Resin composition and molded article

Abstract

To provide a resin composition capable of providing a molded article that is excellent in transparency, releasability, and is suppressed in gas generation, and a molded article formed from the resin composition.SOLUTION: There is provided a resin composition comprising a polycarbonate resin containing a constitutional unit represented by formula (1), an another thermoplastic resin other than the polycarbonate resin containing the constitutional unit represented by formula (1), a glass filler, and an ester compound. The composition contains 7 to 100 pts. mass of the glass filler based on 100 pts. mass of the total amount of the polycarbonate resin and the another thermoplastic resin, and a difference between the refractive index of the thermoplastic resin component contained in the resin composition and the refractive index of the glass filler is 0.0150 or less. The composition contains 0.3 to 5.0 pts. mass of the ester compound based on 100 pts. mass of the total amount of the polycarbonate resin and the another thermoplastic resin, and the ester compound has 40 or more carbon atoms and a melting point of 60°C or more. In formula (1), R1 represents a methyl group.SELECTED DRAWING: None

Description

[Technical Field]

[0001] This invention relates to resin compositions and molded articles. [Background technology]

[0002] Polycarbonate resin is widely used as an engineering plastic in various fields, including electrical and electronic equipment and the automotive industry, due to its excellent mechanical strength, heat resistance, and transparency. Polycarbonate resin is widely used in various fields, including as a type of plastic glass. However, compared to conventional inorganic glass, it tends to have lower rigidity. To improve this drawback, glass-reinforced polycarbonate resin compositions, which incorporate glass fillers into polycarbonate resin, are being investigated. While it is possible to improve mechanical properties such as elastic modulus, flexural strength, and impact resistance by blending glass fillers such as glass fibers into polycarbonate resin, there is a problem in that the excellent transparency inherent in polycarbonate resin is significantly impaired due to the large difference in refractive index between the polycarbonate resin and the glass filler.

[0003] To solve this problem, Patent Document 1 discloses an aromatic polycarbonate resin composition comprising 100 parts by weight of an aromatic polycarbonate resin, 1 to 150 parts by weight of glass fibers having a refractive index difference of 0.0150 or less from the aromatic polycarbonate resin, and 1 to 40 parts by weight of polyoxyalkylene glycol or polyoxyethylene derivative containing 50% by weight or more of a polyoxyethylene glycol component. [Prior art documents] [Patent Documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 09-194712 [Overview of the project] [Problems that the invention aims to solve]

[0005] As described above, improving the transparency of resin compositions containing glass fillers in polycarbonate resin has been studied. However, depending on the application, transparency issues arising from the lifting of the glass filler on the surface of molded products formed from the aforementioned resin compositions can be problematic. Here, the inventors have suppressed glass lifting by lowering the glass transition temperature of the thermoplastic resin component by incorporating an ester compound. However, it was found that gas generation can occur during molding. The present invention aims to solve the aforementioned problems and to provide a resin composition that offers excellent transparency, suppresses gas generation, and provides molded articles with good release properties, as well as molded articles formed from the resin composition. [Means for solving the problem]

