Optically transparent resin composition for laser welding, molded article, kit, and method for manufacturing molded article

Abstract

The present invention provides: a light-transmitting resin composition for laser welding, which has a low light transmittance in a specific wavelength range, while having a high light transmittance of the light for laser welding; a molded article; a kit; a method for producing a molded article; and an in-vehicle camera. A light-transmitting resin composition for laser welding, which contains, relative to 100 parts by mass of a polyamide resin, from 10 to 120 parts by mass of a reinforcing filler and a light-transmitting dye that has a perylene skeleton, wherein: the polyamide resin is composed of a constituent unit derived from a diamine and a constituent unit derived from a dicarboxylic acid; 70% by mole or more of the constituent unit derived from a diamine is derived from a xylylene diamine; and 70% by mole or more of the constituent unit derived from a dicarboxylic acid is derived from an α, ω-linear aliphatic dicarboxylic acid having from 4 to 8 carbon atoms.

Description

[Technical Field]

[0001] The present invention relates to a light-transmitting resin composition for laser welding, a molded article, a kit, a method for manufacturing a molded article, and an on-board camera. The resin composition of the present invention is mainly used as a resin composition that transmits light for laser welding (light-transmitting resin composition).

[0002] Polyamide resin, a typical engineering plastic, is easy to process and has excellent mechanical properties, electrical properties, heat resistance, and other physical and chemical properties. For this reason, it is widely used in vehicle parts, electrical and electronic equipment parts, and other precision equipment parts. Recently, complex-shaped parts have also begun to be manufactured from polyamide resin. For example, various welding techniques, such as adhesive welding, vibration welding, ultrasonic welding, hot plate welding, injection welding, and laser welding, are used to bond parts with hollow sections, such as intake manifolds.

[0003] However, welding with adhesives not only requires time for hardening, but also poses environmental problems such as pollution. Ultrasonic welding and hot plate welding, for example, can cause damage to products due to vibration and heat, and generate abrasion powder and burrs, necessitating post-processing. Injection welding often requires special molds and molding machines, and it cannot be used unless the material has good fluidity.

[0004] Laser welding, on the other hand, is a method of joining two resin members by contacting and welding a resin member (hereinafter sometimes referred to as a "transmissive resin member") that is transparent to laser light (also called non-absorbent or weakly absorbent) with a resin member (hereinafter sometimes referred to as an "absorbent resin member") that is absorptive to laser light. Specifically, the absorbent resin member is melted by the energy of the laser light, and heat is transferred from the absorbing member to the transparent member, causing the two members to melt, cool, solidify, and weld together. Laser welding does not produce abrasion powder or burrs, and causes minimal damage to the product. Furthermore, polyamide resin itself has a relatively high laser transmittance, so laser welding of polyamide resin products has recently attracted attention.

[0005] The transparent resin member is usually molded from a light-transmitting resin composition. Patent Document 1 describes an example of such a light-transmitting resin composition, which is a polyamide resin composition containing 25 to 50 mass % of a semi-aromatic polyamide resin, 3 to 20 mass % of a brominated flame retardant, 1.5 to 10 mass % of zinc stannate, and a light-transmitting dye. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Publication No. 2020-012093 Summary of the Invention [Problem to be solved by the invention]

[0007] The above-mentioned Patent Document 1 describes the use of various polyamide resins for laser welding. On the other hand, in recent years, depending on the application of the laser-welded body (molded article) obtained by laser welding, there are cases where it is required to suppress the transmission of light in a specific wavelength range (for example, wavelengths of 700 to 800 nm and / or wavelengths of 300 to 500 nm).Even in such cases, the resin composition for laser welding needs to maintain high transmittance for the light for laser welding (for example, light rays with wavelengths of 970 nm and / or wavelengths around 1070 nm). The present invention aims to solve these problems, and to provide a light-transmitting resin composition for laser welding that has low light transmittance in a specific wavelength range and high light transmittance for light used for laser welding, a molded article, a kit, a method for manufacturing a molded article, and an on-board camera. [Means for solving the problem]

[0008] As a result of investigations conducted by the present inventors in light of the above-mentioned problems, the above-mentioned problems were solved by using a specific polyamide resin and a light-transmitting dye having a perylene skeleton as the light-transmitting dye. Specifically, the above-mentioned problems were solved by the following means. <1> A light-transmitting resin composition for laser welding, comprising, relative to 100 parts by mass of a polyamide resin, 10 to 120 parts by mass of a reinforcing filler, a light-transmitting dye having a perylene skeleton, and the polyamide resin being composed of diamine-derived structural units and dicarboxylic acid-derived structural units, wherein 70 mol % or more of the diamine-derived structural units are derived from xylylenediamine, and 70 mol % or more of the dicarboxylic acid-derived structural units are derived from an α,ω-linear aliphatic dicarboxylic acid having 4 to 8 carbon atoms. <2> Further, the composition contains at least one of copper iodide, potassium iodide, and cerium oxide. <1> The resin composition according to claim 1. <3> The xylylenediamine contains 50 to 90 mol% of metaxylylenediamine and 10 to 50 mol% of paraxylylenediamine. <1> or <2> The resin composition according to claim 1. <4> The α,ω-linear aliphatic dicarboxylic acid having 4 to 8 carbon atoms includes adipic acid. <1> ~ <3> The resin composition according to any one of the above. <5> the xylylenediamine contains 50 to 90 mol % of meta-xylylenediamine and 10 to 50 mol % of para-xylylenediamine, and the α,ω-linear aliphatic dicarboxylic acid having 4 to 8 carbon atoms contains adipic acid; <1> or <2> The resin composition according to claim 1. <6> the content of the light-transmitting dye having a perylene skeleton is 0.01 to 1.5 parts by mass relative to 100 parts by mass of the polyamide resin; <1> ~ <5> The resin composition according to any one of the above. <7> the content of the light-transmitting dye having a perylene skeleton is 0.10 to 1.5 parts by mass relative to 100 parts by mass of the polyamide resin; <1> ~ <5> The resin composition according to any one of the above. <8> the content of the light-transmitting dye having a perylene skeleton is 0.2 to 1.5 parts by mass relative to 100 parts by mass of the polyamide resin; <1> ~ <5> The resin composition according to any one of the above. <9> The content of the reinforcing filler is 40 to 60 parts by mass relative to 100 parts by mass of the polyamide resin. <1> ~ <8> The resin composition according to any one of the above. <10> When the resin composition is molded into a test piece having a thickness of 1.0 mm, the light transmittance at a wavelength of 750 nm is 5% or less, and the light transmittance at a wavelength of 1070 nm is 20% or more. <1> ~ <9> The resin composition according to any one of the above. <11> Further, metal phosphinates are included. <1> ~ <10> The resin composition according to any one of the above. <12> The resin composition has V-0 performance in the UL94 flammability test at a thickness of 0.75 mm. <11> The resin composition according to claim 1. <13> When the resin composition is molded into a test piece having a thickness of 1.0 mm, the light transmittance at a wavelength of 400 nm is 1.0% or less, and the light transmittance at a wavelength of 940 nm is 3.0% or more. <12> The resin composition according to claim 1. <14> When the resin composition is molded into a test piece having a thickness of 1.0 mm, the light transmittance at a wavelength of 700 nm is 0.2% or less, and the light transmittance at a wavelength of 940 nm is 3.0% or more. <1> ~ <12> The resin composition according to any one of the above. <15> <1> ~ <14> A molded article formed from the resin composition according to any one of the above items. <16> <1> ~ <14> and a light-absorbing resin composition containing a thermoplastic resin and a light-absorbing dye. <17> <1> ~ <14> 1. A method for producing a molded article, the method comprising laser welding a molded article formed from the resin composition according to any one of 1 to 3, and a molded article formed from a light-absorbing resin composition containing a thermoplastic resin and a light-absorbing dye. <18> <1> ~ <14> or a resin composition according to any one of <16> An in-vehicle camera component formed from the kit described in claim 1. <19> <18> An in-vehicle camera including the in-vehicle camera component according to claim 1. [Effects of the Invention]

