Resin composition, molded article, and molded article with hard coat layer

Abstract

Provided are: a resin composition having excellent transparency and mechanical strength; a molded article; and a molded article with a hard coat layer. The resin composition includes 5-100 parts by mass of a glass filler with respect to 100 parts by mass of a resin component. The resin component includes: 40-85 parts by mass of a polycarbonate resin that contains a structural unit represented by formula (1); and 15-60 parts by mass of a thermoplastic resin other than the polycarbonate resin. The absolute value of the difference between the refractive index of the resin component and the refractive index of the glass filler is 0.0042 or less. The dynamic friction coefficient, according to ISO 19252, of the resin component is 0.40 or less. In formula (1), R1 represents a methyl group.

Description

[Technical Field]

[0001] The present invention relates to a resin composition, a molded article, and a molded article with a hard coat layer, and more particularly to a resin composition containing a polycarbonate resin as a main component. [Background technology]

[0002] Polycarbonate resin is a thermoplastic resin that has excellent impact resistance, heat resistance, and transparency, and has a wide range of applications, such as automobile interior panels, automobile headlamp lenses, casings for mobile phones, personal digital assistants, liquid crystal televisions, and personal computers. Furthermore, since it is lighter than inorganic glass and has excellent productivity, it is also used for automobile windows, etc.

[0003] In recent years, attempts have been made to improve the mechanical strength and transparency by blending a glass filler into a polycarbonate resin. For example, Patent Document 1 discloses an aromatic polycarbonate resin composition characterized by containing 1 to 100 parts by mass of an E-glass reinforcing material (C) per 100 parts by mass of a resin component consisting of 60 to 85% by mass of an aromatic polycarbonate resin (A) having a mass average molecular weight of 15,000 to 40,000 and 15 to 40% by mass of a (meth)acrylate copolymer (B) having a mass average molecular weight of 5,000 to 30,000 and having a mass ratio (b1 / b2) of aromatic (meth)acrylate units (b1) to methyl methacrylate units (b2) of 5 to 50 / 50 to 95. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2012-246343 Summary of the Invention [Problem to be solved by the invention]

[0005] As described above, attempts have been made to improve the mechanical strength and transparency of polycarbonate resins by blending glass fillers into them. However, it is difficult to maintain transparency while improving mechanical strength by blending glass fillers into polycarbonate resins. That is, blending glass fillers into polycarbonate resins improves mechanical strength, but the refractive indexes of the polycarbonate resin and the glass filler differ, resulting in light scattering and poor transparency. Furthermore, blending glass fillers into polycarbonate resins results in the presence of the glass fillers on the surface of the resulting molded article, which causes roughness on the surface of the molded article and reduces transparency. The present invention aims to solve the above problems, and aims to provide a resin composition having excellent transparency and mechanical strength, as well as a molded article and a molded article with a hard coat layer. [Means for solving the problem]

[0006] In light of the above-mentioned problems, the present inventors have discovered that the above-mentioned problems can be solved by blending another thermoplastic resin with a polycarbonate resin to reduce the difference in refractive index with the glass filler, and further by lowering the dynamic friction coefficient of the resin component. Specifically, the above problems were solved by the following means. <0> A resin composition comprising a resin component and a glass filler, wherein the resin component comprises a polycarbonate resin containing a structural unit represented by formula (1) and a thermoplastic resin other than a polycarbonate resin, wherein the absolute value of the difference between the refractive index of the resin component and the refractive index of the glass filler is 0.0042 or less, and the dynamic friction coefficient of the resin component in accordance with ISO 19252 is 0.40 or less. Formula (1) [ka] (In formula (1), R 1 represents a methyl group, and R 2 represents a hydrogen atom or a methyl group, and X 1 represents one of the following formulas: [ka] R 3 and R 4 each independently represents a hydrogen atom or a methyl group, and Z represents a group that bonds with C to form an alicyclic hydrocarbon having 6 to 12 carbon atoms which may have a substituent. <1> A resin composition comprising 5 to 100 parts by mass of a glass filler relative to 100 parts by mass of a resin component, the resin component comprising 40 to 85 parts by mass of a polycarbonate resin containing a structural unit represented by formula (1) and 15 to 60 parts by mass of a thermoplastic resin other than a polycarbonate resin, wherein the absolute value of the difference between the refractive index of the resin component and the refractive index of the glass filler is 0.0042 or less, and the dynamic friction coefficient of the resin component in accordance with ISO 19252 is 0.40 or less. Formula (1) [ka] (In formula (1), R 1 represents a methyl group, and R 2 represents a hydrogen atom or a methyl group, and X 1 represents one of the following formulas: [ka] R 3 and R 4 each independently represents a hydrogen atom or a methyl group, and Z represents a group that bonds with C to form an alicyclic hydrocarbon having 6 to 12 carbon atoms which may have a substituent. <2> The polycarbonate resin further contains a structural unit represented by formula (2): <1> The resin composition according to claim 1. Formula (2) [ka] (In formula (2), X 2 represents one of the following formulas: [ka] R 3 and R 4each independently represents a hydrogen atom or a methyl group, and Z represents a group that bonds with C to form an alicyclic hydrocarbon having 6 to 12 carbon atoms which may have a substituent. <3> The refractive index of the thermoplastic resin other than the polycarbonate resin is 1.4900 to 1.5500. <1> or <2> The resin composition according to claim 1. <4> In the resin component, the proportion of the structural unit represented by formula (1) is 15 mass% or more. <1> ~ <3> The resin composition according to any one of the above. <5> The other thermoplastic resin is a (meth)acrylate polymer. <1> ~ <4> The resin composition according to any one of the above. <6> The (meth)acrylate polymer contains an aromatic (meth)acrylate unit (b1). <5> The resin composition according to claim 1. <7> the (meth)acrylate polymer contains aromatic (meth)acrylate units (b1) and methyl methacrylate units (b2), and the mass ratio thereof (b1 / b2) is 5 to 50 / 50 to 95; <5> The resin composition according to claim 1. <8> The glass filler comprises glass fibers having a flat cross section. <1> ~ <7> The resin composition according to any one of the above. <9> The dielectric loss tangent measured by the perturbation method at a frequency of 1 GHz is 0.0060 or less. <1> ~ <8> The resin composition according to any one of the above. <10> The resin component contains 10 to 100 parts by mass of a glass filler relative to 100 parts by mass of the resin component, and the resin component contains 16 to 40 parts by mass of a thermoplastic resin other than the polycarbonate resin relative to 100 parts by mass of the total of the polycarbonate resin and the other thermoplastic resin. <1> ~ <9> The resin composition according to any one of the above. <11> <1> ~ <10> A molded article formed from the resin composition according to any one of the above items. <12> Display parts, mobile information terminal parts, home appliances, or indoor furniture. <11> The molded article according to claim 1. <13> <11> or <12> 2. A molded article with a hard coat layer, comprising the molded article according to claim 1, having a hard coat layer on at least a part of the surface thereof. [Effects of the Invention]

[0007] According to the present invention, it is possible to provide a resin composition excellent in transparency and mechanical strength, a molded article, and a molded article with a hard coat layer. DETAILED DESCRIPTION OF THE INVENTION

[0008] 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, "(meth)acrylate" refers to both or either of acrylate and methacrylate.

[0009] The resin composition of the present embodiment is characterized in that it contains 5 to 100 parts by mass of a glass filler relative to 100 parts by mass of a resin component, the resin component containing 40 to 85 parts by mass of a polycarbonate resin containing a structural unit represented by formula (1) and 15 to 60 parts by mass of a thermoplastic resin other than a polycarbonate resin, the absolute value of the difference between the refractive index of the resin component and the refractive index of the glass filler being 0.0042 or less, and the dynamic friction coefficient of the resin component in accordance with ISO 19252 being 0.40 or less. Formula (1) [ka] In formula (1), R 1 represents a methyl group, and R 2 represents a hydrogen atom or a methyl group, and X 1 represents one of the following formulas: [ka] R 3 and R 4each independently represents a hydrogen atom or a methyl group, and Z represents a group that bonds with C to form an alicyclic hydrocarbon having 6 to 12 carbon atoms which may have a substituent.

[0010] This configuration results in a resin composition with excellent transparency and mechanical strength. The reason for this is presumed to be as follows: The incorporation of a glass filler into the resin component improves the mechanical strength of the resulting molded article. However, the large difference in refractive index between the polycarbonate resin and the glass filler is presumed to reduce the transparency of the resulting resin composition. Therefore, it is presumed that transparency can be improved by incorporating a highly transparent polycarbonate resin as the polycarbonate resin and further incorporating a thermoplastic resin with a refractive index lower than that of the glass filler, thereby keeping the difference in refractive index between the resin component and the glass filler in the resin composition within a predetermined range. Furthermore, it is presumed that the dynamic friction coefficient of the resin component is 0.40 or less, which facilitates penetration of the glass filler into the resin component, thereby effectively suppressing light scattering due to surface roughness of the molded article. Furthermore, in this embodiment, by adopting the above-mentioned configuration, a resin composition having excellent moldability, high surface hardness, and low dielectric loss tangent can be obtained.