[0006] Based on the above problems, the inventors conducted investigations and found that the above problems can be solved by using a predetermined polycarbonate resin and a predetermined ester compound. Specifically, the above problem was solved by the following means. <1> A resin composition comprising a polycarbonate resin containing a structural unit represented by formula (1), another thermoplastic resin other than the polycarbonate resin containing the structural unit represented by formula (1), a glass filler, and an ester compound, wherein the resin composition contains 5 to 100 parts by mass of the glass filler per 100 parts by mass of the total of the polycarbonate resin and the other thermoplastic resin, the difference between the refractive index of the thermoplastic resin component contained in the resin composition and the refractive index of the glass filler is 0.0150 or less, and the resin composition contains 0.3 to 5.0 parts by mass of the ester compound per 100 parts by mass of the total of the polycarbonate resin and the other thermoplastic resin, the ester compound having 40 or more carbon atoms and a melting point of 60°C or higher. Formula (1) [ka] (In formula (1), R 1 represents a methyl group, R 2 represents a hydrogen atom or a methyl group, and X 1 represents any of the following formulas: [Chemical formula] R 3 and R 4 each independently represent a hydrogen atom or a methyl group, and Z represents a group that combines with C to form an optionally substituted alicyclic hydrocarbon having 6 to 12 carbon atoms.) <2>The resin composition according to <1>, wherein the polycarbonate resin further contains a structural unit represented by formula (2). Formula (2) [Chemical formula] (In formula (2), X 2 represents any of the following formulas: [Chemical formula] R 3 and R 4 each independently represent a hydrogen atom or a methyl group, and Z represents a group that combines with C to form an optionally substituted alicyclic hydrocarbon having 6 to 12 carbon atoms.) <3>The resin composition according to <1> or <2>, wherein the refractive index of the other thermoplastic resin is 1.4900 to 1.5500. <4>The resin composition according to any one of <1> to <3>, wherein the proportion of the structural unit represented by formula (1) in the polycarbonate resin is 5% by mass or more. <5>The resin composition according to any one of <1> to <4>, wherein the other thermoplastic resin contains a (meth)acrylate polymer. <6>The resin composition according to <5>, wherein the (meth)acrylate polymer contains an aromatic (meth)acrylate structural unit (b1). <7> The (meth)acrylate polymer contains aromatic (meth)acrylate units (b1) and methyl methacrylate units (b2), and its mass ratio (b1 / b2) is 5-50 / 50-95. <5> The resin composition described above. <8> The glass filler includes glass fibers having a flattened cross-section. <1> ~ <7> A resin composition as described in any one of the following. <9> The ester compound includes an ester compound of an aliphatic carboxylic acid having 10 to 26 carbon atoms and an aliphatic alcohol having 22 or fewer carbon atoms. <1> ~ <8> A resin composition as described in any one of the following. <10> The ester compound includes an ester compound of an aliphatic saturated monocarboxylic acid having 16 to 26 carbon atoms and a monohydric aliphatic saturated alcohol having 16 to 22 carbon atoms, and / or a full ester compound of an aliphatic saturated monocarboxylic acid having 16 to 26 carbon atoms and a polyhydric alcohol having 2 to 12 carbon atoms. <1> ~ <9> A resin composition as described in any one of the following. <11> The coefficient of dynamic friction of the composition obtained by removing the glass filler from the aforementioned resin composition is 0.40 or less, in accordance with ISO 19252. <1> ~ <10> A resin composition as described in any one of the following. <12> <1> ~ <11> A molded article formed from any one of the resin compositions described in that one. <13> The molded product is a display component, a mobile information terminal component, a household electrical appliance, or an interior furnishing. <12> Molded product as described above. [Effects of the Invention]

[0007] The present invention provides a resin composition that offers excellent transparency, good release properties, and suppressed gas generation in a molded product, as well as a molded product formed from the resin composition. [Modes for carrying out the invention]

[0008] The following describes in detail embodiments for carrying out the present invention (hereinafter simply referred to as "this embodiment"). Note that the following embodiment is illustrative for explaining the present invention, and the present invention is not limited to this embodiment. In this specification, "~" is used to mean including the numerical values described before and after it as the lower limit value and the upper limit value. In this specification, unless otherwise specified, various physical property values and characteristic values are those at 23°C. In the notation of groups (atomic groups) in this specification, notations that do not indicate substitution or non-substitution include groups (atomic groups) having substituents as well as groups (atomic groups) having no substituents. For example, the "alkyl group" includes not only an alkyl group having no substituent (unsubstituted alkyl group) but also an alkyl group having a substituent (substituted alkyl group). In this specification, notations that do not indicate substitution or non-substitution preferably mean unsubstituted. When the measurement methods and the like described by the standards shown in this specification differ depending on the year, unless otherwise specified, they are based on the standards as of January 1, 2021.

[0009] The resin composition of this embodiment is a resin composition containing a polycarbonate resin containing a structural unit represented by formula (1), another thermoplastic resin other than the polycarbonate resin containing the structural unit represented by formula (1) (hereinafter sometimes simply referred to as "another thermoplastic resin"), a glass filler, and an ester compound. Based on 100 parts by mass in total of the polycarbonate resin and the other thermoplastic resin, it contains 7 to 100 parts by mass of the glass filler, the difference between the refractive index of the thermoplastic resin component contained in the resin composition and the refractive index of the glass filler is 0.0150 or less, based on 100 parts by mass in total of the polycarbonate resin and the other thermoplastic resin, it contains 0.3 to 5.0 parts by mass of the ester compound, and the ester compound has 40 or more carbon atoms and a melting point of 60°C or more. Formula (1)

