluorobutanesulfonate, cesium perfluorobutanesulfonate, potassium trifluoromethanesulfonate, lithium trifluoromethanesulfonate, sodium trifluoromethanesulfonate, and cesium trifluoromethanesulfonate; dipotassium diphenylsulfon-3,3'-disulfonate, potassium diphenylsulfon-3,3'-disulfonate, sodium benzenesulfonate, and sodium (poly)styrenesulfonate. Examples include alkali metal salts of aromatic sulfonic acids having at least one aromatic group in the molecule, such as sodium p-toluenesulfonate, sodium (branched) dodecylbenzenesulfonate, sodium trichlorobenzenesulfonate, potassium benzenesulfonate, potassium styrenesulfonate, potassium (poly)styrenesulfonate, potassium p-toluenesulfonate, potassium (branched) dodecylbenzenesulfonate, potassium trichlorobenzenesulfonate, cesium benzenesulfonate, cesium (poly)styrenesulfonate, cesium p-toluenesulfonate, cesium (branched) dodecylbenzenesulfonate, and cesium trichlorobenzenesulfonate.

[0065] Among the examples mentioned above, alkali metal salts of fluorine-containing aliphatic sulfonic acids are particularly preferred, and alkali metal salts of perfluoroalkanesulfonic acids are even more preferred. Specifically, potassium perfluorobutanesulfonate and sodium trifluoromethanesulfonate are particularly preferred.

[0066] Organometallic salt flame retardants may be used as a single compound, or two or more different compounds may be used in any combination and ratio. When an organometallic salt-based flame retardant is included, the content is preferably 0.01 parts by mass or more and 0.5 parts by mass or less per 100 parts by mass of polycarbonate resin (A). More preferably 0.02 parts by mass or more, even more preferably 0.03 parts by mass or more, particularly preferably 0.04 parts by mass or more, and also more preferably 0.4 parts by mass or less, even more preferably 0.3 parts by mass or less, particularly preferably 0.2 parts by mass or less.

[0067] Examples of condensed phosphate ester flame retardants include aromatic phosphate esters such as triphenyl phosphate (TPP), tricresyl phosphate (TCP), trixylenyl phosphate (TXP), cresyl diphenyl phosphate (CDP), 2-ethylhexyl diphenyl phosphate (EHDP), tert-butylphenyl diphenyl phosphate, bis-(tert-butylphenyl)phenyl phosphate, tris-(tert-butylphenyl) phosphate, isopropylphenyl diphenyl phosphate, bis-(isopropylphenyl) diphenyl phosphate, and tris-(isopropylphenyl) phosphate; Examples include condensed phosphate esters such as resorcinol bis-diphenyl phosphate (RDP), resorcinol bis-dixylenyl phosphate (RDX), bisphenol A bis-diphenyl phosphate (BDP), and biphenyl bis-diphenyl phosphate.

[0068] When a condensed phosphate ester flame retardant is included, the content is preferably 5 parts by mass or more and 15 parts by mass or less, more preferably 6 parts by mass or more, even more preferably 8 parts by mass or more, even more preferably 13 parts by mass or less, and even more preferably 12 parts by mass or less, per 100 parts by mass of polycarbonate resin (A).

[0069] Examples of phosphazene-based flame retardants include phenoxyphosphazene, (poly)tolyloxyphosphazene (e.g., o-tolyloxyphosphazene, m-tolyloxyphosphazene, p-tolyloxyphosphazene, o,m-tolyloxyphosphazene, o,p-tolyloxyphosphazene, m,p-tolyloxyphosphazene, o,m,p-tolyloxyphosphazene, etc.), and cyclic and / or linear C(C)(poly)xyloxyphosphazene. 1-6 Alkyl C 6-20 aryloxyphosphazenes, (poly)phenoxytriloxyphosphazenes (e.g., phenoxy-o-tolyloxyphosphazene, phenoxy-m-tolyloxyphosphazene, phenoxy-p-tolyloxyphosphazene, phenoxy-o,m-tolyloxyphosphazene, phenoxy-o,p-tolyloxyphosphazene, phenoxy-m,p-tolyloxyphosphazene, phenoxy-o,m,p-tolyloxyphosphazene, etc.), (poly)phenoxyxylyloxyphosphazene, (poly)phenoxytriloxyxylyloxyphosphazene, and other cyclic and / or linear C12C 6-20 Aryl C 1-10 Alkyl C 6-20 Examples include aryloxyphosphazenes.