[0009] The present invention aims to solve these problems and to provide a light-transmitting resin composition for laser welding that has low light transmittance in a specific wavelength range, a molded article, a kit, a method for manufacturing a molded article, and an on-board camera. DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, an embodiment for carrying out the present invention (hereinafter simply referred to as "the present embodiment") will be described in detail. Note that the present embodiment is an example for explaining the present invention, and the present invention is not limited to only this embodiment. In this specification, the symbol "to" is used to mean that the numerical values before and after it are included as the lower limit and upper limit. In this specification, various physical properties and characteristic values are those at 23°C unless otherwise specified. In this specification, "parts by mass" indicates the relative amount of a component, and "% by mass" indicates the absolute amount of a component. If the standards shown in this specification differ depending on the year and the measurement method, etc., they will be based on the standards as of January 1, 2020, unless otherwise stated.

[0011] The optically transparent resin composition for laser welding of this embodiment (hereinafter sometimes simply referred to as "the resin composition of this embodiment") comprises, relative to 100 parts by mass of polyamide resin, 10 to 120 parts by mass of a reinforcing filler, an optically transparent dye having a perylene skeleton, and the polyamide resin is characterized in that it is composed of diamine-derived structural units and dicarboxylic acid-derived structural units, 70 mol % or more of the diamine-derived structural units being derived from xylylenediamine, and 70 mol % or more of the dicarboxylic acid-derived structural units being derived from an α,ω-linear aliphatic dicarboxylic acid having 4 to 8 carbon atoms. This configuration makes it possible to provide a resin composition that has low light transmittance in a specific wavelength range (for example, wavelengths of 700 to 800 nm and / or wavelengths of 400 to 500 nm) and high light transmittance for light used for laser welding (for example, light with a wavelength of 970 nm and / or light with a wavelength of around 1070 nm). In particular, a resin composition can be obtained that has high transmittance for light used for laser welding and low transmittance for wavelengths shorter than the wavelength range of light used for laser welding. Furthermore, generally, when a flame retardant is blended into a thermoplastic resin, the laser transmittance tends to decrease. However, even when a flame retardant is blended into the resin composition of the present embodiment, the resin composition can transmit light rays for laser welding to an extent that laser welding is possible, and can reduce the transmittance of light in a predetermined wavelength range.

[0012] That is, in this embodiment, it was discovered that, from among many polyamide resins, xylylenediamine-based polyamide resins have inherently low light transmittance on the short wavelength side, particularly in the range of 300 to 800 nm, and further, by using a light-transmitting dye having a perylene skeleton as the light-transmitting dye, it has been possible to maintain high light transmittance for light used for laser welding (for example, light with a wavelength of 900 to 1200 nm) and to successfully reduce light transmittance on the shorter wavelength side than that of light used for laser welding (for example, light transmittance for 300 to 800 nm, more specifically, wavelengths of 700 to 800 nm and / or wavelengths of 400 to 500 nm).

[0013] <Polyamide resin> The resin composition of this embodiment includes a polyamide resin composed of diamine-derived structural units and dicarboxylic acid-derived structural units, in which 70 mol % or more of the diamine-derived structural units are derived from xylylenediamine, and 70 mol % or more of the dicarboxylic acid-derived structural units are derived from an α,ω-linear aliphatic dicarboxylic acid having 4 to 8 carbon atoms. Such polyamide resins are sometimes referred to as xylylenediamine-based polyamide resins in this specification. It is believed that the selection of a xylylenediamine-based polyamide resin can maintain high light transmittance for laser welding light (e.g., light with a wavelength of 900 to 1200 nm) and reduce light transmittance for wavelengths shorter than that of laser welding light (e.g., light transmittance for 300 to 800 nm). Furthermore, the excellent performance inherent to xylylenediamine-based polyamide resins, such as mechanical strength, can be utilized.

[0014] In the xylylenediamine-based polyamide resin used in this embodiment, preferably 80 mol% or more, more preferably 90 mol% or more, even more preferably 95 mol% or more, and even more preferably 99 mol% or more of the diamine-derived structural units are derived from xylylenediamine. The xylylenediamine-derived structural units are preferably metaxylylenediamine-derived structural units and / or paraxylylenediamine-derived structural units, more preferably 50 to 90 mol% metaxylylenediamine and 10 to 50 mol% paraxylylenediamine (however, the total does not exceed 100 mol%), and even more preferably 60 to 80 mol% metaxylylenediamine and 20 to 40 mol% paraxylylenediamine. In the xylylenediamine-based polyamide resin used in this embodiment, it is preferred that 95 mol% or more (preferably 99 mol% or more) of the xylylenediamine-derived structural units are metaxylylenediamine-derived structural units and / or paraxylylenediamine-derived structural units.

[0015] Diamines other than xylylenediamine that can be used as raw diamine components for xylylenediamine-based polyamide resins include aliphatic diamines such as tetramethylenediamine, pentamethylenediamine, 2-methylpentanediamine, hexamethylenediamine, heptamethylenediamine, octamethylenediamine, nonamethylenediamine, decamethylenediamine, dodecamethylenediamine, 2,2,4-trimethylhexamethylenediamine, and 2,4,4-trimethylhexamethylenediamine; 1,3-bis(aminomethyl)silane; Examples include alicyclic diamines such as cyclohexane, 1,4-bis(aminomethyl)cyclohexane, 1,3-diaminocyclohexane, 1,4-diaminocyclohexane, bis(4-aminocyclohexyl)methane, 2,2-bis(4-aminocyclohexyl)propane, bis(aminomethyl)decalin, and bis(aminomethyl)tricyclodecane; and diamines having an aromatic ring such as bis(4-aminophenyl)ether, paraphenylenediamine, and bis(aminomethyl)naphthalene; and these can be used alone or in combination of two or more.

[0016] In the xylylenediamine-based polyamide resin used in the present embodiment, 70 mol % or more, preferably 75 mol % or more, more preferably 85 mol % or more, even more preferably 95 mol % or more, and even more preferably 99 mol % or more of the dicarboxylic acid-derived structural units are derived from α,ω-linear aliphatic dicarboxylic acids having 4 to 8 carbon atoms.

[0017] Examples of α,ω-straight-chain aliphatic dicarboxylic acids having 4 to 8 carbon atoms include succinic acid, glutaric acid, adipic acid, pimelic acid, and suberic acid, with adipic acid being preferred. The α,ω-straight-chain aliphatic dicarboxylic acids having 4 to 8 carbon atoms can be used alone or in combination of two or more.

[0018] Examples of dicarboxylic acid components other than the above-mentioned α,ω-linear aliphatic dicarboxylic acids having 4 to 8 carbon atoms include aliphatic dicarboxylic acids having 9 or more carbon atoms, such as sebacic acid; phthalic acid compounds, such as isophthalic acid, terephthalic acid, and orthophthalic acid; and isomers of naphthalenedicarboxylic acid, such as 1,2-naphthalenedicarboxylic acid, 1,3-naphthalenedicarboxylic acid, 1,4-naphthalenedicarboxylic acid, 1,5-naphthalenedicarboxylic acid, 1,6-naphthalenedicarboxylic acid, 1,7-naphthalenedicarboxylic acid, 1,8-naphthalenedicarboxylic acid, 2,3-naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid, and 2,7-naphthalenedicarboxylic acid. These can be used alone or in combination of two or more.