Chemical formula

Chemical formula

[0010] By adopting this configuration, a resin composition can be obtained that provides molded products with excellent transparency, good release properties, and suppressed gas generation. In other words, the inventors considered using bisphenol C type polycarbonate resin as the polycarbonate resin to improve the transparency of molded products. Bisphenol C type polycarbonate resin inherently has high fluidity, which can increase the fluidity of the resin composition and allow the thermoplastic resin component to sufficiently fill the area around the glass filler. By improving the filling properties in this way, the floating of the glass filler can be suppressed, and an improvement in the transparency of the molded product can be expected. However, bisphenol C type polycarbonate resin has a large refractive index difference with the glass filler. Therefore, it was found that the transparency was inferior from this perspective. Therefore, it is presumed that transparency could be improved by further blending a thermoplastic resin with a lower refractive index than the glass filler in addition to the polycarbonate resin, and keeping the difference in refractive index between the thermoplastic resin component and the glass filler in the resin composition below a predetermined range. Furthermore, by blending an ester compound, the glass transition temperature of the plastic resin component was lowered, and the floating of the glass was suppressed. It was also found that some types of ester compounds generate gas. Therefore, by incorporating an ester compound having 40 or more carbon atoms and a melting point of 60°C or higher (hereinafter sometimes referred to as "a specified ester compound"), gas generation could be effectively suppressed. In particular, this embodiment is highly valuable because it can improve transparency without using an insulating mold or the like.

[0011] The thermoplastic resin component refers to the total of polycarbonate resin and other thermoplastic resins containing the constituent unit represented by formula (1). In this embodiment, the resin composition used is such that, of the components of the resin composition excluding the glass filler, typically 95% by mass or more, preferably 97% by mass or more, and more preferably 99% by mass or more, is composed of thermoplastic resin components.

[0012] <Polycarbonate resin containing the constituent units represented by formula (1)> The resin composition of this embodiment includes a polycarbonate resin containing a structural unit represented by formula (1). By including the constituent unit represented by formula (1) in the polycarbonate resin, a molded product with excellent gloss and a smooth surface can be obtained. Formula (1) [ka] In formula (1), R 1 represents a methyl group, R 2 X represents a hydrogen atom or a methyl group. 1 This represents one of the following expressions: [ka] R 3 and R 4 Each of these independently represents a hydrogen atom or a methyl group, and Z represents a group that, when bonded to C, forms an alicyclic hydrocarbon having 6 to 12 carbon atoms, which may have substituents.

[0013] Examples of alicyclic hydrocarbons formed by the bonding of Z with C include cycloalkylidene groups such as cyclohexylidene, cycloheptylidene, cyclododecylidene, adamantylidene, and cyclododecylidene. Examples of alicyclic hydrocarbons having substituents formed by the bonding of Z with C include methyl-substituted and ethyl-substituted derivatives of the above-mentioned alicyclic hydrocarbon groups. Among these, cyclohexylidene, methyl-substituted derivatives of cyclohexylidene (preferably 3,3,5-trimethyl-substituted derivatives), and cyclododecylidene are preferred.

[0014] In formula (1), X1 but, [ka] If R 3 and R 4 Preferably, at least one of them is a methyl group, and more preferably, both are methyl groups. Also X 1 but, [ka] In this case, Z bonds with the carbon C bonded to the two phenyl groups in formula (1) above to form a divalent alicyclic hydrocarbon group having 6 to 12 carbon atoms. Examples of divalent alicyclic hydrocarbon groups include cycloalkylidene groups such as cyclohexylidene, cycloheptylidene, cyclododecylidene, adamantylidene, and cyclododecylidene. Substituted forms include those having methyl substituents and ethyl substituents. Among these, cyclohexylidene, methyl-substituted cyclohexylidene (preferably 3,3,5-trimethyl-substituted), and cyclododecylidene are preferred. In formula (1), X 1 The following structure is preferred. [ka]

[0015] A preferred specific example of the constituent unit represented by formula (1) above is a constituent unit (carbonate constituent unit) composed of 2,2-bis(3-methyl-4-hydroxyphenyl)propane, i.e., bisphenol C.

[0016] In this embodiment, the polycarbonate resin may contain only one or more constituent units represented by formula (1).

[0017] In this embodiment, the polycarbonate resin containing the constituent unit represented by formula (1) may further contain the constituent unit represented by formula (2). Here, "containing the constituent unit represented by formula (2)" means that the polycarbonate resin contained in the resin composition of this embodiment is a polycarbonate resin containing the constituent unit represented by formula (1) and the constituent unit represented by formula (2), or it may be a blend of a polycarbonate resin containing the constituent unit represented by formula (1) and a polycarbonate resin containing the constituent unit represented by formula (2). Including the constituent unit represented by formula (2) tends to further improve the heat resistance of the resulting molded article. Formula (2) [ka] In formula (2), X 2 This represents one of the following expressions: [ka] R 3 and R 4 Each of these independently represents a hydrogen atom or a methyl group, and Z represents a group that, when bonded to C, forms an alicyclic hydrocarbon having 6 to 12 carbon atoms, which may have substituents.