[0011] <Resin component> The resin composition of this embodiment contains a resin component. The resin component contains a polycarbonate resin containing a structural unit represented by formula (1) and a thermoplastic resin other than the polycarbonate resin. By blending a thermoplastic resin (usually a resin with a lower refractive index than polycarbonate) with the polycarbonate resin, the refractive index of the resin component can be made closer to the refractive index of the glass filler. In this embodiment, the resin component has a dynamic friction coefficient of 0.40 or less in accordance with ISO 19252. By making the dynamic friction coefficient of the resin component 0.40 or less, the glass filler can easily penetrate into the resin component, and light scattering due to surface roughness of the molded article can be effectively suppressed. Formula (1) [ka] In formula (1), R 1 represents a methyl group, and R 2 represents a hydrogen atom or a methyl group, and X 1 represents one of the following formulas: [ka] R 3 and R 4 each independently represents a hydrogen atom or a methyl group, and Z represents a group that bonds with C to form an alicyclic hydrocarbon having 6 to 12 carbon atoms which may have a substituent.

[0012] <<Dynamic friction coefficient>> The resin component in this embodiment has a dynamic friction coefficient of 0.40 or less in accordance with ISO 19252. By making the dynamic friction coefficient of the resin component 0.40 or less, the glass filler can easily penetrate into the resin component, and light scattering due to surface roughness of the molded article can be effectively suppressed. The dynamic friction coefficient is preferably 0.39 or less, more preferably 0.37 or less, even more preferably 0.36 or less, even more preferably 0.35 or less, even more preferably 0.34 or less, and even more preferably 0.33 or less. There is no particular lower limit for the dynamic friction coefficient, but a value of 0.01 or more is practical, and even a value of 0.20 or more will fully satisfy the required performance.

[0013] <<Resin component content>> The content of the resin components (total of polycarbonate resin and other thermoplastic resin) in the resin composition of this embodiment is preferably 10% by mass or more, more preferably 59% by mass or more, more preferably 60% by mass or more, and even 70% by mass or more, particularly 75% by mass or more. By setting the content at or above the lower limit, the impact strength and heat resistance of a molded article formed from the resin composition tend to be further improved. Furthermore, from the viewpoints of the surface hardness of the molded article and the fluidity of the resin composition, the upper limit of the content is preferably 95% by mass or less, more preferably 91% by mass or less, even more preferably 90% by mass or less, and even more preferably 85% by mass or less, of the resin composition. In the resin composition of the present embodiment, it is more preferable that the total amount of the polycarbonate resin and the (meth)acrylate polymer falls within the above range.

[0014] <<Refractive index of resin components>> The refractive index of the resin component in the resin composition of this embodiment is, for example, 1.5942 or less, further 1.5930 or less, and particularly 1.5920 or less. The refractive index of the resin component is, for example, 1.5458 or more, further 1.5470 or more, and particularly 1.5480 or more. The refractive index is measured as described in the Examples below.

[0015] <<Polycarbonate resin>> The polycarbonate resin used in this embodiment contains a structural unit represented by formula (1). By containing the structural unit represented by formula (1), the transparency of the resin component can be increased. Furthermore, the surface hardness of the resulting molded article can be increased. Furthermore, the dielectric loss tangent of the resulting molded article can be reduced. Formula (1) [ka] In formula (1), R 1 represents a methyl group, and R 2 represents a hydrogen atom or a methyl group, and X 1 represents one of the following formulas: [ka] R 3 and R 4 each independently represents a hydrogen atom or a methyl group, and Z represents a group that bonds with C to form an alicyclic hydrocarbon having 6 to 12 carbon atoms which may have a substituent.

[0016] Examples of the alicyclic hydrocarbon formed by bonding Z to C include cycloalkylidene groups such as a cyclohexylidene group, a cycloheptylidene group, a cyclododecylidene group, an adamantylidene group, and a cyclododecylidene group. Examples of the alicyclic hydrocarbon having a substituent formed by bonding Z to C include methyl-substituted and ethyl-substituted alicyclic hydrocarbon groups described above. Among these, a cyclohexylidene group, a methyl-substituted cyclohexylidene group (preferably a 3,3,5-trimethyl-substituted cyclohexylidene group), and a cyclododecylidene group are preferred.

[0017] In formula (1), X 1 but, [ka] If R 3 and R 4 At least one of the groups is preferably a methyl group, and both are more preferably methyl groups. Also X 1 but, [ka] In this case, Z bonds to the carbon C bonded to the two phenyl groups in formula (1) to form a divalent alicyclic hydrocarbon group having 6 to 12 carbon atoms. Examples of the divalent alicyclic hydrocarbon group include cycloalkylidene groups such as cyclohexylidene, cycloheptylidene, cyclododecylidene, adamantylidene, and cyclododecylidene. Substituted groups include those having a methyl or ethyl substituent. Among these, a cyclohexylidene group, a methyl-substituted cyclohexylidene group (preferably a 3,3,5-trimethyl-substituted cyclohexylidene group), and a cyclododecylidene group are preferred. In formula (1), X 1 is preferably the following structure: [ka]

[0018] A preferred example of the structural unit represented by the above formula (1) is 2,2-bis(4-hydroxyphenyl)propane, that is, a structural unit formed from bisphenol A (carbonate structural unit).

[0019] In the present embodiment, the polycarbonate resin may contain only one type of constitutional unit represented by formula (1), or may contain two or more types.

[0020] In this embodiment, the polycarbonate resin preferably further contains a structural unit represented by formula (2). By containing a structural unit represented by formula (2), heat resistance tends to be further improved. Formula (2) [ka] In formula (2), X 2 represents one of the following formulas: [ka] R 3 and R 4each independently represents a hydrogen atom or a methyl group, and Z represents a group that bonds with C to form an alicyclic hydrocarbon having 6 to 12 carbon atoms which may have a substituent.

[0021] In formula (2), X 2 but, [ka] If R 3 and R 4 At least one of the groups is preferably a methyl group, and both are more preferably methyl groups. Also X 2 but, [ka] In this case, Z bonds to the carbon C bonded to the two phenyl groups in formula (2) to form a divalent alicyclic hydrocarbon group having 6 to 12 carbon atoms. Examples of the divalent alicyclic hydrocarbon group include cycloalkylidene groups such as cyclohexylidene, cycloheptylidene, cyclododecylidene, adamantylidene, and cyclododecylidene. Substituted groups include those having a methyl or ethyl substituent. Among these, a cyclohexylidene group, a methyl-substituted cyclohexylidene group (preferably a 3,3,5-trimethyl-substituted cyclohexylidene group), and a cyclododecylidene group are preferred. In formula (2), X 2 is preferably the following structure: [ka]

[0022] In this embodiment, the polycarbonate resin may contain only one type of constitutional unit represented by formula (2), or may contain two or more types.

[0023] In this embodiment, the polycarbonate resin may contain other structural units in addition to the structural unit represented by formula (1) and the structural unit represented by formula (2). Examples of other structural units include structural units derived from dihydroxy compounds shown below.

[0024] Bis(4-hydroxyphenyl)methane, 2,2-bis(4-hydroxyphenyl)butane, 2,2-bis(4-hydroxyphenyl)pentane, 2,2-bis(4-hydroxyphenyl)-4-methylpentane, 2,2-bis(4-hydroxy-3-methylphenyl)propane, 2,2-bis(4-hydroxy-3,5-dimethylphenyl)propane, 2,2-bis(4-hydroxy-3-(1-methylethyl)phenyl)propane, 2,2-bis(4-hydroxy-3-tert-butylphenyl)propane, 2,2-bis(4-hydroxy-3-(1-methylpropyl)phenyl)propane, 2,2-bis(4-hydroxy-3-cyclohexylphenyl)propane, 2,2-bis(4-hydroxy-3-phenylphenyl)propane, 1,1-bis(4-hydroxyphenyl)decane, 1,1-bis(4-hydroxyphenyl) Cyclohexane, 1,1-bis(4-hydroxyphenyl)-1-phenylethane, 1,1-bis(4-hydroxyphenyl)phenylmethane, 1,1-bis(4-hydroxy-3-methylphenyl)cyclohexane, 1,1-bis(4-hydroxy-3,5-dimethylphenyl)cyclohexane, 1,1-bis(4-hydroxy-3-(1-methylethyl)phenyl)cyclohexane, 1,1-bis(4-hydroxy-3-tert-butylphenyl)cyclohexane, 1,1-bis(4-hydroxy-3-(1-methylpropyl)phenyl)cyclohexane, 1,1-bis(4-hydroxy-3-cyclohexylphenyl)cyclohexane, 1,1-bis(4-hydroxy-3-phenylphenyl)cyclohexane, 1,1-bis(4-hydroxy-3-methylphenyl)-1-phenylethane, 1,1-bis(4-hydroxy-3 ,1,1-bis(4-hydroxy-3-(1-methylethyl)phenyl)-1-phenylethane, 1,1-bis(4-hydroxy-3-tert-butylphenyl)-1-phenylethane, 1,1-bis(4-hydroxy-3-(1-methylpropyl)phenyl)-1-phenylethane, 1,1-bis(4-hydroxy-3-cyclohexylphenyl)-1-phenylethane, 1,1-bis(4-hydroxy-3-phenylphenyl)-1-phenylethane, 1,1-bis(4-hydroxyphenyl)cyclopentane, 1,1-bis(4-hydroxyphenyl)cyclopentane, 1,1-bis(4-hydroxyphenyl)cyclooctane, 4,4'-(1,3-phenylenediisopropylidene)bisphenol, 4,4'-(1,4-phenylenediisopropylidene)bisphenol, 9,9-bis(4-hydroxyphenyl)fluorene, 9,9-bis(4-hydroxy-3-methylphenyl)fluorene, 4,4'-dihydroxybenzophenone, 4,4'-dihydroxyphenyl ether, 4,4'-dihydroxybiphenyl, 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, 1,1-bis(4-hydroxy-6-methyl-3-tert-butylphenyl)butane.