[0019] In the xylylenediamine-based polyamide resin, the raw material xylylenediamine preferably contains 50 to 90 mol % of meta-xylylenediamine and 10 to 50 mol % of para-xylylenediamine, and the α,ω-straight-chain aliphatic dicarboxylic acid having 4 to 8 carbon atoms contains adipic acid. More preferably, 90 mol % or more of the raw material diamine is xylylenediamine, and the xylylenediamine contains 60 to 80 mol % of meta-xylylenediamine and 40 to 20 mol % of para-xylylenediamine, totaling 99 mol % or more of the xylylenediamine, and 90 mol % or more of the straight-chain aliphatic dicarboxylic acid is adipic acid.

[0020] Although the xylylenediamine-based polyamide resin is primarily composed of diamine-derived structural units and dicarboxylic acid-derived structural units, other structural units are not completely excluded, and it goes without saying that it may contain structural units derived from lactams such as ε-caprolactam and laurolactam, and aliphatic aminocarboxylic acids such as aminocaproic acid and aminoundecanoic acid. Here, the term "major component" refers to the structural units constituting the xylylenediamine-based polyamide resin in which the total number of diamine-derived structural units and dicarboxylic acid-derived structural units is the largest among all structural units. In this embodiment, the total of the diamine-derived structural units and dicarboxylic acid-derived structural units in the xylylenediamine-based polyamide resin preferably accounts for 90% by mass or more, and more preferably 95% by mass or more, of all structural units.

[0021] The resin composition of this embodiment may or may not contain other polyamide resins in addition to the xylylenediamine-based polyamide resin. Examples of other polyamide resins include aliphatic polyamide resins, and polyamide 6 is preferred. It is presumed that by using a polyamide resin with a relatively higher transmittance than a xylylenediamine-based polyamide resin such as polyamide 6, wavelength selectivity can be shifted to the shorter wavelength side. When the resin composition of this embodiment contains another polyamide resin (preferably an aliphatic polyamide resin, more preferably polyamide 6), the proportion thereof is preferably 1 part by mass or more, more preferably 2 parts by mass or more, and preferably 10 parts by mass or less, more preferably 5 parts by mass or less, and even more preferably 4 parts by mass or less, per 100 parts by mass of the xylylenediamine-based polyamide resin.

[0022] The resin composition of this embodiment preferably contains polyamide resin in a proportion of 30% by mass or more of the resin composition, more preferably 35% by mass or more, even more preferably 40% by mass or more, and even more preferably 45% by mass or more. The upper limit of the polyamide resin content is preferably 80% by mass or less, more preferably 75% by mass or less. The polyamide resin may contain only one kind or two or more kinds. When two or more kinds are contained, the total amount is preferably in the above range.

[0023] <Reinforcing filler> The resin composition of this embodiment contains a reinforcing filler in a ratio of 10 to 120 parts by mass relative to 100 parts by mass of the polyamide resin. By containing the reinforcing filler in this ratio, high mechanical strength can be achieved. Note that the reinforcing filler in this embodiment does not include substances equivalent to cerium oxide and nucleating agents, which will be described later. The reinforcing filler that can be contained in the resin composition of this embodiment has the effect of improving the mechanical properties of the resulting resin composition when blended with the resin, and can be a commonly used plastic reinforcing material. The reinforcing filler can be either organic or inorganic, with inorganic materials being preferred. The reinforcing filler is preferably a fibrous reinforcing filler such as glass fiber, carbon fiber, basalt fiber, wollastonite, or potassium titanate fiber. Other reinforcing fillers that can be used include granular or amorphous fillers such as calcium carbonate, titanium oxide, feldspar minerals, clay, organoclay, and glass beads; and scaly reinforcing materials such as glass flakes, mica, and graphite. Among these, fibrous fillers, particularly glass fiber, are preferred in terms of mechanical strength, rigidity, and heat resistance. Glass fibers with either a round or irregular cross-sectional shape can be used. It is more preferable to use a reinforcing filler that has been surface-treated with a surface treatment agent such as a coupling agent. Glass fibers with a surface treatment agent attached thereto are preferred because they have excellent durability, moist heat resistance, hydrolysis resistance, and heat shock resistance.

[0024] The glass fiber is made of a glass composition such as A-glass, C-glass, E-glass, S-glass, R-glass, M-glass, D-glass, or boron-free glass (glass with a boron content of 30 mass ppm or less), and E-glass (alkali-free glass) is particularly preferred. Glass fiber refers to a fiber whose cross section cut perpendicular to the length direction has a circular or polygonal shape and exhibits a fibrous appearance.

[0025] The glass fiber used in the resin composition of this embodiment may be a single fiber or a plurality of single fibers twisted together. The glass fiber may be in any form, such as a "glass roving" made by continuously winding a single fiber or a plurality of twisted single fibers, a "chopped strand" cut to a length of 1 to 10 mm, or a "milled fiber" pulverized to a length of 10 to 500 μm. Such glass fibers are readily available commercially from Asahi Fiber Glass Co., Ltd. under the trade names "Glaslon Chopped Strand" and "Glaslon Milled Fiber." Glass fibers of different forms can also be used in combination.

[0026] The glass fibers used in this embodiment may have a circular or non-circular cross section. By using glass fibers having a non-circular cross section, warpage of the resulting molded article can be more effectively suppressed. In this embodiment, warpage can also be effectively suppressed even when glass fibers having a circular cross section are used.

[0027] The content of the reinforcing filler in the resin composition of this embodiment is 10 parts by mass or more, more preferably 20 parts by mass or more, more preferably 30 parts by mass or more, and even more preferably 40 parts by mass or more, relative to 100 parts by mass of the polyamide resin. The upper limit is 120 parts by mass or less, more preferably 110 parts by mass or less, and may be 60 parts by mass or less, relative to 100 parts by mass of the polyamide resin. The content of the reinforcing filler in the resin composition of this embodiment is preferably 20% by mass or more, more preferably 25% by mass or more, of the resin composition, and the upper limit is preferably 70% by mass or less, more preferably 65% by mass or less, even more preferably 60% by mass or less, and even more preferably 55% by mass or less. The resin composition of this embodiment may contain only one type of reinforcing filler, or may contain two or more types. When two or more types are contained, the total amount falls within the above range. Note that the content of the reinforcing filler in this embodiment is intended to include the amounts of the sizing agent and the surface treatment agent.

[0028] <Light-transmitting dyes with perylene skeleton> The resin composition of this embodiment contains a light-transmitting dye having a perylene skeleton. By using the light-transmitting dye having a perylene skeleton and a predetermined xylylenediamine-based polyamide resin, a resin composition can be obtained that has high light transmittance for light used for laser welding (for example, light with a wavelength of 900 to 1200 nm) and low light transmittance for light with wavelengths shorter than that of the laser welding light (for example, light transmittance for 300 to 800 nm). The light-transmitting dye used in this embodiment is preferably a black dye, a black-purple dye, or the like, which appears black to the human eye. The light-transmitting dye refers to a dye that has a transmittance of 20% or more when a mixture of, for example, polyamide resin, 30% by mass of glass fiber, and 0.2% by mass of a dye (a dye considered to be a light-transmitting dye) is blended to a total of 100% by mass, and the light transmittance at a wavelength of 1070 nm is measured using the measurement method described in the Examples below. The light-transmitting coloring matter may be either a dye or a pigment, but is preferably a pigment. Examples of dyes having a perylene skeleton include Spectrasence (registered trademark) Black K0087 (formerly Lumogen (registered trademark) Black FK4280) and Spectrasence Black K0088 (formerly Lumogen Black FK4281), both manufactured by BASF Color & Effects Japan Ltd.