[0018] In formula (2), X 2 but, [ka] If R 3 and R 4 Preferably, at least one of them is a methyl group, and more preferably, both are methyl groups. Also X 2 but, [ka] In this case, Z bonds with the carbon C bonded to the two phenyl groups in formula (2) above to form a divalent alicyclic hydrocarbon group having 6 to 12 carbon atoms. Examples of divalent alicyclic hydrocarbon groups include cycloalkylidene groups such as cyclohexylidene, cycloheptylidene, cyclododecylidene, adamantylidene, and cyclododecylidene. Substituted forms include those having methyl substituents and ethyl substituents. Among these, cyclohexylidene, methyl-substituted cyclohexylidene (preferably 3,3,5-trimethyl-substituted), and cyclododecylidene are preferred. In formula (2), X 2 The following structure is preferred. [ka]

[0019] In this embodiment, the polycarbonate resin may contain only one type of constituent unit represented by formula (2), or it may contain two or more types.

[0020] In this embodiment, the polycarbonate resin may contain other structural units besides those represented by formula (1) and formula (2). Examples of other structural units include those derived from the dihydroxy compounds shown below.

[0021] 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-3,5-dimethylphenyl)-1-phenylethane, 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)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.

[0022] Furthermore, as another embodiment of the constituent unit, reference can be made to the constituent unit represented by formula (2) described in paragraph 0008 of International Publication No. 2017 / 099226, the descriptions in paragraphs 0043 to 0052 of International Publication No. 2017 / 099226, and the descriptions in Japanese Patent Application Publication No. 2011-046769, the contents of which are incorporated herein by reference.

[0023] Furthermore, the polycarbonate resin used in this embodiment preferably has a proportion of 5% by mass or more of the constituent units represented by formula (1), more preferably 10% by mass or more, even more preferably 15% by mass or more, and may also have a proportion of 35% by mass or more, 40% by mass or more, 50% by mass or more, 70% by mass or more, or 75% by mass or more. Setting it above the lower limit tends to further improve the transparency of the resulting molded product, increase the surface hardness of the molded product, and further tend to lower the dielectric loss tangent. The proportion of the constituent units represented by formula (1) may also be 100% by mass. Setting it below the upper limit tends to further increase the load deflection temperature.

[0024] In the polycarbonate resin used in this embodiment, the sum of the constituent units represented by formula (1) and formula (2) above preferably accounts for 90% by mass or more of all constituent units excluding end groups, more preferably 95% by mass or more, and even more preferably 99% by mass or more. The upper limit of the sum is 100% by mass or less.

[0025] The polycarbonate resin used in this embodiment is preferably in the following form. (A1) Polycarbonate resin containing the constituent unit represented by formula (1) (A2) A blend of polycarbonate resin containing the constituent units represented by formula (1) and polycarbonate resin containing the constituent units represented by formula (2). (A3) Polycarbonate resin containing the constituent units represented by formula (1) and the constituent units represented by formula (2) (A4) A polycarbonate resin containing the constituent units represented by formula (1), and a blend of polycarbonate resins containing the constituent units represented by formula (1) and the constituent units represented by formula (2). (A5) A blend of polycarbonate resin containing the constituent units represented by formula (2) and polycarbonate resin containing the constituent units represented by formula (1) and the constituent units represented by formula (2). (A6) A blend of polycarbonate resin containing the constituent units represented by formula (1), polycarbonate resin containing the constituent units represented by formula (2), and polycarbonate resin containing the constituent units represented by formula (1) and formula (2). (A7) In (A1) to (A6) above, the polycarbonate resin constituting the polycarbonate resin or its blend contains other constituent units other than the constituent units represented by formula (1) and the constituent units represented by formula (2). (A8) A blend of polycarbonate resin consisting of the polycarbonate resin or blend described in (A1) to (A7) above and other constituent units.

[0026] The refractive index of the polycarbonate resin used in this embodiment at a wavelength of 486 nm is, for example, 1.5600 or higher, more preferably 1.5700 or higher, and particularly preferably 1.5800 or higher. Furthermore, the upper limit of the refractive index of the polycarbonate resin is preferably 1.6500 or lower, more preferably 1.6400 or lower, even more preferably 1.6300 or lower, even more preferably 1.6200 or lower, even more preferably 1.6100 or lower, and may also be 1.6000 or lower, and particularly preferably 1.5990 or lower. The refractive index is measured according to the examples described below. If two or more types of polycarbonate resins are included, the refractive index of the mixture is used.