[0025] In addition, as an embodiment of other structural units, the structural unit represented by formula (2) described in paragraph 0008 of WO 2017 / 099226, the description in paragraphs 0043 to 0052 of WO 2017 / 099226, and the description in JP 2011-046769 A can be referred to, the contents of which are incorporated herein by reference.

[0026] Furthermore, the polycarbonate resin used in this embodiment preferably contains 15% by mass or more of the structural unit represented by formula (1), more preferably 20% by mass or more, even more preferably 35% by mass or more, even more preferably 45% by mass or more, even more preferably 50% by mass or more, even more preferably 70% by mass or more, and particularly preferably 80% by mass or more. By setting the content at or above the lower limit, the transparency of the obtained molded article tends to be further improved, the surface hardness of the molded article can be increased, and the dielectric loss tangent can be reduced. Furthermore, the content of the structural unit represented by formula (1) is preferably 95% by mass or less, more preferably 90% by mass or less, and may be 84% by mass or less. By setting the content at or below the upper limit, the deflection temperature under load tends to be higher.

[0027] In the polycarbonate resin used in this embodiment, the total of the structural units represented by the above formula (1) and the structural units represented by the formula (2) preferably accounts for 90% by mass or more, more preferably 95% by mass or more, and even more preferably 99% by mass or more of all structural units excluding terminal groups. The upper limit of this total is 100% by mass or less.

[0028] The polycarbonate resin used in this embodiment preferably has the following form. (A1) Polycarbonate resin containing a structural unit represented by formula (1) (A2) A blend of a polycarbonate resin containing a structural unit represented by formula (1) and a polycarbonate resin containing a structural unit represented by formula (2) (A3) Polycarbonate resin containing a structural unit represented by formula (1) and a structural unit represented by formula (2) (A4) A blend of a polycarbonate resin containing a structural unit represented by formula (1) and a polycarbonate resin containing a structural unit represented by formula (1) and a structural unit represented by formula (2). (A5) A blend of a polycarbonate resin containing a structural unit represented by formula (2) and a polycarbonate resin containing a structural unit represented by formula (1) and a structural unit represented by formula (2). (A6) A blend of a polycarbonate resin containing a structural unit represented by formula (1), a polycarbonate resin containing a structural unit represented by formula (2), and a polycarbonate resin containing a structural unit represented by formula (1) and a structural unit represented by formula (2). (A7) In the above (A1) to (A6), the polycarbonate resin or the polycarbonate resin constituting the blend thereof contains a structural unit represented by formula (1) and a structural unit other than the structural unit represented by formula (2). (A8) A blend of the polycarbonate resin or blend of any of the above (A1) to (A7) with a polycarbonate resin comprising other structural units.

[0029] The refractive index of the polycarbonate resin used in this embodiment is, for example, 1.5600 or more, further 1.5700 or more, and particularly 1.5800 or more. The upper limit of the refractive index of the polycarbonate resin is preferably 1.6500 or less, more preferably 1.6400 or less, further preferably 1.6300 or less, even more preferably 1.6200 or less, and still more preferably 1.6100 or less. The refractive index is measured as described in the Examples below. When two or more polycarbonate resins are contained, the refractive index is the refractive index of the mixture.

[0030] The viscosity average molecular weight (Mv) of the polycarbonate resin used in this embodiment has a lower limit of preferably 5,000 or more, more preferably 8,000 or more, even more preferably 10,000 or more, and still more preferably 12,000 or more. The upper limit of Mv is preferably 32,000 or less, more preferably 30,000 or less, even more preferably 29,000 or less, and still more preferably 27,000 or less. By setting the viscosity average molecular weight to the above lower limit or more, moldability is improved and molded articles with high mechanical strength can be obtained, while by setting the viscosity average molecular weight to the above upper limit or less, the flowability of the resin composition is improved and thin-walled molded articles can be efficiently produced. When the resin composition contains two or more types of polycarbonate resins, the total is the sum of values ​​obtained by multiplying the viscosity average molecular weight of each polycarbonate resin by the mass fraction. In particular, the viscosity average molecular weight of the polycarbonate resin containing the structural unit represented by formula (1) is preferably 20,000 to 30,000, and more preferably 20,000 to 28,000.The viscosity average molecular weight of the polycarbonate resin containing the structural unit represented by formula (2) is preferably 12,000 to 28,000, and more preferably 18,000 to 27,000. The viscosity average molecular weight (Mv) is measured according to the method described in the examples below.

[0031] The polycarbonate resin used in this embodiment (all polycarbonate resins including the structural unit represented by formula (1) and the structural unit represented by formula (2)) has a pencil hardness measured in accordance with ISO 15184 of, for example, 3B to 2H, and preferably 2B to 2H. The pencil hardness is measured according to the method described in the examples below. In particular, the pencil hardness of a polycarbonate resin containing a structural unit represented by formula (1) is preferably H to 2H, and the pencil hardness of a polycarbonate resin containing a structural unit represented by formula (2) is preferably 2B to HB.

[0032] The method for producing the polycarbonate resin used in this embodiment is not particularly limited, but for example, the description in paragraphs 0027 to 0043 and the Examples of JP-A-2014-065901 can be referred to, the contents of which are incorporated herein by reference.

[0033] <<Other thermoplastic resins other than polycarbonate resin>> The resin component contains a thermoplastic resin other than polycarbonate resin. By including the other thermoplastic resin (usually a resin having a lower refractive index than polycarbonate resin), the refractive index of the resin component can be lowered. The type of thermoplastic resin other than the polycarbonate resin is not particularly limited, but typically one having a lower refractive index than the polycarbonate resin and the glass filler is selected. Specifically, the refractive index of the other thermoplastic resin (preferably a (meth)acrylate polymer described below) is preferably 1.5500 or less, more preferably 1.5400 or less, even more preferably 1.5300 or less, and even more preferably 1.5250 or less. The lower limit of the refractive index of the other thermoplastic resin is preferably 1.4900 or more, more preferably 1.5000 or more, and even more preferably 1.5100 or more. By adjusting the refractive index to be equal to or greater than the lower limit, the surface hardness of the molded article formed from the resin composition can be further increased.

[0034] Examples of other thermoplastic resins include (meth)acrylate polymers, acrylonitrile-styrene copolymers (AS resins), methyl methacrylate-styrene copolymers (MS resins), polystyrene resins, polyamide resins, polyethylene terephthalate resins, polybutylene terephthalate resins, polyarylate resins, polysulfone resins, and polyphenylene sulfide resins, with (meth)acrylate polymers being preferred. In particular, the inclusion of a (meth)acrylate polymer can increase the surface hardness of molded articles formed from the resin composition and can also increase the fluidity of the resin composition. The (meth)acrylate polymer used in this embodiment preferably contains an aromatic (meth)acrylate unit (b1), and more preferably contains an aromatic (meth)acrylate structural unit (b1) and a methyl methacrylate structural unit (b2). By containing the aromatic (meth)acrylate structural unit (b1), compatibility with polycarbonate resins can be improved, and by containing the methyl methacrylate structural unit (b2), the surface hardness of molded articles formed from the resin composition can be increased.

[0035] The aromatic (meth)acrylate (b1), which is a monomer constituting the aromatic (meth)acrylate structural unit, refers to a (meth)acrylate having an aromatic group. The aromatic (meth)acrylate (b1) is preferably a (meth)acrylate containing a benzene ring and / or a naphthalene ring, more preferably a (meth)acrylate containing a benzene ring. Specific examples of the aromatic (meth)acrylate (b1) include phenyl (meth)acrylate, biphenyl (meth)acrylate, and benzyl (meth)acrylate. Of these, phenyl methacrylate and benzyl methacrylate are preferred, and phenyl methacrylate is more preferred. The (meth)acrylate polymer may contain only one type of aromatic (meth)acrylate unit (b1), or may contain two or more types.

[0036] The monomer that constitutes the methyl methacrylate structural unit (b2) is methyl methacrylate.