[0029] The resin composition of this embodiment preferably contains 0.01 parts by mass or more of the light-transmitting dye having a perylene skeleton relative to 100 parts by mass of the polyamide resin, more preferably 0.04 parts by mass or more, even more preferably 0.08 parts by mass or more, even more preferably 0.10 parts by mass or more, even more preferably 0.15 parts by mass or more, even more preferably 0.18 parts by mass or more, and particularly preferably 0.20 parts by mass or more. The resin composition of this embodiment preferably contains 1.5 parts by mass or less of the light-transmitting dye having a perylene skeleton relative to 100 parts by mass of the polyamide resin, more preferably 1.0 part by mass or less, even more preferably 0.8 parts by mass or less, and may be 0.6 parts by mass or less, 0.5 parts by mass or less, or 0.45 parts by mass or less, depending on the application.

[0030] In this embodiment, it is also preferable to blend a light-transmitting dye having a perylene skeleton so that, when the resin composition of this embodiment is molded into a test piece having a thickness of 1.0 mm, the light transmittance at a wavelength of 750 nm is 5% or less and the light transmittance at a wavelength of 1070 nm is 20% or more. In this embodiment, it is also preferable to blend a light-transmitting dye having a perylene skeleton so that, when the resin composition of this embodiment is molded into a test piece having a thickness of 1.0 mm, the light transmittance at a wavelength of 400 nm is 1.0% or less and the light transmittance at a wavelength of 940 nm is 3.0% or more. In this embodiment, it is also preferable to blend a light-transmitting dye having a perylene skeleton so that, when the resin composition of this embodiment is molded into a test piece having a thickness of 1.0 mm, the light transmittance at a wavelength of 700 nm is 1.0% or less and the light transmittance at a wavelength of 940 nm is 3.0% or more.

[0031] The resin composition of the present embodiment may contain only one type of light-transmitting dye having a perylene skeleton, or may contain two or more types. When two or more types are contained, the total amount is preferably in the above range. In particular, the resin composition of the present embodiment is preferable because it uses a light-transmitting dye having a perylene skeleton, thereby making it possible to achieve a desired wavelength without using two or more light-transmitting dyes. The resin composition of this embodiment may contain other dyes besides the light-transmitting dye having a perylene skeleton, but is preferably substantially free of such dyes. For example, "substantially free of such dyes" means that the content of such other dyes is less than 1% by mass of the content of the light-transmitting dye having a perylene skeleton.

[0032] <Copper iodide, potassium iodide and cerium oxide> The resin composition of this embodiment preferably contains at least one of copper iodide, potassium iodide, and cerium oxide. The inclusion of copper iodide tends to further improve the heat resistance of the resulting molded article. Furthermore, the inclusion of potassium iodide tends to facilitate the formation of a complex in the polyamide resin, more effectively inhibiting resin decomposition. Furthermore, the inclusion of cerium oxide effectively inhibits hue change due to oxidation and effectively inhibits migration (color transfer) after a wet heat test or a hot water test. In other words, blending these components makes it possible to impart performance tailored to the application.

[0033] The proportion of copper iodide in the resin composition of this embodiment is preferably 0.01 to 1 mass % in the resin composition, more preferably 0.02 mass % or more, more preferably 0.5 mass % or less, and even more preferably 0.3 mass % or less. The resin composition of the present embodiment may contain only one type of copper iodide, or may contain two or more types. When two or more types are contained, the total amount is preferably in the above range. The content of potassium iodide in the resin composition of this embodiment is preferably 0.01 to 2% by mass, more preferably 0.02% by mass or more, and more preferably 1% by mass or less, in the resin composition. The content of cerium oxide in the resin composition of this embodiment is preferably 0.01 to 2% by mass, more preferably 0.02% by mass or more, and more preferably 1% by mass or less, in the resin composition. The resin composition of the present embodiment may contain only one type of cerium oxide, or may contain two or more types. When two or more types are contained, the total amount is preferably in the above range.

[0034] <Release agent> The resin composition of the present embodiment may contain a release agent. Examples of the release agent include aliphatic carboxylic acids, salts of aliphatic carboxylic acids, esters of aliphatic carboxylic acids and alcohols, aliphatic hydrocarbon compounds having a number average molecular weight of 200 to 15,000, polysiloxane-based silicone oils, ketone waxes, and light amides. Of these, aliphatic carboxylic acids, salts of aliphatic carboxylic acids, and esters of aliphatic carboxylic acids and alcohols are preferred, and salts of aliphatic carboxylic acids are more preferred. For details about the release agent, please refer to paragraphs 0055 to 0061 of JP 2018-095706 A, the contents of which are incorporated herein by reference. When the resin composition of the present embodiment contains a release agent, the content thereof in the resin composition is preferably 0.05 to 3 mass %, more preferably 0.1 to 0.8 mass %, and even more preferably 0.2 to 0.6 mass %. The resin composition of the present embodiment may contain only one type of release agent, or may contain two or more types. When two or more types are contained, the total amount is preferably in the above range.

[0035] <Nucleating agent> The resin composition of the present embodiment may contain a nucleating agent. The nucleating agent is not particularly limited as long as it remains unmelted during melt processing and can serve as a nucleus for crystals during the cooling process. Among these, talc and calcium carbonate are preferred, with talc being more preferred. The lower limit of the number average particle size of the nucleating agent is preferably 0.1 μm or more, more preferably 1 μm or more, and even more preferably 3 μm or more.The upper limit of the number average particle size of the nucleating agent is preferably 40 μm or less, more preferably 30 μm or less, even more preferably 28 μm or less, even more preferably 15 μm or less, and even more preferably 10 μm or less.

[0036] The content of the nucleating agent in the resin composition of this embodiment is preferably 0.01 to 1% by mass, more preferably 0.1% by mass or more, and more preferably 0.5% by mass or less. The resin composition of the present embodiment may contain only one type of nucleating agent, or may contain two or more types. When two or more types are contained, the total amount is preferably in the above range.

[0037] <Flame retardant> The resin composition of the present embodiment may contain a flame retardant. By containing a flame retardant, the flame retardancy of the resin composition can be improved. In this embodiment, the flame retardant is preferably a phosphorus-based flame retardant, more preferably a metal phosphinate, a metal diphosphinate, phosphorus, a phosphate, a phosphate ester, phosphazene, or a reaction product of melamine and phosphoric acid, further preferably contains at least one of a metal phosphinate and a metal diphosphinate, and even more preferably contains at least one of a metal phosphinate. Metal phosphinates have excellent tracking resistance and can be effectively used in applications such as CTI (Computer Telephony Integration). Furthermore, although the incorporation of a flame retardant into a thermoplastic resin tends to reduce light transmittance, the use of a phosphorus-based flame retardant (particularly, a metal phosphinate) can effectively suppress the reduction in light transmittance of the resin composition. In particular, metal phosphinates are more effective because they tend to achieve high flame retardancy even when incorporated in small amounts.

[0038] The metal phosphinate or diphosphinate preferably contains at least one of the compound represented by formula (I) and the compound represented by formula (2).

[0039] [ka] (In formula (I), R 1 and R 2 each independently represents a linear or branched alkyl group having 1 to 6 carbon atoms, or an aryl group having 6 to 10 carbon atoms. M represents a calcium ion, an aluminum ion, a magnesium ion, or a zinc ion. m is a natural number representing the valence of M.

[0040] In formula (I), R 1 and R 2 are each independently a linear or branched alkyl group having 1 to 6 carbon atoms or an aryl group having 6 to 10 carbon atoms, and are preferably a methyl group, an ethyl group, a propyl group, or a phenyl group. M represents a calcium ion, an aluminum ion, a magnesium ion, or a zinc ion. m is a natural number representing the valence of M, and is preferably 2 or 3.