[0027] The viscosity-average molecular weight (Mv) of the polycarbonate resin used in this embodiment is preferably 5,000 or more at the lower limit, more preferably 8,000 or more, even more preferably 10,000 or more, and even 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 even more preferably 27,000 or less. By setting the viscosity-average molecular weight above the lower limit, moldability is improved and molded products with high mechanical strength can be obtained. Furthermore, by setting it below the upper limit, the fluidity of the resin composition is improved, and thin-walled molded products can be manufactured efficiently. If the resin composition contains two or more types of polycarbonate resins, the sum of the values ​​obtained by multiplying the viscosity-average molecular weight of each polycarbonate resin by its mass fraction shall be used. In particular, the viscosity-average molecular weight of the polycarbonate resin containing the constituent unit represented by formula (1) is preferably 20,000 to 30,000, and more preferably 20,000 to 28,000. Furthermore, the viscosity-average molecular weight of the polycarbonate resin containing the constituent 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.

[0028] The polycarbonate resin used in this embodiment (a total polycarbonate resin including the constituent units represented by formula (1) and formula (2)) is exemplified by having a pencil hardness of 3B to 2H, measured according to ISO 15184, with 2B to 2H being preferred. The pencil hardness is measured according to the method described in the examples below. In particular, the pencil hardness of polycarbonate resin containing the constituent unit represented by formula (1) is preferably H to 2H, and the pencil hardness of polycarbonate resin containing the constituent unit represented by formula (2) is preferably 2B to HB.

[0029] The method for producing the polycarbonate resin used in this embodiment is not particularly limited, but for example, paragraphs 0027 to 0043 and the examples of Japanese Patent Application Publication No. 2014-065901 can be referenced, and the contents of these are incorporated herein.

[0030] The polycarbonate resin content in the resin composition of this embodiment is preferably 40 parts by mass or more, more preferably 50 parts by mass or more, even more preferably 60 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 also be 76 parts by mass or more, per 100 parts by mass of the thermoplastic resin component. Setting the content above the lower limit tends to further improve the impact strength of the molded product formed from the resin composition, and also tends to effectively suppress the decrease in the heat resistance of the resin composition. Furthermore, the polycarbonate resin content in the resin composition of this embodiment is preferably 85 parts by mass or less per 100 parts by mass of the resin component. Setting the content below the upper limit tends to further improve the surface hardness of the molded product formed from the resin composition, and the fluidity of the resin composition.

[0031] <Other thermoplastic resins other than polycarbonate resin containing the constituent units represented by formula (1)> The resin composition of this embodiment includes a polycarbonate resin containing the constituent units represented by formula (1), in addition to other thermoplastic resins. By including the other thermoplastic resin (usually a resin with a lower refractive index than the polycarbonate resin), the refractive index of the thermoplastic resin component can be lowered. While there are no specific requirements regarding the type of thermoplastic resin other than the polycarbonate resin, it is generally selected to have a lower refractive index than the polycarbonate resin and the glass filler. Specifically, the refractive index of the other thermoplastic resin (preferably the (meth)acrylate polymer described later) at a wavelength of 486 nm 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. Furthermore, 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 setting the refractive index above the lower limit, the surface hardness of the molded article formed from the resin composition can be further increased.

[0032] 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, including (meth)acrylate polymers can increase the surface hardness of molded articles formed from the resin composition and also increase the fluidity of the resin composition. The (meth)acrylate polymer used in this embodiment preferably contains aromatic (meth)acrylate structural units (b1), and more preferably contains aromatic (meth)acrylate structural units (b1) and methyl methacrylate structural units (b2). Including aromatic (meth)acrylate structural units (b1) can improve compatibility with polycarbonate resin, and including methyl methacrylate structural units (b2) can improve the surface hardness of molded articles formed from the resin composition.

[0033] Aromatic (meth)acrylate (b1), which is a monomer constituting an aromatic (meth)acrylate unit, refers to a (meth)acrylate having an aromatic group. Preferably, aromatic (meth)acrylate (b1) is a (meth)acrylate containing a benzene ring and / or a naphthalene ring, and more preferably a (meth)acrylate containing a benzene ring. Specific examples of 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 constituent unit (b1), or it may contain two or more types.

[0034] The monomer that constitutes the methyl methacrylate constituent unit (b2) is methyl methacrylate.