[0037] When the (meth)acrylate polymer used in this embodiment contains an aromatic (meth)acrylate structural unit (b1) and a methyl methacrylate structural unit (b2), the mass ratio of (b1) / (b2) is preferably 5 to 80 / 95 to 20. The mass ratio of (b1) / (b2) is more preferably 5 to 50 / 50 to 95, even more preferably 25 to 50 / 50 to 75, even more preferably 25 to 45 / 55 to 75, and even more preferably 30 to 40 / 60 to 70. When the (meth)acrylate polymer used in this embodiment contains an aromatic (meth)acrylate structural unit (b1) and a methyl methacrylate structural unit (b2), it may or may not contain other structural units. When other structural units are contained, styrene structural units and (meth)acrylate structural units other than (b1) and (b2) are preferred, and (meth)acrylate structural units other than (b1) and (b2) are more preferred. Examples of (meth)acrylate structural units other than (b1) and (b2) include aliphatic (meth)acrylates other than methyl methacrylate. In the (meth)acrylate polymer used in this embodiment, the total of the aromatic (meth)acrylate structural units (b1) and the methyl methacrylate structural units (b2) preferably accounts for 90% by mass or more, more preferably 95% by mass or more, and even more preferably 99% by mass or more of all structural units excluding terminal groups. The upper limit of this total may be 100% by mass or less of all structural units excluding terminal groups.

[0038] The weight-average molecular weight of the (meth)acrylate polymer used in this embodiment is preferably 5,000 or more, more preferably 10,000 or more, and even more preferably 13,000 or more. By making it equal to or greater than the lower limit, the impact strength and heat resistance of the obtained molded article tend to be further improved. Furthermore, the weight-average molecular weight of the (meth)acrylate polymer is preferably 30,000 or less, more preferably 25,000 or less, even more preferably 20,000 or less, and even more preferably 16,000 or less. By making it equal to or less than the upper limit, the fluidity of the resin composition tends to be further improved. The weight average molecular weight of the (meth)acrylate polymer is measured according to the description in the Examples section below.

[0039] The pencil hardness of the (meth)acrylate polymer used in this embodiment, measured according to ISO 15184, is preferably 2H or harder. Although there is no particular upper limit, it is practical to set it to 4H or softer. By using a polymer with a pencil hardness of 2H or harder, the surface hardness of the resulting molded article can be improved. Furthermore, when the resin composition of the present embodiment contains two or more types of (meth)acrylate polymers, the pencil hardness of the mixture is preferably within the above range. The pencil hardness is measured as described in the Examples below.

[0040] In addition to the above, the (meth)acrylate polymer used in this embodiment may be any of those described in International Publication No. 2014 / 038500, International Publication No. 2013 / 094898, JP 2006-199774, JP 2010-116501, JP 2014-065901, and JP 2016-27068, as well as the "aromatic (meth)acrylate" described in JP 2016-47937, the contents of which are incorporated herein by reference.

[0041] The content of the polycarbonate resin in the resin composition of this embodiment is 40 parts by mass or more, preferably 50 parts by mass or more, more preferably 60 parts by mass or more, even more preferably 68 parts by mass or more, even more preferably 70 parts by mass or more, even more preferably 72 parts by mass or more, even more preferably 75 parts by mass or more, and may even be 76 parts by mass or more, per 100 parts by mass of the resin component (preferably, when the total of the polycarbonate resin and the other thermoplastic resin is 100 parts by mass). By ensuring that the content is equal to or greater than the lower limit, the impact strength of a molded article formed from the resin composition tends to be further improved, and a decrease in the heat resistance of the resin composition tends to be effectively suppressed. Furthermore, the content of the polycarbonate resin in the resin composition of this embodiment may be 85 parts by mass or less, or 84 parts by mass or less, per 100 parts by mass of the resin component (preferably, when the total of the polycarbonate resin and the other thermoplastic resin is 100 parts by mass). By making the content equal to or less than the upper limit, the surface hardness of a molded article formed from the resin composition and the flowability of the resin composition tend to be further improved. The content of the other thermoplastic resin (preferably a (meth)acrylate polymer) in the resin composition of this embodiment is 15 parts by mass or more, and may be 16 parts by mass or more, per 100 parts by mass of the resin component (preferably, when the total of the polycarbonate resin and the other thermoplastic resin is 100 parts by mass). By ensuring that the content is equal to or greater than the lower limit, the surface hardness of a molded article formed from the resin composition and the flowability of the resin composition tend to be further improved. Furthermore, the content of the other thermoplastic resin (preferably a (meth)acrylate polymer) in the resin composition of this embodiment is 60 parts by mass or less, preferably 50 parts by mass or less, more preferably 40 parts by mass or less, even more preferably 32 parts by mass or less, even more preferably 30 parts by mass or less, even more preferably 28 parts by mass or less, even more preferably 25 parts by mass or less, and may be 24 parts by mass or less, per 100 parts by mass of the resin component (preferably, when the total of the polycarbonate resin and the other thermoplastic resin is 100 parts by mass). By ensuring that the content is equal to or less than the upper limit, the impact strength of a molded article formed from the resin composition tends to be further improved, and a decrease in the heat resistance of the resin composition tends to be effectively suppressed.

[0042] <Glass filler> The resin composition of the present embodiment contains a glass filler, which can improve the mechanical strength of the resulting molded article. The glass filler in this embodiment is not particularly limited, and a wide variety of fillers used to reinforce thermoplastic resins can be used.

[0043] The refractive index of the glass filler used in this embodiment is, for example, 1.5500 or more, further 1.5600 or more, particularly 1.5700 or more. The refractive index of the glass filler is, for example, 1.5900 or less, further 1.5850 or less, particularly 1.5800 or less. The refractive index is measured as described in the Examples below. When two or more glass fillers are contained, the refractive index of the glass fillers is the sum of the values ​​obtained by multiplying the refractive index of each glass filler by the mass fraction.

[0044] The glass filler used in this embodiment may be in any shape such as fiber, plate, or bead, but is preferably in fiber form. When the glass filler used in this embodiment is fibrous, it preferably has a number average fiber length (cut length) of 0.5 to 10.0 mm, more preferably 1.0 to 5.0 mm. By using a glass filler (glass fiber) with such a number average fiber length, mechanical strength can be further improved. Examples of glass fibers with a number average fiber length (cut length) of 0.5 to 10.0 mm include those sold as chopped strands. The number average fiber length is calculated by randomly selecting glass fibers to be measured for fiber length from an image obtained by observation with an optical microscope, measuring the long sides of the fibers, and then calculating the number average fiber length from the obtained measurements. The observation is performed at a magnification of 20x, and the number of fibers measured is 1,000 or more. This roughly corresponds to the cut length. The cross-sectional shape of the glass fiber may be any shape, such as a circle, an ellipse, an oval, a rectangle, a rectangle with semicircles on both short sides, a cocoon, etc. In this embodiment, the cross section of the glass fiber is preferably flat, more preferably flat with an aspect ratio of 1.5 to 8, and even more preferably flat with an aspect ratio of 2 to 6. By using such flat glass fibers, light scattering can be effectively suppressed, and the transparency of the resulting molded article can be further improved. The lower limit of the number average fiber diameter of the glass fibers is preferably 4.0 μm or more, more preferably 4.5 μm or more, and even more preferably 5.0 μm or more. The upper limit of the number average fiber diameter of the glass filler is preferably 15.0 μm or less, more preferably 12.0 μm or less. The number average fiber diameter of the glass fibers is calculated from the measured values ​​obtained by randomly selecting glass fibers to be measured for fiber diameter from an image obtained by observation with an electron microscope, measuring the fiber diameter near the center, and then measuring the measured values. The observation is performed at a magnification of 1,000 times, and the number of fibers measured is 1,000 or more. The number average fiber diameter of glass fibers having a cross section other than a circle is the number average fiber diameter when converted into a circle with the same area as the cross section.

[0045] Next, the glass fiber preferably used in this embodiment will be described. The glass fiber is a fiber obtained by melt spinning a commonly supplied glass such as E-glass, C-glass, A-glass, S-glass, D-glass, R-glass, or M-glass, but is not particularly limited as long as it can be made into a glass fiber. In this embodiment, it is preferable to include E-glass. The glass fibers used in this embodiment are preferably surface-treated with a surface treatment agent such as a silane coupling agent, for example, γ-methacryloxypropyltrimethoxysilane, γ-glycidoxypropyltrimethoxysilane, or γ-aminopropyltriethoxysilane. The amount of the surface treatment agent attached is preferably 0.01 to 1% by mass of the glass fibers. Furthermore, if necessary, glass fibers may be surface-treated with a lubricant such as a fatty acid amide compound or silicone oil, an antistatic agent such as a quaternary ammonium salt, a resin capable of forming a film, such as an epoxy resin or a urethane resin, or a mixture of a resin capable of forming a film with a heat stabilizer or a flame retardant. The glass fibers used in this embodiment may be bundled with a sizing agent. In this case, epoxy-based or urethane-based sizing agents are preferred.

[0046] Glass fibers are commercially available, such as T-187, T-286H, T-756H, and T-289H manufactured by Nippon Electric Glass Co., Ltd., DEFT2A manufactured by Owens Corning, HP3540 manufactured by PPG, and CSG3PA820 manufactured by Nitto Boseki Co., Ltd.