[0041] [ka] (In formula (II), R 4 and R 5 R each independently represents a linear or branched alkyl group having 1 to 6 carbon atoms, or an aryl group having 6 to 10 carbon atoms. 3 represents a linear or branched alkylene group having 1 to 10 carbon atoms, an arylene group having 6 to 10 carbon atoms, an alkylarylene group having 7 to 10 carbon atoms, or an arylalkylene group having 7 to 10 carbon atoms. M represents a calcium ion, an aluminum ion, a magnesium ion, or a zinc ion. n is a natural number representing the valence of M. n, a, and b are natural numbers that satisfy the relational expression 2×b=n×a. In formula (II), R 4 and R 5R each independently represents a linear or branched alkyl group having 1 to 6 carbon atoms or an aryl group having 6 to 10 carbon atoms, and is preferably a methyl group, an ethyl group, a propyl group, or a phenyl group. 3 represents a linear or branched alkylene group having 1 to 10 carbon atoms, an arylene group having 6 to 10 carbon atoms, an alkylarylene group having 7 to 10 carbon atoms, or an arylalkylene group having 7 to 10 carbon atoms, and is preferably a methylene group, an ethylene group, a propylene group, or a phenylene group. M represents a calcium ion, an aluminum ion, a magnesium ion, or a zinc ion. n is a natural number representing the valence of M. n, a, and b are natural numbers that satisfy the relational expression 2×b=n×a. n is preferably 2 or 3. b is preferably 1, 2, or 3, and more preferably 1 or 3. a is preferably 1 or 2.

[0042] Specific examples of metal phosphinates or metal diphosphinates include those produced in an aqueous medium using phosphinic acid and a metal carbonate, metal hydroxide, or metal oxide. Metal phosphinates or metal diphosphinates are basically monomeric compounds, but depending on the reaction conditions and environment, they may become polymeric metal phosphinates with a condensation degree of 1 to 3.

[0043] Examples of phosphinic acids or diphosphinic acids include dimethylphosphinic acid, ethylmethylphosphinic acid, diethylphosphinic acid, methyl-n-propylphosphinic acid, methanedi(methylphosphinic acid), benzene-1,4-di(methylphosphinic acid), methylphenylphosphinic acid, and diphenylphosphinic acid.

[0044] Examples of the metal phosphinate include calcium dimethylphosphinate, magnesium dimethylphosphinate, aluminum dimethylphosphinate, zinc dimethylphosphinate, calcium ethylmethylphosphinate, magnesium ethylmethylphosphinate, aluminum ethylmethylphosphinate, zinc ethylmethylphosphinate, calcium diethylphosphinate, magnesium diethylphosphinate, aluminum diethylphosphinate, zinc diethylphosphinate, calcium methyl-n-propylphosphinate, magnesium methyl-n-propylphosphinate, aluminum methyl-n-propylphosphinate, zinc methyl-n-propylphosphinate, calcium methylphenylphosphinate, magnesium methylphenylphosphinate, aluminum methylphenylphosphinate, zinc methylphenylphosphinate, calcium diphenylphosphinate, magnesium diphenylphosphinate, aluminum diphenylphosphinate, and zinc diphenylphosphinate.

[0045] Examples of metal diphosphinates include calcium methane di(methylphosphinate), magnesium methane di(methylphosphinate), aluminum methane di(methylphosphinate), zinc methane di(methylphosphinate), calcium benzene-1,4-di(methylphosphinate), magnesium benzene-1,4-di(methylphosphinate), aluminum benzene-1,4-di(methylphosphinate), and zinc benzene-1,4-di(methylphosphinate).

[0046] Among these metal phosphinates or diphosphinates, aluminum ethylmethylphosphinate, aluminum diethylphosphinate, and zinc diethylphosphinate are particularly preferred from the viewpoints of flame retardancy and electrical properties. Specific commercial products include EXOLIT OP 1230 (aluminum phosphinate) and EXOLIT OP 1400 (both trade names) manufactured by Clariant.

[0047] The content of the flame retardant (preferably a metal phosphinate) in the resin composition of this embodiment is preferably 1% by mass or more, more preferably 2% by mass or more, even more preferably 2.5% by mass or more, and even more preferably 3% by mass or more, and the upper limit is preferably 25% by mass or less, and more preferably 20% by mass or less. The resin composition of the present embodiment may contain only one flame retardant (preferably a metal phosphinate) or may contain two or more flame retardants. When two or more flame retardants are contained, the total amount is preferably in the above range.

[0048] When the resin composition of the present embodiment contains a flame retardant, it preferably has V-0 performance in the UL94 flammability test when molded into a test piece with a thickness of 0.75 mm.

[0049] <Anti-drip agent> The resin composition of the present embodiment may contain an anti-dripping agent. By blending an anti-dripping agent together with a flame retardant into the resin composition of the present embodiment, the flame retardancy of the resulting molded article can be further improved. Examples of the anti-dripping agent include fluoroolefin resins. Fluoroolefin resins are usually polymers or copolymers containing a fluoroethylene structure. Specific examples include difluoroethylene resins, tetrafluoroethylene resins, tetrafluoroethylene / hexafluoropropylene copolymer resins, and tetrafluoroethylene / perfluoroalkyl vinyl ether copolymer resins. Among these, tetrafluoroethylene resins are preferred. Examples of the fluoroethylene resins include fluoroethylene resins that have fibril-forming ability. For details of the anti-dripping agent, please refer to paragraphs 0066 to 0071 of JP 2013-082786 A, the contents of which are incorporated herein by reference.

[0050] When incorporated, the content of the anti-dripping agent in the resin composition of this embodiment is preferably 0.001 parts by mass or more, more preferably 0.01 parts by mass or more, even more preferably 0.05 parts by mass or more, and even more preferably 0.1 parts by mass or more, relative to 100 parts by mass of the polyamide resin. The upper limit of the content is preferably 1.0 parts by mass or less, more preferably 0.75 parts by mass or less, and even more preferably 0.5 parts by mass or less. By setting the content at or above the lower limit, flame retardancy is more effectively exhibited, while by setting the content at or below the upper limit, the appearance defect and mechanical strength of the resulting molded article tend to be further improved. The resin composition of the present embodiment may contain only one type of anti-dripping agent, or may contain two or more types. When two or more types are contained, the total amount is preferably in the above range.

[0051] <Other ingredients> The resin composition of this embodiment may contain other components within the scope of the present invention. Examples of such additives include light stabilizers, antioxidants, UV absorbers, fluorescent brighteners, antistatic agents, antifogging agents, antiblocking agents, flow improvers, plasticizers, dispersants, and antibacterial agents. The resin composition of this embodiment may also contain copper compounds other than copper iodide, alkali metal halides other than potassium iodide, and the like. These components may be used alone or in combination of two or more. In the resin composition of this embodiment, the contents of the xylylenediamine polyamide resin, reinforcing filler, light-transmitting dye having a perylene skeleton, and other additives are adjusted so that the total of each component is 100% by mass. In this embodiment, the total of the xylylenediamine polyamide resin, reinforcing filler, light-transmitting dye having a perylene skeleton, at least one of copper iodide, potassium iodide, and cerium oxide, the nucleating agent, and the release agent accounts for 99% by mass or more of the resin composition. In this embodiment, the xylylenediamine polyamide resin, polyamide 6, reinforcing filler, light-transmitting dye having a perylene skeleton, at least one of copper iodide, potassium iodide, and cerium oxide, a nucleating agent, and a release agent account for 99% by mass or more of the resin composition.