[0035] In the (meth)acrylate polymer used in this embodiment, when it contains aromatic (meth)acrylate constituent units (b1) and methyl methacrylate constituent units (b2), the mass ratio of (b1) / (b2) is more preferably 5-50 / 50-95, even more preferably 25-50 / 50-75, even more preferably 25-45 / 55-75, and even more preferably 30-40 / 60-70. In this embodiment, the (meth)acrylate polymer used contains aromatic (meth)acrylate units (b1) and methyl methacrylate units (b2), but may or may not contain other units. If other units are included, styrene units and (meth)acrylate units other than (b1) and (b2) are preferred, and (meth)acrylate units other than (b1) and (b2) are more preferred. Examples of (meth)acrylate units other than (b1) and (b2) include aliphatic (meth)acrylates other than methyl methacrylate. In this embodiment, the (meth)acrylate polymer used preferably has a total of aromatic (meth)acrylate units (b1) and methyl methacrylate units (b2) accounting for 90% or more by mass of all units excluding terminal groups, more preferably 95% or more by mass, and even more preferably 99% or more by mass. The upper limit of the total may be 100% or less by mass of all units excluding terminal groups.

[0036] 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. Setting it above the lower limit tends to further improve the impact strength and heat resistance of the resulting molded article. 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. Setting it below the upper limit tends to further improve the fluidity of the resin composition. The weight-average molecular weight of the (meth)acrylate polymer is measured according to the example described below.

[0037] In addition to those mentioned above, the (meth)acrylate polymer used in this embodiment may be those described in International Publication No. 2014 / 038500, International Publication No. 2013 / 094898, Japanese Patent Publication No. 2006-199774, Japanese Patent Publication No. 2010-116501, Japanese Patent Publication No. 2014-065901, Japanese Patent Publication No. 2016-027068, and the "aromatic (meth)acrylate" described in Japanese Patent Publication No. 2016-047937. These details are incorporated herein by reference.

[0038] The content of other thermoplastic resins (preferably (meth)acrylate polymers) in the resin composition of this embodiment is preferably 15 parts by mass or more per 100 parts by mass of the thermoplastic resin component. Setting it above the lower limit tends to further improve the surface hardness of the molded article formed from the resin composition and the fluidity of the resin composition. Furthermore, the content of other thermoplastic resins (preferably (meth)acrylate polymers) in the resin composition of this embodiment is preferably 60 parts by mass or less, more preferably 50 parts by mass or less, even more preferably 40 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 also be 24 parts by mass or less per 100 parts by mass of the thermoplastic resin component. Setting it below the upper limit tends to further improve the impact strength of the molded article formed from the resin composition and also tends to effectively suppress the decrease in the heat resistance of the resin composition.

[0039] <Glass filler> The resin composition of this embodiment contains a glass filler. The inclusion of the glass filler improves the mechanical strength of the resulting molded product. The glass filler in this embodiment is not particularly specified, and any filler used for strengthening thermoplastic resins can be widely used.

[0040] The refractive index of the glass filler used in this embodiment at a wavelength of 486 nm is, for example, 1.5500 or higher, more specifically 1.5600 or higher, and particularly 1.5700 or higher. Furthermore, the refractive index of the glass filler is, for example, 1.5900 or lower, more specifically 1.5850 or lower, and particularly 1.5800 or lower. The refractive index is measured according to the description in the examples described later. When two or more types of glass fillers are included, the refractive index of the glass fillers shall be the sum of the values ​​obtained by multiplying the refractive index of each glass filler by its mass fraction.

[0041] The glass filler used in this embodiment may be in any shape, such as fibrous, plate-shaped, or bead-shaped, but it is preferably fibrous. In this embodiment, if the glass filler used is fibrous, a number-average fiber length (cut length) of 0.5 to 10.0 mm is preferred, and 1.0 to 5.0 mm is more preferred. By using a glass filler (glass fiber) with such a number-average fiber length, the 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 from an image obtained by observation with an optical microscope, measuring their longest side, and then calculating the number-average fiber length from the obtained measurement values. The observation magnification is 20x, and the number of measurements is 1,000 or more. This generally corresponds to the cut length. Furthermore, the cross-sectional shape of the glass fiber may be any shape, such as circular, elliptical, oblong, rectangular, a rectangle with semicircles attached to both short sides, or cocoon-shaped. In this embodiment, the glass filler preferably contains glass fibers having a flattened cross-section, more preferably with a flattening ratio of 1.5 to 8, and even more preferably with a flattening ratio of 2 to 6. By using such flattened glass fibers, light scattering can be effectively suppressed, and the transparency of the resulting molded product can be further improved. The number-average fiber diameter of glass fibers is preferably 4.0 μm or more at the lower limit, more preferably 4.5 μm or more, and even more preferably 5.0 μm or more. The number-average fiber diameter of glass filler is preferably 25.0 μm or less at the upper limit, and more preferably 20.0 μm or less. The number-average fiber diameter of glass fibers is calculated by randomly selecting glass fibers to be measured from an image obtained by electron microscope observation, measuring the fiber diameter near the center, and obtaining the measured values. The observation magnification is 1,000x, and the number of measurements is 1,000 or more. For glass fibers with a cross-section other than circular, the number-average fiber diameter is the number-average fiber diameter when converted to a circle with the same area as the cross-sectional area.