[0047] The content of the glass filler (preferably glass fiber) in the resin composition of this embodiment is 5 parts by mass or more, preferably 10 parts by mass or more, and more preferably 15 parts by mass or more, per 100 parts by mass of the resin component. By ensuring that the content is above the lower limit, the mechanical strength of the resulting molded article tends to be further improved. Furthermore, the content of the glass filler (preferably glass fiber) in the resin composition of this embodiment is 100 parts by mass or less, more preferably 90 parts by mass or less, even more preferably 80 parts by mass or less, and even more preferably 70 parts by mass or less, per 100 parts by mass of the resin component. By ensuring that the content is below the upper limit, the flowability during injection molding tends to be improved. The content of the glass filler (preferably glass fiber) in the resin composition of this embodiment is preferably 5% by mass or more, more preferably 9% by mass or more, even more preferably 10% by mass or more, and even more preferably 15% by mass or more. The content of the glass filler (preferably glass fiber) is preferably 90% by mass or less, more preferably 41% by mass or less, even more preferably 40% by mass or less, and may even be 30% by mass or less, particularly 25% by mass or less. The resin composition of the present embodiment may contain only one type of glass filler, or may contain two or more types. When two or more types are contained, the total amount is preferably in the above range.

[0048] <Other ingredients> The resin composition of the present embodiment may contain, in addition to the polycarbonate resin, other thermoplastic resin (e.g., a (meth)acrylate polymer), and glass filler, other components as needed, as long as the desired physical properties are not significantly impaired. Examples of the other components include various resin additives. Examples of resin additives include release agents (such as ester compounds), stabilizers (such as heat stabilizers and antioxidants), UV absorbers, antistatic agents, flame retardants, flame retardant aids, dyes, pigments, antifogging agents, lubricants, antiblocking agents, flow improvers, plasticizers, dispersants, and antibacterial agents. One type of resin additive may be contained, or two or more types may be contained in any combination and ratio. For details of these additives, please refer to paragraphs 0059 to 0080 of JP 2014-065901 A, the contents of which are incorporated herein by reference. The resin composition of this embodiment is adjusted so that the total of the polycarbonate resin, other thermoplastic resin (such as a (meth)acrylate polymer), glass filler, and resin additives (e.g., ester compounds, stabilizers) blended as needed is 100 mass %.

[0049] <<Release Agent>> The resin composition of the present embodiment may contain a mold release agent. By containing a mold release agent, the mold releasability tends to be further improved. Although known release agents can be used, ester compounds are preferred, and ester compounds of aliphatic alcohols (e.g., saturated aliphatic monohydric alcohols having 16 to 22 carbon atoms or polyhydric alcohols having 2 to 12 carbon atoms) and aliphatic carboxylic acids (e.g., mono- or dicarboxylic acids having 16 to 22 carbon atoms) are more preferred. For details of the ester compounds, please refer to paragraphs 0047 to 0054 of JP 2020-029481 A, the contents of which are incorporated herein by reference.

[0050] When the resin composition of this embodiment contains a mold release agent (preferably an ester compound), the content thereof is preferably 0.05 parts by mass or more, and more preferably 0.1 parts by mass or more, per 100 parts by mass of the resin component. By ensuring that the content is equal to or greater than the above-mentioned lower limit, the effect of improving mold releasability tends to be effectively exhibited. The upper limit is preferably 2.2 parts by mass or less, and may be 1.5 parts by mass or less, or even 1.0 part by mass or less, per 100 parts by mass of the resin component. By ensuring that the content is equal to or less than the above-mentioned upper limit, problems such as mold contamination during injection molding can be effectively suppressed. Furthermore, the transparency of the resulting molded article tends to be further improved. 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.

[0051] <<Stabilizer>> The stabilizer includes a heat stabilizer and an antioxidant. As the heat stabilizer, a phosphorus-based stabilizer is preferably used. Any known phosphorus-based stabilizer can be used. Specific examples include phosphorus oxoacids such as phosphoric acid, phosphonic acid, phosphorous acid, phosphinic acid, and polyphosphoric acid; metal acid pyrophosphates such as sodium acid pyrophosphate, potassium acid pyrophosphate, and calcium acid pyrophosphate; phosphates of Group 1 or Group 2B metals such as potassium phosphate, sodium phosphate, cesium phosphate, and zinc phosphate; organic phosphate compounds, organic phosphite compounds, and organic phosphonite compounds, with organic phosphite compounds being particularly preferred.

[0052] As the antioxidant, a hindered phenol-based stabilizer is preferably used. Specific examples of hindered phenol stabilizers include pentaerythritol tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, thiodiethylene bis[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]phosphate, 3,3',3'',5,5',5''-hexa-tert-butyl-a,a',a''-(mesityle) 4,6-bis(octylthiomethyl)-o-cresol, ethylene bis(oxyethylene) bis[3-(5-tert-butyl-4-hydroxy-m-tolyl)propionate], hexamethylene bis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], 1,3,5-tris(3,5-di-tert-butyl)tri-p-cresol -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-triazin-2-ylamino)phenol, 2-[1-(2-hydroxy-3,5-di-tert-pentylphenyl)ethyl]-4,6-di-tert-pentylphenyl acrylate, and the like.

[0053] Specific examples of such hindered phenol stabilizers include "Irganox (registered trademark; the same applies hereinafter) 1010" and "Irganox 1076" manufactured by BASF, and "ADK STAB AO-50" and "ADK STAB AO-60" manufactured by ADEKA Corporation.

[0054] The content of the stabilizer in the resin composition of this embodiment is usually 0.001 part by mass or more, preferably 0.005 part by mass or more, more preferably 0.01 part by mass or more, and usually 1 part by mass or less, preferably 0.5 part by mass or less, more preferably 0.3 part by mass or less, relative to 100 parts by mass of the resin component. By setting the content of the stabilizer within this range, the effect of adding the stabilizer can be more effectively exerted. The resin composition of the present embodiment may contain only one stabilizer, or may contain two or more stabilizers. When two or more stabilizers are contained, the total amount is preferably in the above range.

[0055] <Difference in refractive index> In this embodiment, the absolute value of the difference between the refractive index of the resin component and the refractive index of the glass filler is adjusted to 0.0042 or less. This configuration can improve the transmittance of the resulting molded article. The upper limit of the refractive index difference is preferably 0.0041 or less, more preferably 0.0040 or less, even more preferably 0.0035 or less, even more preferably 0.0030 or less, even more preferably 0.0028 or less, even more preferably 0.0025 or less, and even more preferably 0.0020 or less, 0.0010 or less, 0.0009 or less, or 0.0008 or less. Ideally, the lower limit of the refractive index difference is 0, but the required performance can be sufficiently met, for example, if it is 0.0001 or more, or even 0.0003 or more.

[0056] <Other physical properties> The resin composition of this embodiment preferably has excellent transparency. Specifically, when molded to a thickness of 2 mm, a flat test piece has a haze of preferably 50% or less, more preferably 45% or less, at 23°C according to JIS K-7105. Ideally, the lower limit of the haze is 0%, but practical values ​​are, for example, 5% or more, and even 10% or more. The resin composition of this embodiment preferably has an excellent flexural modulus. Specifically, when the resin composition of this embodiment is molded into an ISO multipurpose test piece (4 mm thick), the flexural modulus based on the ISO-178 standard is preferably 4500 MPa or more, and more preferably 5500 MPa or more. There is no particular upper limit to the flexural modulus, but even if it is, for example, 18000 MPa or less, the performance requirements are fully met.

[0057] The resin composition of this embodiment preferably has a high pencil hardness. Specifically, the pencil hardness measured on a 2 mm thick plate-shaped test piece using a pencil hardness tester in accordance with ISO 15184 under a load of 750 g is preferably H or harder, more preferably 2H or harder. There is no particular upper limit to the pencil hardness, but it is practical to have a pencil hardness of 5H or softer.

[0058] The resin composition of this embodiment preferably has a low dielectric loss tangent. Specifically, the dielectric loss tangent measured by a perturbation method at a frequency of 1 GHz is preferably 0.0060 or less, more preferably 0.0057 or less, even more preferably 0.0055 or less, even more preferably 0.0053 or less, and even more preferably 0.0050 or less. There is no particular lower limit, but a value of 0.0010 or more is practical, for example. The haze, flexural modulus, pencil hardness, and dielectric loss tangent are measured according to the methods described in the examples below.

[0059] <Method of manufacturing resin composition> The method for producing the resin composition of this embodiment is not particularly limited, and a wide variety of known methods for producing resin compositions can be used, including a method in which the polycarbonate resin, other thermoplastic resins, glass fillers, and other components added as needed are premixed using a mixer such as a tumbler or Henschel mixer, and then melt-kneaded using a mixer such as a Banbury mixer, roll, Brabender, single-screw kneading extruder, twin-screw kneading extruder, kneader, etc. The melt-kneading temperature is not particularly limited, but is usually in the range of 240 to 320°C.

[0060] <Molded products> The molded article of this embodiment is a molded article formed from the resin composition of this embodiment, and therefore, the molded article of this embodiment can be made to have high transparency and excellent mechanical strength. The shape of the molded product is not particularly limited and can be appropriately selected depending on the use and purpose of the molded product. Examples include various shapes such as plate-like, plate-like, rod-like, sheet-like, film-like, cylindrical, ring-like, circular, elliptical, polygonal, irregularly shaped, hollow, frame-like, box-like, panel-like, and special shapes.