[0052] <Physical properties of resin composition> In one example of wavelength selectivity, the resin composition of this embodiment is required to have low light transmittance at wavelengths of 700 to 800 nm and high light transmittance at wavelengths around 1070 nm. For example, when the resin composition of this embodiment is molded into a 1.0 mm thick test piece, the light transmittance at a wavelength of 750 nm is preferably 5% or less (preferably 0 to 3%, more preferably 0 to 2%, even more preferably 0 to 1%, and even more preferably 0 to 0.5%), and the light transmittance at a wavelength of 1070 nm is preferably 20% or more. A light transmittance of 20% or more at a wavelength of 1070 nm ensures sufficient laser welding. Furthermore, the light transmittance at a wavelength of 1070 nm of the 1.0 mm thick test piece is preferably 25% or more, more preferably 30% or more, and even more preferably 35% or more. The upper limit of the light transmittance at a wavelength of 1070 nm of the 1.0 mm thick test piece is, for example, 90% or less, and may be 70% or less. In particular, for applications where it is desirable that light does not easily penetrate into the interior of the molded article after laser welding, the upper limit of the light transmittance at a wavelength of 1070 nm is preferably 50% or less.

[0053] In another example of wavelength selectivity of the resin composition of this embodiment, low light transmittance in the 300 to 500 nm range and high light transmittance at a wavelength of around 970 nm are required. For example, when the resin composition of this embodiment is molded into a test piece with a thickness of 1.0 mm, it is preferable that the light transmittance at a wavelength of 400 nm is 1.0% or less (preferably 0.2% or less, or, for example, 0% or more) and the light transmittance at a wavelength of 940 nm is 3.0% or more (preferably 5.0% or more, or, for example, 30% or less). The wavelength selectivity of this embodiment can be achieved, for example, by blending a polyamide resin (e.g., polyamide 6) having a relatively higher transmittance than xylylenediamine-based polyamide resin as part of the polyamide resin component.

[0054] In yet another example of the wavelength selectivity of the resin composition of this embodiment, low light transmittance at 700 nm and high light transmittance at 970 nm are required. For example, when the resin composition of this embodiment is molded into a test piece with a thickness of 1.0 mm, it is preferable that the light transmittance at 700 nm is 1.0% or less (preferably 0.2% or less, for example, 0% or more) and the light transmittance at 940 nm is 3.0% or more (preferably 5.0% or more, for example, 30% or less). The wavelength selectivity of this embodiment is achieved by adjusting the content of the light-transmitting dye having a perylene skeleton to 0.2 to 1.5 parts by mass per 100 parts by mass of the polyamide resin. The light transmittance is measured according to the description in the examples below.

[0055] <Method of manufacturing resin composition> The method for producing the resin composition of this embodiment is not particularly limited, but a method using a single-screw or twin-screw extruder equipped with a degassing device through a vent port as a kneader is preferred. The polyamide resin component, reinforcing filler, and optically transparent dye, as well as other additives blended as needed, may be fed to the kneader all at once, or the polyamide resin component may be fed first, followed by the other blended components. The reinforcing filler is preferably fed midway through the extruder to prevent it from being crushed during blending. Alternatively, two or more components selected from each component may be mixed and kneaded in advance. In this embodiment, the light-transmitting dye may be prepared in advance as a masterbatch of a polyamide resin or the like, and then kneaded with other components (a polyamide resin component, a reinforcing filler, a light-transmitting dye, etc.) to obtain the resin composition of this embodiment.

[0056] The method for producing a molded article using the resin composition of this embodiment is not particularly limited, and molding methods commonly used for thermoplastic resins, such as injection molding, blow molding, extrusion molding, and press molding, can be applied. In this case, injection molding is particularly preferred because of its good fluidity. During injection molding, it is preferable to control the resin temperature to 250 to 300°C.

[0057] <Kit> The resin composition of this embodiment and a light-absorbing resin composition containing a thermoplastic resin and a light-absorbing dye are preferably used as a kit for producing a molded article by laser welding. That is, the resin composition of the present embodiment included in the kit serves as a light-transmitting resin composition, and a molded article formed from such a light-transmitting resin composition becomes a transmissive resin member for laser light during laser welding, whereas a molded article formed from a light-absorbing resin composition becomes an absorptive resin member for laser light during laser welding.

[0058] <<Light-absorbing resin composition>> The light-absorbing resin composition used in this embodiment contains a thermoplastic resin and a light-absorbing dye, and may further contain other components such as a reinforcing filler. Examples of thermoplastic resins include polyamide resins, olefin resins, vinyl resins, styrene resins, acrylic resins, polyphenylene ether resins, polyester resins, polycarbonate resins, and polyacetal resins, and polyamide resins, polyester resins, and polycarbonate resins are particularly preferred, with polyamide resins being more preferred, due to their good compatibility with the light-transmitting resin composition (the resin composition of the present embodiment). The thermoplastic resin may be one type or two or more types. The type of polyamide resin used in the light-absorbing resin composition is not particularly limited, but the above-mentioned xylylenediamine polyamide resin is preferred. Examples of reinforcing fillers include glass fiber, carbon fiber, silica, alumina, carbon black, and fillers capable of absorbing laser light, such as inorganic powder coated with a laser-absorbing material, with glass fiber being preferred. The glass fiber has the same meaning as the glass fiber that may be blended into the resin composition of the present embodiment. The content of the reinforcing filler is preferably 20 to 70 mass %, more preferably 25 to 60 mass %, and even more preferably 30 to 55 mass %. The light-absorbing dye includes a dye having an absorption wavelength in the wavelength range of the irradiated laser light, for example, in this embodiment, a wavelength range of 800 to 1100 nm, particularly a wavelength range of 900 to 1100 nm. Furthermore, the light-absorbing dye includes, for example, a dye that, when blended at 0.3 parts by mass with 100 parts by mass of xylylenediamine-based polyamide resin and the light transmittance is measured by the measurement method described in the Examples below, exhibits a transmittance of less than 30%, or even 10% or less, in the upper range. Specific examples of light-absorbing dyes include inorganic pigments (black pigments such as carbon black (e.g., acetylene black, lamp black, thermal black, furnace black, channel black, ketjen black, etc.), red pigments such as iron oxide red, orange pigments such as molybdate orange, and white pigments such as titanium oxide), and organic pigments (yellow pigments, orange pigments, red pigments, blue pigments, green pigments, etc.). Among these, inorganic pigments are generally preferred because of their strong hiding power, and black pigments are more preferred. Two or more of these light-absorbing dyes may be used in combination. The content of the light-absorbing dye is preferably 0.01 to 30 parts by mass per 100 parts by mass of the xylylenediamine-based polyamide resin.

[0059] In the above kit, it is preferable that 80% by mass or more of the components in the resin composition excluding the light-transmitting dye and reinforcing filler are common to the components in the light-absorbing resin composition excluding the light-absorbing dye and reinforcing filler, more preferably 90% by mass or more, and even more preferably 95 to 100% by mass are common to the components in the resin composition excluding the light-absorbing dye and reinforcing filler.

[0060] <<Laser welding method>> Next, a laser welding method will be described. In this embodiment, a molded article (laser-welded article) can be produced by laser welding a molded article (transmissive resin member) formed from the resin composition of this embodiment and a molded article (absorbent resin member) formed by molding the light-absorbing resin composition. By laser welding, the transmissive resin member and the absorbent resin member can be firmly welded together without using an adhesive. The shape of the members is not particularly limited, but since the members are used by joining them together by laser welding, they usually have a shape that has at least a surface contact area (flat surface, curved surface). In laser welding, the laser light that passes through the transparent resin member is absorbed by the absorbing resin member, melting it, and welding the two members together. The molded article formed from the resin composition of this embodiment has high laser light transmittance and can be preferably used as a transparent resin member. Here, the thickness of the member through which the laser light passes (the thickness in the laser transmission direction at the portion through which the laser light passes) can be appropriately determined taking into consideration the application, the composition of the resin composition, and other factors, but is, for example, 5 mm or less, preferably 4 mm or less.