[0042] Next, glass fibers preferably used in this embodiment will be described. Glass fibers are generally obtained by melt-spinning supplied E glass, C glass, A glass, S glass, D glass, R glass, M glass, etc., but any material that can be made into glass fibers can be used and is not particularly limited. 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, such as γ-methacrylateoxypropyltrimethoxysilane, γ-glycidoxypropyltrimethoxysilane, or γ-aminopropyltriethoxysilane. The amount of surface treatment agent applied 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 with film-forming ability such as epoxy resin or urethane resin, or a mixture of a resin with film-forming ability and a heat stabilizer or flame retardant. The glass fibers used in this embodiment may also be bundled with a sizing agent. In this case, an epoxy-based sizing agent or a urethane-based sizing agent is preferred.

[0043] Glass fibers are available commercially. Examples of commercially available products include T-187, T-286H, T-756H, T-289H, and T-511-FGF from Nippon Electric Glass Co., Ltd., DEFT2A from Owens Corning, HP3540 from PPG, and CSG3PA820 from Nitto Boseki Co., Ltd.

[0044] The content of glass filler (preferably glass fiber) in the resin composition of this embodiment is 5 parts by mass or more, preferably 6 parts by mass or more, preferably 7 parts by mass or more, preferably 8 parts by mass or more, more preferably 9 parts by mass or more, even more preferably 10 parts by mass or more, even more preferably 12 parts by mass or more, even more preferably 15 parts by mass or more, even more preferably 18 parts by mass or more, and especially most preferably 20 parts by mass or more. Setting the content above the lower limit tends to further improve the mechanical strength of the resulting molded product. Furthermore, the content of glass filler (preferably glass fiber) in the resin composition of this embodiment is 100 parts by mass or less, preferably 90 parts by mass or less, even more preferably 80 parts by mass or less, even more preferably 70 parts by mass or less, and may also be 50 parts by mass or less or 30 parts by mass or less, based on 100 parts by mass of the thermoplastic resin component. Setting the content below the upper limit tends to improve the fluidity during injection molding. Furthermore, 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. In addition, the content of the glass filler (preferably glass fiber) in the resin composition is preferably 50% by mass or less, more preferably 41% by mass or less, even more preferably 40% by mass or less, and may be 30% by mass or less, and particularly 28% by mass or less. The resin composition of this embodiment may contain only one type of glass filler, or it may contain two or more types. When it contains two or more types, it is preferable that the total amount is within the above range.

[0045] <Ester compounds> The resin composition of this embodiment contains an ester compound having 40 or more carbon atoms and a melting point of 60°C or higher. Including such a predetermined ester compound tends to improve the release properties and transparency of the resulting molded product.

[0046] The carbon number of the specified ester compound is 40 or more, preferably 45 or more, more preferably 50 or more, even more preferably 55 or more, even more preferably 60 or more, even more preferably 65 or more, even more preferably 70 or more, and may also be 75 or more. Setting it above the lower limit tends to improve gaseous properties during extrusion and release properties during injection molding. Furthermore, the carbon number of the specified ester compound is preferably 100 or less, more preferably 95 or less, and may also be 90 or less, or 85 or less. Setting it below the upper limit tends to improve compatibility with thermoplastic resins, improve transparency, and enhance release properties during injection molding. If the resin composition of this embodiment contains two or more predetermined ester compounds, the total number of carbon atoms is the sum of the values ​​obtained by multiplying the number of carbon atoms of the ester of each ester compound by its mass fraction.

[0047] The melting point of the specified ester compound is 60°C or higher, may be greater than 65°C, or 66°C or higher. Setting it above the lower limit tends to improve gaseous properties during extrusion and release properties during injection molding. Furthermore, the melting point of the specified ester compound is preferably 80°C or lower, more preferably 75°C or lower, and may be less than 70°C. Setting it below the upper limit tends to improve compatibility with thermoplastic resins, enhance transparency, and improve release properties during injection molding. If the resin composition of this embodiment contains two or more predetermined ester compounds, its melting point shall be the sum of the values ​​obtained by multiplying the melting point of each ester compound by its mass fraction.

[0048] The specified ester compound is preferably an ester compound of one or more aliphatic carboxylic acids and one or more aliphatic alcohols.