[0070] When a phosphazene-based flame retardant is included, the content is preferably 0.1 parts by mass or more and 15 parts by mass or less, more preferably 0.5 parts by mass or more, even more preferably 1 part by mass or more, even more preferably 12 parts by mass or less, and even more preferably 10 parts by mass or less, per 100 parts by mass of polycarbonate resin (A).

[0071] [Flame retardant] The polycarbonate resin composition of the present invention may also preferably contain a flame retardant. A flame retardant is a substance that, when used in combination with a flame retardant used to make the polycarbonate resin flame retardant, exhibits a synergistic effect.

[0072] Fluoropolymers are a preferred example of a flame retardant additive. As the fluoropolymer, fluoroolefin resins are preferred. Fluoroolefin resins are typically polymers or copolymers containing a fluoroethylene structure. Specific examples include difluoroethylene resins, tetrafluoroethylene resins, and tetrafluoroethylene / hexafluoropropylene copolymer resins, but tetrafluoroethylene resins are particularly preferred. Furthermore, the fluoropolymer is preferably one that has fibril-forming ability, and specifically, a fluoroolefin resin having fibril-forming ability is an example. Having fibril-forming ability tends to significantly improve the ability to prevent dripping during combustion.

[0073] The fluoropolymer may contain one type, or two or more types in any combination and ratio.

[0074] The preferred content of the flame retardant additive is 0.1 to 5 parts by mass per 100 parts by mass of polycarbonate resin (A), more preferably 0.3 parts by mass or more, even more preferably 0.5 parts by mass or more, even more preferably 4 parts by mass or less, even more preferably 3 parts by mass or less, and particularly preferably 2 parts by mass or less.

[0075] [Stabilizer] The polycarbonate resin composition of the present invention preferably contains a stabilizer, and phosphorus-based stabilizers or phenol-based stabilizers are preferred.

[0076] 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.

[0077] 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.

[0078] 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 polycarbonate resin (A), and 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.

[0079] 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.

[0080] 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.

[0081] 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 polycarbonate resin (A). By setting the content of the phenolic stabilizer to be above the lower limit of the above range, the effect of the phenolic stabilizer can be sufficiently obtained, and by setting it to be below the upper limit of the above range, the effect does not plateau, making it economical.

[0082] [Release agent] The polycarbonate resin composition of the present invention 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.

[0083] 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.

[0084] 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.

[0085] 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.

[0086] 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.

[0087] 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.

[0088] 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.

[0089] Examples of polysiloxane-based silicone oils include dimethyl silicone oil, methylphenyl silicone oil, diphenyl silicone oil, and fluorinated alkyl silicone.

[0090] 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 polycarbonate resin (A). 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.

[0091] [Additives, etc.] The polycarbonate resin composition of the present invention may contain other additives besides those mentioned above, such as ultraviolet absorbers, fluorescent whitening agents, pigments such as carbon black, dyes, plasticizers, and compatibilizers. These additives may be present in one or more types.

[0092] Furthermore, it is possible to include other resins besides polycarbonate resin (A) in smaller amounts than polycarbonate resin (A). Examples of other resins include thermoplastic polyester resins such as polyethylene terephthalate, polytrimethylene terephthalate, and polybutylene terephthalate; 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. When other resins are included besides polycarbonate resin (A), the content is preferably 45 parts by mass or less per 100 parts by mass of polycarbonate resin (A), and more preferably 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 preferably 1 part by mass or less. When polybutylene terephthalate resin is included, it is preferably 45 parts by mass or less per 100 parts by mass of polycarbonate resin (A), and more preferably 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 preferably 1 part by mass or less.

[0093] The polycarbonate resin composition of the present invention is molded into a molded article. The manufacturing method for the molded product can be any molding method commonly used for polycarbonate resin compositions. Examples include injection molding, ultra-high-speed injection molding, injection compression molding, two-color molding, hollow molding methods such as gas-assisted molding, molding using insulated molds, molding using rapidly heated molds, foam molding (including supercritical fluids), insert molding, IMC (in-mold coating) molding, extrusion molding, sheet molding, thermoforming, rotational molding, lamination molding, press molding, and blow molding. Molding methods using a hot runner system can also be used. Among these, injection molding methods such as injection molding, ultra-high-speed injection molding, and injection compression molding are preferred.