[0061] Molded articles obtained by molding the resin composition of the present embodiment have excellent transparency and mechanical strength, and are therefore preferably used for, for example, display parts, mobile information terminal parts, household electrical appliances, automobile parts, railway axle members, aircraft members, or indoor furnishings, and are more preferably used for display parts, mobile information terminal parts, household electrical appliances, or indoor furnishings. More specifically, it is preferably used for molding applications such as window glass for buildings (buildings, houses, greenhouses, etc.); window glass for cars, airplanes, and construction machinery; roofs for garages, arcades, etc.; sunroofs, roof panels, sunshades; various peepholes; lenses for lighting, traffic light lenses, and lenses for optical equipment; lens covers; mirrors, eyeglasses, goggles, and motorcycle windshields; solar cell covers; protective covers; various automotive lamp covers such as headlamps, inner lenses, and rear lamps; automotive interior panels; displays, display panel members, and gaming machine (pachinko, etc.) parts; housings for various portable terminals (smartphones, tablets, wearable devices), cameras, game consoles, and other electrical and electronic equipment and office automation equipment; helmets; and sheets, films, and laminates thereof.

[0062] This embodiment further discloses a molded article with a hard coat layer, which has a hard coat layer on at least a part of the surface of the molded article. The hard coat layer may be formed on at least a part of the thermoplastic resin molded article of the present invention. When the molded article is flat, the hard coat layer may be formed on only one side or both sides. When the molded article is a housing or the like, the hard coat layer may be formed on only one side or two or more sides, but it is preferable that the hard coat layer be formed on two or more sides.

[0063] In this embodiment, the hard coat layer can be formed by applying a hard coat agent to at least a part of the surface of the molded article of this embodiment and curing it according to the curing method of the hard coat agent.

[0064] As the hard coating agent for forming the hard coating layer, known materials can be appropriately used, and for example, various hard coating agents can be used that contain various polyfunctional monomers or polyfunctional prepolymers such as silicone-based, acrylic-based, epoxy-based, silazane-based, and urethane-based as the main component, inorganic fillers such as silica, polymerization initiators, and UV absorbers dissolved in a solvent, and various additives such as antioxidants, light stabilizers, viscosity modifiers, antifoaming agents, antistatic agents, dispersants, slip agents, dyes, and pigments can be added as needed. To improve adhesion and weather resistance, a two-coat type hard coating agent in which a primer layer is provided before applying the hard coating agent may also be used.

[0065] In forming the hard coat layer, the coating method of the hard coat agent is not particularly limited, and the hard coat agent can be applied by any coating method such as spray coating, dip coating, flow coating, spin coating, bar coating, curtain coating, die coating, gravure coating, roll coating, blade coating, and air knife coating.

[0066] As described above, the hard coat layer may be formed by applying a hard coat agent to the surface of the molded article of the present embodiment and curing the hard coat agent. Alternatively, a preformed film for the hard coat layer may be laminated onto the molded article of the present embodiment. Alternatively, a film for the hard coat layer may be set in a mold in advance, and the resin composition of the present embodiment may be injection molded therein. In this way, the step of forming the hard coat layer after injection molding can be omitted.

[0067] The thickness of the hard coat layer is preferably 5 to 50 μm, more preferably 7 to 30 μm, from the viewpoint of preventing layer peeling due to differences in thermal expansion and contraction from the molded article of this embodiment and enhancing transparency. For other details regarding the hard coat layer, please refer to the descriptions in paragraphs 0094 to 0097 of JP-A-2020-163597, the contents of which are incorporated herein by reference.

[0068] The molded article with a hard coat layer of this embodiment can be made to have excellent transparency in addition to various properties such as excellent dimensional stability, rigidity (flexural strength), and heat resistance due to the incorporation of a glass filler, and furthermore, the surface hardness is sufficiently high due to the hard coat layer, so that it can be suitably used in various products such as cameras, office automation equipment, communication equipment, precision instruments, electric and electronic parts, automobile parts, and general machine parts. In particular, it is suitable for cameras, office automation equipment, electric and electronic parts, and automobile parts, where transparency is important.

[0069] <Method of manufacturing molded products> The resin composition of the present embodiment is pelletized and then molded into a molded article by various molding methods. Alternatively, the resin melt-kneaded in an extruder can be directly molded into a molded article without going through pelletization.

[0070] The method for molding the molded article is not particularly limited, and any conventionally known molding method can be used, such as injection molding, injection compression molding, extrusion molding, profile extrusion, transfer molding, hollow molding, gas-assisted hollow molding, blow molding, extrusion blow molding, IMC (in-mold coating) molding, rotational molding, multilayer molding, two-color molding, insert molding, sandwich molding, foam molding, pressure molding, and heat & cool molding using a rapid heating and cooling mold. In this embodiment, the molded article is preferably produced by injection molding, and the resin composition of this embodiment is preferably molded using an insulated mold. Specifically, it is preferable to perform injection molding using a mold having a ceramic layer on the cavity surface, or to perform injection molding of the resin composition of this embodiment using a mold having, from the cavity surface side, a metal layer and a thermosetting resin layer in that order. Injection molding using such a mold tends to improve the surface smoothness of the molded article and further improve transparency.

[0071] The insulated mold is preferably a mold having a ceramic layer on the cavity surface (preferably the surface) (hereinafter sometimes referred to as a "ceramic insulated mold"), or a mold having a metal layer and a thermosetting resin layer formed in that order from the cavity surface side (hereinafter sometimes referred to as a "resin insulated mold").

[0072] An example of a ceramic heat-insulating mold is one in which a ceramic covering plate (insertion insert) is attached to the cavity surface of a metal mold body. The ceramic material is not particularly limited as long as it has excellent heat insulation, heat resistance, and stability. However, ceramics with a thermal conductivity of 5 W / m·K or less are preferred, such as zirconium oxide (ZrO2). Here, the zirconia may be partially stabilized zirconia containing one or more of calcia (calcium oxide, CaO), yttria (yttrium oxide, YO2O3), magnesia (magnesium oxide, MgO), silica (silicon oxide, SiO2), and ceria (cerium oxide, CeO2) as a partial stabilizer, or conductive zirconia containing one or more of Fe2O3, NiO, Co3O4, Cr2O3, TiO2, TiN, TiC, WC, TaC, etc. as a conductivity imparting agent.

[0073] The thickness of the ceramic layer is not particularly limited as long as it can provide the required thermal insulation, but is usually 0.1 to 10 mm, preferably 0.5 to 10 mm, more preferably 1 to 7 mm, and even more preferably 2 to 5 mm. If the ceramic layer is too thin, sufficient thermal insulation cannot be obtained, and the transparency improvement effect is smaller than when a normal mold is used. If the ceramic layer is too thick, the thermal insulation effect becomes too great, and it takes time to cool the molten resin in the cavity, lengthening the molding cycle.

[0074] An example of a resin-insulated mold is one in which a metal layer is placed on the cavity surface of a metal mold body via a thermosetting resin layer. Here, the thermosetting resin layer functions as an insulating layer and also as an adhesive layer between the mold body and the metal layer. Thermosetting resins include epoxy acrylate resin, phenolic resin, epoxy resin, melamine resin, urea resin, unsaturated polyester resin, alkyd resin, polyurethane, and thermosetting polyimide. The thermal conductivity of these thermosetting resins is usually around 0.3 to 3 W / m·K.

[0075] The thermosetting resin may contain inorganic particles such as glass beads as a reinforcing agent. The inorganic particles are preferably spherical and have an average particle size of about 1 to 100 μm. The content of the inorganic particles in the thermosetting resin layer is preferably 60 to 90 mass %.

[0076] The thickness of the thermosetting resin layer varies depending on the heat insulating properties (thermal conductivity) of the thermosetting resin, but is preferably about 0.2 to 1.5 mm.

[0077] Specific examples of materials for the metal layer that forms the cavity surface include steel materials such as alloy tool steel, die steel, tool steel, and martensitic stainless steel, as well as thin films of chromium, zinc, nickel, diamond, etc. Steel materials that have been subjected to processing such as quenching are preferred. The thickness of the metal layer is usually about 0.2 to 1.5 mm.

[0078] The metal layer can be formed on the surface of the thermosetting resin layer by plating or the like, but a thin plate of hardened steel or the like may also be bonded with a thermosetting resin. If necessary, a reinforcing layer made of ceramics may be formed between the metal layer and the thermosetting resin layer.

[0079] The molding conditions for injection molding the resin composition of this embodiment can be, for example, injection molding conditions of a cylinder temperature of 280 to 320°C and a mold temperature of 60 to 100°C, regardless of the type of mold. [Example]

[0080] The present invention will be explained in more detail below with reference to examples. The materials, amounts used, ratios, processing details, processing procedures, etc. shown in the following examples can be appropriately changed without departing from the spirit of the present invention. Therefore, the scope of the present invention is not limited to the specific examples shown below. If the measuring instruments used in the examples are difficult to obtain due to discontinuation or the like, measurements can be made using other instruments with equivalent performance.