[0061] The laser light source used for laser welding can be determined depending on the absorption wavelength of the light of the light-absorbing dye, and a laser with a wavelength in the range of 900 to 1100 nm is preferred, and for example, a semiconductor laser or fiber laser can be used.

[0062] More specifically, for example, when welding a transparent resin member and an absorbing resin member, the portions of the two members to be welded are first brought into contact with each other. At this time, surface contact between the two welded portions is desirable, and they may be flat surfaces, curved surfaces, or a combination of flat and curved surfaces. Next, laser light is irradiated from the transparent resin member side. If necessary, a lens may be used to focus the laser light at the interface between the two members. The focused beam passes through the transparent resin member and is absorbed near the surface of the absorbing resin member, generating heat and melting it. The heat is then transferred by thermal conduction to the transparent resin member, melting it and forming a molten pool at the interface between the two members. After cooling, the two members are joined. The molded product in which the transparent resin member and the absorbing resin member are welded in this manner has high weld strength. Note that the molded product in this embodiment is intended to include not only finished products and parts, but also parts that form part of these.

[0063] The molded product obtained by laser welding in this embodiment has good mechanical strength, high welding strength, and little damage to the resin due to laser irradiation. Therefore, it can be applied to various uses, such as various storage containers, electrical and electronic equipment parts, office automation (OA) equipment parts, household appliance parts, mechanical mechanism parts, vehicle mechanism parts, etc. In particular, it can be suitably used for food containers, medicine containers, oil and fat product containers, hollow parts for vehicles (various tanks, intake manifold parts, camera housings, etc.), electrical parts for vehicles (various control units, ignition coil parts, etc.), motor parts, various sensor parts, connector parts, switch parts, breaker parts, relay parts, coil parts, transformer parts, lamp parts, etc. In particular, the in-vehicle camera parts formed from the resin composition or kit of this embodiment are suitable for in-vehicle cameras.

Examples

[0064] The present invention will be described more specifically with reference to the following examples. The materials, amounts used, ratios, treatment contents, treatment procedures, etc. shown in the following examples can be appropriately changed as long as they do not depart from the spirit of the present invention. Therefore, the scope of the present invention is not limited to the specific examples shown below. When the measuring instruments used in the examples are difficult to obtain due to obsolescence or the like, measurements can be made using other devices having equivalent performance.

[0065] <Polyamide resin> MP6: The molar ratio of metaxylylenediamine / paraxylylenediamine (M / P) = 7:3, synthesized according to the following synthesis example. <<Synthesis example of MP6 (M / P molar ratio = 7:3)>> After adipic acid was heated and dissolved in a reaction vessel under a nitrogen atmosphere, while stirring the contents, a mixed diamine with a molar ratio of 3:7 of p-xylylenediamine (manufactured by Mitsubishi Gas Chemical Company) and m-xylylenediamine (manufactured by Mitsubishi Gas Chemical Company) was gradually dropped under pressure (0.35 MPa) while raising the temperature to 270 °C so that the molar ratio of diamine to adipic acid (manufactured by Rhodia) became approximately 1:1. After completion of the dropping, the pressure was reduced to 0.06 MPa and the reaction was continued for 10 minutes to adjust the amount of components with a molecular weight of 1,000 or less. Thereafter, the contents were taken out in a strand shape and pelletized with a pelletizer to obtain a polyamide resin (MP6).

[0066] MP10: M / P molar ratio = 7:3, synthesized according to the following synthesis example. <<Synthesis example of MP10 (M / P molar ratio = 7:3)>> After sebacic acid was heated and dissolved in a reaction vessel under a nitrogen atmosphere, while stirring the contents, a mixed diamine with a molar ratio of 3:7 of p-xylylenediamine (manufactured by Mitsubishi Gas Chemical Company) and m-xylylenediamine (manufactured by Mitsubishi Gas Chemical Company) was gradually dropped under pressure (0.35 MPa) while raising the temperature to 235 °C so that the molar ratio of diamine to sebacic acid became approximately 1:1. After completion of the dropping, the reaction was continued for 60 minutes to adjust the amount of components with a molecular weight of 1,000 or less. After completion of the reaction, the contents were taken out in a strand shape and pelletized with a pelletizer to obtain a polyamide resin (MP10).

[0067] PA66: Polyamide 66, manufactured by INVISTA Nylon Polymer, Invista U4800 PA6: Polyamide 6, manufactured by Ube Industries, 1013B

[0068] [[ID=ID=18]]<Nucleating agent> Talc: #5000S, manufactured by Hayashi Kasei Co., Ltd., Micron White

[0069] <Flame retardant> OP1230: Manufactured by Clariant, metal phosphinate <Dripping inhibitor> FA-500H: Polyflon, manufactured by Daikin Industries, Ltd.

[0070] <Copper iodide (CuI)> Cuprous iodide, manufactured by Nippon Chemical Industry Co., Ltd. <Potassium iodide> Fujifilm Wako Pure Chemical Industries, Ltd. <Zinc stearate(II)> Fujifilm Wako Pure Chemical Industries, Ltd. <Cerium oxide> Cerium Hydrate90, manufactured by TREIBACHER INDUTRIE AG

[0071] <Reinforcing filler> ECS03T-211H: Nippon Electric Glass Co., Ltd., glass fiber, single fiber diameter 10.5 μm, length 3.5 mm ECS03T-275H: Nippon Electric Glass Co., Ltd., glass fiber, single fiber diameter 10.5 μm, length 3.5 mm

[0072] <Release agent> CS8CP: Montan acid soap, manufactured by Nitto Kasei Kogyo Co., Ltd. WH-255: Light amide, manufactured by Kyoeisha Chemical Co., Ltd.

[0073] <Light-transmitting dye> Spectrasence Black K 0088: BASF Color & Effects Japan, perylene pigment, Spectrasence Black K 0088 (formerly Lumogen Black K 0088, formerly Lumogen Black FK 4281)

[0074] Examples 1 to 12, Comparative Examples 1 to 3 <Compound> The components other than the glass fiber were weighed and dry-blended to obtain the composition shown in Tables 1 and 2 below (each component is expressed in parts by mass). The components were then added to a twin-screw extruder (Shibaura Machine Co., Ltd. (formerly Toshiba Machine Co., Ltd.), TEM26SS) from the base of the screw using a twin-screw cassette weighing feeder (Kubota, CE-W-1-MP). The glass fiber was added to the side of the extruder using a vibrating cassette weighing feeder (Kubota, CE-V-1B-MP), and melt-kneaded with the resin components to obtain resin composition pellets. The extruder temperature was set to 260°C when MP10 was used as the polyamide resin, 280°C when MP6 was used, and 280°C when PA66 was used.

[0075] <Flexural strength and flexural modulus> The resin pellets obtained by the above manufacturing method were dried at 120°C for 4 hours and then injection molded into 4 mm thick ISO tensile test specimens using an NEX140III manufactured by Nissei Plastic Industrial Co., Ltd. During molding, the cylinder temperature was 260°C when MP10 was used as the polyamide resin, 280°C when MP6 was used, and 280°C when PA66 was used, and the mold temperature was 110°C when MP10 was used as the polyamide resin, 130°C when MP6 was used, and 90°C when PA66 was used. In accordance with ISO178, the flexural strength (unit: MPa) and flexural modulus (unit: MPa) were measured at a temperature of 23°C using the above ISO tensile test pieces (4 mm thick).