[0094] [Molded products] Examples of molded products include parts for electrical and electronic equipment, office automation equipment, information terminal equipment, machine parts, home appliances, vehicle parts, building materials, various containers, leisure goods and miscellaneous items, and lighting equipment. In particular, it is suitable for use in parts for electrical and electronic equipment, office automation equipment, information terminal equipment, home appliances, and lighting equipment. [Examples]

[0095] 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.

[0096] [Table 1]

[0097] (Examples 1-17, Comparative Examples 1-13) <Manufacturing of resin composition pellets> Among the above-described components, those other than the inorganic filler were blended at the ratios (parts by mass) shown in Table 2 below and mixed in a tumbler for 20 minutes. After that, they were supplied to a twin-screw extruder "TEX30α" manufactured by Japan Steel Works, Ltd. equipped with 1 vent, and while further supplying the inorganic filler from the middle of the barrel by a side feeder at the ratio (parts by mass) shown in Table 2 below, they were kneaded under the conditions of a screw rotation speed of 200 rpm, a discharge rate of 25 kg / hr, and a barrel temperature of 280°C. The molten resin extruded in a strand shape was rapidly cooled in a water tank and pelletized using a pelletizer to obtain pellets of the polycarbonate resin composition.

[0098] <Measurement of Charpy Impact Strength> After drying the pellets obtained above at 120°C for 5 hours, they were injection molded using a NEX80III-9EG type injection molding machine manufactured by Nissei Plastic Industrial Co., Ltd. under the conditions of a cylinder temperature of 300°C, a mold temperature of 110°C, and a molding cycle of 50 seconds to injection mold ISO multipurpose test pieces (4 mmt). Using the above ISO multipurpose test pieces (4 mmt), in accordance with ISO179-1 and ISO179-2, the Charpy impact strength with notch (unit: kJ / m 2 ) and / or the Charpy impact strength without notch (unit: kJ / m 2 ) was measured. When the test piece was not broken in this measurement, it was designated as NB (No Break).

[0099] <Evaluation of Tensile Properties and Flexural Properties> Using the ISO multipurpose test pieces (4 mmt) obtained by the above method, in accordance with ISO527-1 and ISO527-2, at 23°C, the tensile strength (unit: MPa) and the tensile modulus (unit: MPa) were measured. Also, using the above ISO multipurpose test pieces (4 mmt), in accordance with ISO178, at 23°C, the flexural strength (unit: MPa) and the flexural modulus (unit: MPa) were measured.

[0100] The above results are shown in Table 2 below. In the table, Ex. n represents Example n and Comp. n represents Comparative Example n.

[0101] [Table 2]

[0102] [Table 3]

[0103] [Table 4]

[0104] [Table 5]

[0105] [Table 6]

[0106] [Table 7]

[0107] [Table 8]

[0108] [Table 9]

[0109] [Table 10] [Industrial applicability]

[0110] The polycarbonate resin composition of the present invention is a polycarbonate resin material that exhibits excellent tensile strength and flexural strength, as well as improved Charpy impact strength, and can therefore be suitably used in various molded products.

Claims

1. A polycarbonate resin composition characterized by containing 5 to 60 parts by mass of an inorganic filler (B) surface-treated with urethane or silicone, per 100 parts by mass of polycarbonate resin (A), which contains more than 0% by mass and 90% by mass or less of polycarbonate resin (A1) with a terminal OH content of 200 ppm or less, and 10% by mass or more and less than 100% by mass of polycarbonate resin (A2) with a terminal OH content of 400 ppm or more.

2. The polycarbonate resin composition according to claim 1, wherein polycarbonate resin (A1) is 10 to 90% by mass and polycarbonate resin (A2) is 10 to 90% by mass.

3. The polycarbonate resin composition according to claim 1 or 2, wherein the polycarbonate resin (A) is a bisphenol A type polycarbonate resin.

4. The polycarbonate resin composition according to claim 1 or 2, wherein the inorganic filler (B) is glass fiber.

5. Pellets of the polycarbonate resin composition according to claim 1 or 2.

6. A molded article of the polycarbonate resin composition according to claim 1 or 2.

7. A molded article of pellets according to claim 5.

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