[0081] 1. Raw materials <Production Example 1: Production of Polycarbonate Resin A1-1> 26.14 mol (6.75 kg) of bisphenol C (BPC) and 26.79 mol (5.74 kg) of diphenyl carbonate were placed in an aluminum (SUS) reactor (internal volume: 10 L) equipped with a stirrer and a distillate condenser, and after the reactor was purged with nitrogen gas, the temperature was raised to 220°C in a nitrogen gas atmosphere over 30 minutes. Next, the reaction solution in the reactor was stirred, and cesium carbonate (Cs2CO3) was added as a transesterification catalyst to the molten reaction solution in an amount of 1.5 × 10 per mole of BPC. -6 The reaction mixture was stirred and fermented under a nitrogen gas atmosphere at 220°C for 30 minutes. Next, the pressure inside the reactor was reduced to 100 Torr over 40 minutes at the same temperature, and the reaction was continued for a further 100 minutes to distill off phenol. Next, the temperature inside the reactor was raised to 284°C over 60 minutes while the pressure was reduced to 3 Torr, and almost the entire theoretical amount of phenol was distilled out. The pressure inside the reactor was then maintained at less than 1 Torr at the same temperature, and the reaction was continued for another 60 minutes to complete the polycondensation reaction. The stirring speed of the stirrer was 38 rpm, and the reaction liquid temperature just before the end of the reaction was 289°C, with a stirring power of 1.00 kW. Next, the reaction liquid in a molten state was fed into a twin-screw extruder, and butyl p-toluenesulfonate in an amount four times by mole relative to the cesium carbonate was fed into the first feed port of the twin-screw extruder and kneaded with the reaction liquid. Thereafter, the reaction liquid was extruded into strands through the die of the twin-screw extruder and cut with a cutter to obtain pellets of polycarbonate resin A1-1.

[0082] <Production Example 2: Production of Polycarbonate Resin A1-2> 26.14 mol (6.75 kg) of bisphenol C (BPC) and 26.79 mol (5.74 kg) of diphenyl carbonate were placed in an aluminum (SUS) reactor (internal volume: 10 L) equipped with a stirrer and a distillate condenser, and after the reactor was purged with nitrogen gas, the temperature was raised to 220°C in a nitrogen gas atmosphere over 30 minutes. Next, the reaction solution in the reactor was stirred, and cesium carbonate (Cs2CO3) was added as a transesterification catalyst to the molten reaction solution in an amount of 1.5 × 10 per mole of BPC. -6 The reaction mixture was stirred and fermented under a nitrogen gas atmosphere at 220°C for 30 minutes. Next, the pressure inside the reactor was reduced to 100 Torr over 40 minutes at the same temperature, and the reaction was continued for a further 100 minutes to distill off phenol. Next, the temperature inside the reactor was raised to 284°C over 60 minutes while the pressure was reduced to 3 Torr, and almost the entire theoretical amount of phenol was distilled out. The pressure inside the reactor was then maintained at less than 1 Torr at the same temperature, and the reaction was continued for another 60 minutes to complete the polycondensation reaction. The stirring speed of the stirrer was 38 rpm, and the reaction liquid temperature just before the end of the reaction was 289°C, with a stirring power of 0.60 kW. Next, the reaction liquid in a molten state was fed into a twin-screw extruder, and butyl p-toluenesulfonate in an amount four times by mole relative to the cesium carbonate was fed into the first feed port of the twin-screw extruder and kneaded with the reaction liquid. Thereafter, the reaction liquid was extruded into strands through the die of the twin-screw extruder and cut with a cutter to obtain pellets of polycarbonate resin A1-2.

[0083] <Production Example 3: Production of Polycarbonate Resin A3-1> 50 moles of 2,2-bis(4-hydroxyphenyl)propane, 50 moles of 2,2-bis(4-hydroxy-3-methylphenyl)cyclohexane, 103 moles of diphenyl carbonate (DPC), and 1.5 × 10 moles of cesium carbonate (Cat) as a catalyst. -6 The moles were precisely weighed to prepare a mixture, which was then placed in a first reactor equipped with a stirrer, a heat medium jacket, a vacuum pump, and a reflux condenser. Thereafter, an aromatic polycarbonate resin (A3-1) was obtained in the same manner as for PC (A1-1).

[0084] <Production Example 4: Production of Polycarbonate Resin A4-1> 50 moles of 2,2-bis(4-hydroxyphenyl)propane, 50 moles of 2,2-bis(4-hydroxy-3-methylphenyl)propane, 103 moles of diphenyl carbonate (DPC), and 1.5 × 10 moles of cesium carbonate (Cat) as a catalyst. -6 The moles were precisely weighed to prepare a mixture, which was then placed in a first reactor equipped with a stirrer, a heat medium jacket, a vacuum pump, and a reflux condenser. Thereafter, an aromatic polycarbonate resin PC(A4-1) was obtained in the same manner as for PC(A1-1). The raw materials listed in Table 1 below were used.

[0085] [Table 1-1] [Table 1-2]

[0086] <Measurement of viscosity average molecular weight (Mv) of polycarbonate resin> The viscosity average molecular weight (Mv) of the polycarbonate resin was calculated from the intrinsic viscosity (η) (unit: dL / g) at 20°C using an Ubbelohde viscometer with methylene chloride as a solvent, using the following Schnell viscosity formula: η = 1.23 × 10 -4 Mv 0.83

[0087] <Measurement of Pencil Hardness of Polycarbonate Resin> After drying polycarbonate resin pellets at 100 °C for 5 hours, a flat test piece (90 mm × 50 mm × 2 mm thick) was injection molded using an injection molding machine (“J55-60H” manufactured by Japan Steel Works, Ltd.) under the conditions of a cylinder set temperature of 280 °C, a mold temperature of 80 °C, a screw rotation speed of 100 rpm, and an injection speed of 100 mm / s. Regarding the flat test piece (90 mm × 50 mm × 2 mm thick) obtained above, in accordance with ISO 15184, the pencil hardness measured at a load of 750 g was determined using a pencil hardness tester. The pencil hardness tester used was the one manufactured by Toyo Seiki Seisaku-sho, Ltd.

[0088] <Weight Average Molecular Weight (Mw) of (Meth)acrylate Polymer> The weight average molecular weight of the (meth)acrylate polymer was taken as the value in terms of polystyrene (PS) measured using gel permeation chromatography with chloroform as the solvent.

[0089] 2. Examples 1 to 22, Comparative Examples 1 to 7 <Production of Resin Composition Pellets> Each component (excluding the glass filler) described in Table 1 above was blended at the ratios shown in Tables 2 to 6 below (expressed in parts by mass unless otherwise specified), and after uniformly mixing using a tumbler mixer, it was fed from the upstream feeder to a twin-screw extruder (manufactured by Toshiba Machine Co., Ltd., TEM26SX). Further, the glass filler was fed from the middle of the barrel (from the upstream (hopper part) of the extruder to the downstream position of 3 / 5 of the barrel length L), and fed to the extruder from the barrel at the upstream part of the extruder at a cylinder set temperature of 26 °C, a screw rotation speed of 250 rpm, and a discharge rate of 25 kg / hr, and melt-kneaded to obtain resin composition pellets. Note that in Comparative Examples 6 and 7, pellets could not be produced due to poor supply to the hopper.

[0090] <HAZE (General Mold, 80 °C)> After drying the resin composition pellets obtained above at 100°C for 5 hours, using an injection molding machine ("J55-60H" manufactured by Japan Steel Works, Ltd.), at a cylinder set temperature of 280°C and a mold temperature of 80°C, under the conditions of a screw rotation speed of 100 rpm and an injection speed of 100 mm / s, a flat test piece (90 mm × 50 mm × 2 mm thick) was injection molded. Regarding the flat test piece obtained above, in accordance with JIS K-7105, using a haze meter, the HAZE (haze) at 23°C was measured. As the haze meter, an NDH-4000 type haze meter manufactured by Nippon Denshoku Industries Co., Ltd. was used. The unit of HAZE was expressed in %. In addition, regarding Examples 21 and 22, the measurement was performed on the flat test piece after providing the hard coat layer.

[0091] <HAZE (Insulating Mold, 100°C)> After drying the resin composition pellets obtained above at 100°C for 5 hours, using an injection molding machine ("J55-60H" manufactured by Japan Steel Works, Ltd.), at a cylinder set temperature of 290°C and a mold temperature of 100°C, under the conditions of a screw rotation speed of 100 rpm and an injection speed of 100 mm / s, a flat test piece (80 mm × 30 mm × 2 mm thick) was injection molded. As the mold, an insulating mold equipped with a plate of zirconium oxide (ZrO2) of 80 mm × 30 mm × 3 mm on the fixed-side cavity and the movable-side cavity surfaces was used. Regarding the flat test piece obtained above, in accordance with JIS K-7105, using a haze meter, the HAZE (haze) at 23°C was measured. As the haze meter, an NDH-4000 type haze meter manufactured by Nippon Denshoku Industries Co., Ltd. was used. The unit of HAZE was expressed in %. In addition, regarding Examples 21 and 22, the measurement was performed on the flat test piece after providing the hard coat layer.

[0092] <Flexural Modulus> The resin composition pellets were dried at 100°C for 5 hours or more, and then injection molded using an injection molding machine (Toyo Machinery & Metal Co., Ltd., "Si-80-6S") under conditions of a cylinder setting temperature of 280°C, a mold temperature of 70°C, and a molding cycle of 50 seconds to prepare ISO multipurpose test specimens (4 mm thick). Both ends of the obtained ISO multipurpose test piece were processed into a shape based on ISO-178 standard, and a bending test was carried out at 23°C based on ISO-178 standard to measure the bending modulus (unit: MPa).