[0076] <Light transmittance> The resin composition pellets obtained above were dried at 120°C for 4 hours, and then test pieces (60 mm x 60 mm x 1.0 mm thick) for measuring light transmittance were prepared using an injection molding machine (SE-50D, manufactured by Sumitomo Heavy Industries, Ltd.) The cylinder temperature and mold temperature were the same as those for the ISO tensile test pieces. The light transmittance was measured using a visible / ultraviolet spectrophotometer (Shimadzu Corporation, UV-3100PC), and the light transmittance (unit: %) at each wavelength shown in Tables 1 and 2 was measured.

[0077] [Table 1]

[0078] [Table 2]

[0079] As is clear from the above results, the resin compositions described in Examples 1 to 12 had high light transmittance at a wavelength of 1,070 nm and low light transmittance at wavelengths of 700 to 800 nm. Furthermore, they maintained high mechanical strength. In contrast, when MP10 or PA66 was used as the polyamide resin (Comparative Examples 1 to 3), the light transmittance at wavelengths of 700 to 800 nm was high.

[0080] Pellets for forming an absorbent resin member were obtained in the same manner as in Example 1, except that no light-transmitting dye was added and 3 parts by mass of carbon black #45 (manufactured by Mitsubishi Chemical Corporation) was added. The pellets obtained in Example 1 and the pellets for forming an absorbent resin member were laser welded together in accordance with the description in paragraphs 0072 and 0073 and FIG. 1 of JP 2018-168346 A. Appropriate laser welding was confirmed.

[0081] Examples 13 to 17, Comparative Examples 4 and 5 <Compound> The components other than the glass fiber were weighed and dry-blended to obtain the composition shown in Table 3 below (each component in Table 3 is expressed in parts by mass), and then the components were fed into a twin-screw extruder (Shibaura Machine Co., Ltd., TEM26SS) from the screw base using a twin-screw cassette weighing feeder (Kubota Corporation, CE-W-1-MP). The glass fiber was fed into the twin-screw extruder from the side using a vibrating cassette weighing feeder (Kubota Corporation, CE-V-1B-MP), and melt-kneaded with the resin components, etc., to obtain resin composition pellets. The extruder temperature was set to 280°C. The mold temperature was set to 110°C.

[0082] <Light transmittance> The resin composition pellets obtained above were dried at 120°C for 4 hours, and then test pieces (60 mm x 60 mm x 1.0 mm thick) for measuring light transmittance were prepared using an injection molding machine (SE-50D, manufactured by Sumitomo Heavy Industries, Ltd.) with a cylinder temperature of 280°C and a mold temperature of 110°C. The light transmittance was measured using a visible / ultraviolet spectrophotometer (Shimadzu Corporation, UV-3100PC), and the light transmittance (unit: %) at each wavelength shown in Table 3 was measured.

[0083] <UL94 flammability test> The pellets obtained above were injection molded in an injection molding machine (Shibaura Machine Co., Ltd., "EC160") at a cylinder temperature of 280°C and a mold temperature of 110°C to obtain test pieces with thicknesses of 0.75 mm and 1.50 mm. The test pieces obtained were evaluated based on the UL94 flammability test. "Fail" means that the test piece did not meet any of the criteria of V-0, V-1, or V-2. The results are shown in Table 3.

[0084] [Table 3]

[0085] As is clear from the above results, the resin compositions described in Examples 13 to 17 had high light transmittance at a wavelength of 970 nm and low light transmittance at wavelengths of 300 nm to 500 nm (even more so at 300 nm to 600 nm, and particularly at 300 nm to 700 nm). Furthermore, they had high flame retardancy. In contrast, when PA66 was used as the polyamide resin (Comparative Examples 4 and 5), the light transmittance at wavelengths of 400 to 750 nm was high, and flame retardancy was not achieved.

[0086] Pellets for forming an absorbent resin member were obtained in the same manner as in Example 13, except that no light-transmitting dye was added and 3 parts by mass of carbon black #45 (manufactured by Mitsubishi Chemical Corporation) was added. The pellets obtained in Example 1 and the pellets for forming an absorbent resin member were laser welded using the pellets obtained in Example 1 and the pellets for forming an absorbent resin member as described in paragraphs 0072 and 0073 and FIG. 1 of JP 2018-168346 A. Appropriate laser welding was confirmed.

Claims

1. For 100 parts by mass of polyamide resin, 10 to 120 parts by mass of a reinforcing filler; a light-transmitting dye having a perylene skeleton; the polyamide resin is composed of diamine-derived structural units and dicarboxylic acid-derived structural units, 70 mol % or more of the diamine-derived structural units are derived from xylylenediamine, and 70 mol % or more of the dicarboxylic acid-derived structural units are derived from an α,ω-linear aliphatic dicarboxylic acid having 4 to 8 carbon atoms; A resin composition, wherein when the resin composition is molded into a test piece having a thickness of 1.0 mm, the light transmittance at a wavelength of 750 nm is 5% or less and the light transmittance at a wavelength of 1070 nm is 20% or more.

2. The resin composition according to claim 1, further comprising at least one of copper iodide, potassium iodide, and cerium oxide.

3. 3. The resin composition according to claim 1, wherein the xylylenediamine comprises 50 to 90 mol% of metaxylylenediamine and 10 to 50 mol% of paraxylylenediamine.

4. The resin composition according to any one of claims 1 to 3, wherein the α,ω-linear aliphatic dicarboxylic acid having 4 to 8 carbon atoms includes adipic acid.

5. 3. The resin composition according to claim 1, wherein the xylylenediamine comprises 50 to 90 mol% of meta-xylylenediamine and 10 to 50 mol% of para-xylylenediamine, and the α,ω-linear aliphatic dicarboxylic acid having 4 to 8 carbon atoms comprises adipic acid.

6. The resin composition according to any one of claims 1 to 5, wherein the content of the light-transmitting dye having a perylene skeleton is 0.01 to 1.5 parts by mass per 100 parts by mass of the polyamide resin.

7. The resin composition according to any one of claims 1 to 5, wherein the content of the light-transmitting dye having a perylene skeleton is 0.10 to 1.5 parts by mass per 100 parts by mass of the polyamide resin.

8. The resin composition according to any one of claims 1 to 5, wherein the content of the light-transmitting dye having a perylene skeleton is 0.2 to 1.5 parts by mass per 100 parts by mass of the polyamide resin.

9. The resin composition according to any one of claims 1 to 8, wherein the content of the reinforcing filler is 40 to 60 parts by mass per 100 parts by mass of the polyamide resin.

10. The resin composition according to any one of claims 1 to 9, further comprising a metal phosphinate.

11. The resin composition according to claim 10, wherein the resin composition has V-0 performance in a UL94 flammability test at a thickness of 0.75 mm.

12. 12. The resin composition according to claim 11, wherein when the resin composition is molded into a test piece having a thickness of 1.0 mm, the light transmittance at a wavelength of 400 nm is 1.0% or less and the light transmittance at a wavelength of 940 nm is 3.0% or more.

13. When the resin composition is molded into a test piece having a thickness of 1.0 mm, the light transmittance at a wavelength of 700 nm is 0.2% or less, and the light transmittance at a wavelength of 940 nm is 3.0% or more. The resin composition according to any one of claims 1 to 11.

14. A molded article formed from the resin composition according to any one of claims 1 to 13.

15. A kit comprising the resin composition according to any one of claims 1 to 13 and a light-absorbing resin composition containing a thermoplastic resin and a light-absorbing dye.

16. A method for producing a molded article, comprising laser welding a molded article formed from the resin composition according to any one of claims 1 to 13 and a molded article formed from a light-absorbing resin composition containing a thermoplastic resin and a light-absorbing dye.

17. An in-vehicle camera part formed from the resin composition according to any one of claims 1 to 13 or the kit according to claim 15.

18. An in-vehicle camera comprising the in-vehicle camera component of claim 17.

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