[0093] <Dynamic friction coefficient> In each of the above examples and comparative examples, resin composition pellets were produced in the same manner except that no glass filler was added. The pellets were dried at 100°C for 5 hours and then injection-molded into flat test pieces (100 mm x 100 mm x 2 mm thick) using an injection molding machine (manufactured by The Japan Steel Works, Ltd., "J55-60H") under conditions of a cylinder setting temperature of 280°C, a mold temperature of 80°C, a screw rotation speed of 100 rpm, and an injection speed of 25 mm / s. The flat test piece obtained above was scanned with a 1 mm diameter spherical probe at a test speed of 100 mm / sec over a test distance of 100 mm while varying the vertical load from 1 N to 50 N using a scratch tester in accordance with ISO 19252. The horizontal and vertical loads were measured at a load of 30 N to determine the dynamic friction coefficient (horizontal load / vertical load). A smaller dynamic friction coefficient is preferable. The scratch tester used was manufactured by Kato Tech Co., Ltd.

[0094] <Measurement of pencil hardness of resin composition> The resin composition pellets were dried at 100°C for 5 hours, and then injection-molded into flat test pieces (90 mm x 50 mm x 2 mm thick) using an injection molding machine ("J55-60H" manufactured by The Japan Steel Works, Ltd.) under conditions of a cylinder set temperature of 280°C, a mold temperature of 80°C, a screw rotation speed of 100 rpm, and an injection speed of 100 mm / s. The pencil hardness of the obtained flat test piece was determined in accordance with ISO 15184 using a pencil hardness tester under a load of 750 g. The pencil hardness tester used was manufactured by Toyo Seiki Co., Ltd.

[0095] <Dielectric loss tangent> The dielectric loss tangent was measured at a frequency of 1 GHz by a perturbation method using a flat plate-shaped test piece formed from the resin composition pellets. Specifically, the resin composition pellets obtained above were dried at 100°C for 5 hours, and then injection-molded into flat test pieces (100 mm x 100 mm x 2.0 mm thick) using an injection molding machine ("J55-60H" manufactured by The Japan Steel Works, Ltd.) under conditions of a cylinder setting temperature of 280°C, a mold temperature of 80°C, a screw rotation speed of 100 rpm, and an injection speed of 100 mm / s. From the obtained flat plate test piece, a flat plate test piece of 100 mm x 2.0 mm x 1 mm was obtained by cutting, and then the dielectric loss tangent at a frequency of 1 GHz was measured by the perturbation method. For the measurement, a network analyzer manufactured by KEYSIGHT and a cavity resonator manufactured by Kanto Electronics Application Development Co., Ltd. were used.

[0096] <Refractive index measurement method> The refractive indexes of the resin component and the glass filler were measured as follows. The refractive index of the resin component was measured by the following method. The refractive index at a wavelength of 486 nm was measured for the flat test piece described below. The refractive index was measured using a "MODEL2010 Prism Coupler" manufactured by Seki Technotron Co., Ltd. A flat test piece (90 mm × 50 mm × 1 mm thick) for measuring the refractive index was prepared by producing resin composition pellets in the same manner as above, but removing the glass filler from the resin composition pellets, drying the pellets at 100°C for 5 hours, and then injection-molding the pellets using an injection molding machine (manufactured by The Japan Steel Works, Ltd., "J55-60H") under conditions of a cylinder setting temperature of 280°C, a mold temperature of 80°C, a screw rotation speed of 100 rpm, and an injection speed of 100 mm / s. The refractive index of the glass filler was calculated by subtracting the refractive index of the resin component from the refractive index of the resin composition (a mixture of the resin component and the glass filler). Further, the refractive index difference (refractive index of resin component - refractive index of glass filler, absolute value) was calculated from the obtained refractive index.

[0097] <Formation of Hard Coat Layer (Examples 21 and 22)> Molded articles (test pieces) obtained from the resin compositions of Examples 21 and 22 were provided with hard coat layers. A hard coating agent was applied to one side of a test piece produced in the same manner as the flat test piece (90 mm x 50 mm x 2 mm thick) molded in the pencil hardness measurement section above, using a bar coater. The test piece was then heated in an infrared drying oven at 60°C for 90 seconds to volatilize the solvent, and then irradiated with ultraviolet light from a high-pressure mercury lamp at a cumulative 1000 mJ / cm. 2 The hard coat layer was then cured by irradiation to obtain a flat test piece having a 10 μm thick hard coat layer. When both sides were hard coated, a 10 μm thick hard coat layer was also formed on the back side. As for the hard coating agent, in Example 21, a light-resistant hard coating agent (GWH-101M, manufactured by Arakawa Chemical Industries, Ltd.) was used, and in Example 22, a high-hardness hard coating agent (Beamset 907LZ, manufactured by Arakawa Chemical Industries, Ltd.) was used.

[0098] <Measurement of surface roughness Ra of molded products> Using a SURFCOM 3000A manufactured by Tokyo Seimitsu Co., Ltd., the cutoff wavelength λc was set to 0.8 mm, the cutoff type was set to Gaussian, λs to 2.67 μm, and the evaluation length was set to 8 mm. The surface roughness Ra was measured for test pieces produced in the same manner as the flat test pieces (90 mm × 50 mm × 2 mm thick) molded in the pencil hardness measurement section above. The smaller the Ra, the smoother the surface of the molded article. In order to obtain molded articles with excellent transparency, it is preferable to set Ra to 0.5 μm or less. In Examples 21 and 22, the measurements were carried out on the flat test pieces after the hard coat layer was provided.

[0099] [Table 2]

[0100] [Table 3]

[0101] [Table 4]

[0102] [Table 5]

[0103] [Table 6]

[0104] In the above table, "refractive index difference (absolute value)" indicates the difference (absolute value) between the refractive index of the resin component and the refractive index of the glass filler. As is clear from the above results, the molded articles formed from the resin compositions of the present invention were excellent in transparency and mechanical strength (Examples 1 to 22). Furthermore, they had excellent moldability, high pencil hardness, and low dielectric loss tangent.

Claims

1. containing 5 to 100 parts by mass of a glass filler relative to 100 parts by mass of the resin component, The resin component includes 40 to 85 parts by mass of a polycarbonate resin containing a structural unit represented by formula (1) and 15 to 60 parts by mass of a thermoplastic resin other than the polycarbonate resin, the absolute value of the difference between the refractive index of the resin component and the refractive index of the glass filler is 0.0042 or less, The resin composition, wherein the resin component has a dynamic friction coefficient of 0.40 or less in accordance with ISO 19252. Formula (1) 【Chemistry 1】 (In formula (1), R １ represents a methyl group, R ２ represents a hydrogen atom or a methyl group, and X １ represents one of the following formulas: 【Chemistry 2】 R ３ and R ４ each independently represents a hydrogen atom or a methyl group, and Z represents a group that bonds with C to form an alicyclic hydrocarbon having 6 to 12 carbon atoms which may have a substituent.

2. The resin composition according to claim 1, wherein the polycarbonate resin further comprises a structural unit represented by formula (2): Formula (2) 【Transformation 3】 (In formula (2), X ２ represents one of the following formulas: 【Chemistry 4】 R ３ and R ４ each independently represents a hydrogen atom or a methyl group, and Z represents a group that bonds with C to form an alicyclic hydrocarbon having 6 to 12 carbon atoms which may have a substituent.

3. 3. The resin composition according to claim 1, wherein the refractive index of the thermoplastic resin other than the polycarbonate resin is 1.4900 to 1.5500.

4. The resin composition according to any one of claims 1 to 3, wherein the proportion of the structural unit represented by formula (1) in the resin component is 15 mass% or more.

5. The resin composition according to any one of claims 1 to 4, wherein the other thermoplastic resin is a (meth)acrylate polymer.

6. The resin composition according to claim 5 , wherein the (meth)acrylate polymer contains an aromatic (meth)acrylate unit (b1).

7. The (meth)acrylate polymer contains an aromatic (meth)acrylate unit (b1) and a methyl methacrylate unit (b2), and the mass ratio (b1 / b2) thereof is 5 to 50 / 50 to 95. The resin composition according to claim 5.

8. The resin composition according to any one of claims 1 to 7, wherein the glass filler comprises glass fibers having a flat cross section.

9. The resin composition according to any one of claims 1 to 8, having a dielectric loss tangent of 0.0060 or less as measured by a perturbation method at a frequency of 1 GHz.

10. The composition contains 10 to 100 parts by mass of a glass filler relative to 100 parts by mass of the resin component, The resin component contains 16 to 40 parts by mass of a thermoplastic resin other than the polycarbonate resin, when the total of the polycarbonate resin and the other thermoplastic resin is 100 parts by mass. The resin composition according to any one of claims 1 to 9.

11. A molded article formed from the resin composition according to any one of claims 1 to 10.

12. The molded article according to claim 11, which is a display part, a mobile information terminal part, a household electrical appliance, or an interior furnishing.

13. A molded article with a hard coat layer, comprising the molded article according to claim 11 or 12, and a hard coat layer on at least a part of the surface thereof.

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