[0049] The number of carbon atoms in the aliphatic carboxylic acid is preferably 10 or more, more preferably 13 or more, even more preferably 16 or more, and even more preferably 18 or more. Setting it above the lower limit tends to improve gaseous properties during extrusion and release properties during injection molding. Furthermore, the number of carbon atoms in the aliphatic carboxylic acid is preferably 26 or less, more preferably 24 or less, and even more preferably 22 or less. Setting it below the upper limit tends to improve compatibility with thermoplastic resins, improve transparency, and release properties during injection molding. The aliphatic carboxylic acid may be either an aliphatic saturated carboxylic acid or an aliphatic unsaturated carboxylic acid, but it is preferably an aliphatic saturated carboxylic acid. Furthermore, the aliphatic carboxylic acid is preferably a monocarboxylic acid, dicarboxylic acid, tricarboxylic acid, or tetracarboxylic acid, with monocarboxylic acid being preferable.

[0050] Specific examples of aliphatic carboxylic acids include palmitic acid, stearic acid, caproic acid, capric acid, lauric acid, arachidic acid, behenic acid, lignoceric acid, cerotic acid, melissic acid, tetrariacontanoic acid, montanic acid, adipic acid, and azelaic acid.

[0051] The carbon number of the aliphatic alcohol is preferably 2 or more, and more preferably 4 or more, depending on the valence of the alcohol. Setting it above the lower limit tends to improve gaseous properties during extrusion. Furthermore, the carbon number of the aliphatic alcohol is preferably 22 or less, more preferably 20 or less, even more preferably 16 or less, even more preferably 12 or less, and even more preferably 8 or less. Setting it below the upper limit tends to improve compatibility with thermoplastic resins, improve transparency, and improve release properties during injection molding.

[0052] The aliphatic alcohol may be a saturated alcohol or an unsaturated alcohol, but it is preferably a saturated alcohol. The aliphatic alcohol may be a monoalcohol or a polyhydric alcohol, but it is preferably a polyhydric alcohol. The valency of the alcohol in the polyhydric alcohol is preferably 2 or higher, more preferably 3 or higher, preferably 10 or lower, more preferably 8 or lower, and even more preferably 6 or lower.

[0053] Specific examples of aliphatic alcohols include octanol, decanol, dodecanol, stearyl alcohol, behenyl alcohol, ethylene glycol, diethylene glycol, glycerin, pentaerythritol, 2,2-dihydroxyperfluoropropanol, neopentylene glycol, ditrimethylolpropane, and dipentaerythritol.

[0054] The number of ester groups in a given ester compound is preferably one or more per molecule, more preferably two or more, even more preferably three or more, and even more preferably four or more. Setting it above the lower limit tends to further improve gaseous properties during extrusion. Furthermore, the number of ester groups in a given ester compound is preferably eight or less per molecule, more preferably seven or less, even more preferably six or less, even more preferably five or less, and even more preferably four or less. Setting it below the upper limit tends to improve compatibility with thermoplastic resins, improve transparency, and improve release properties during injection molding.

[0055] In this embodiment, it is preferable that the predetermined ester compound includes an ester compound of an aliphatic carboxylic acid having 10 to 26 carbon atoms (preferably 10 to 22 carbon atoms) and an aliphatic alcohol having 22 carbon atoms or less, and it is more preferable that it includes an ester compound of an aliphatic saturated monocarboxylic acid having 16 to 26 carbon atoms (preferably 16 to 22 carbon atoms) and a monohydric aliphatic saturated alcohol having 16 to 22 carbon atoms, and / or a full ester compound of an aliphatic saturated monocarboxylic acid having 16 to 26 carbon atoms (preferably 16 to 22 carbon atoms) and a polyhydric alcohol having 2 to 12 carbon atoms. Furthermore, details of the specified ester compound can be found in paragraphs 0047 to 0054 of Japanese Patent Publication No. 2020-029481, and this information is incorporated into the specification.

[0056] In this embodiment, the molecular weight of the predetermined ester compound is preferably 500 or more, more preferably 700 or more, even more preferably 900 or more, and may also be 1100 or more. Furthermore, it is preferably 2000 or less, more preferably 1800 or less, and even more preferably 1600 or less.

[0057] The ester compound content in the resin composition of this embodiment is preferably 0.3 parts by mass or more, more preferably 0.4 parts by mass or more, more preferably 0.6 parts by mass or more, even more preferably 0.8 parts by mass or more, even more preferably 1.1 parts by mass or more, even more preferably 1.5 parts by mass or more, and even more preferably 1.8 parts by mass or more, based on 100 parts by mass of the thermoplastic resin component. Setting the content above the lower limit allows for more effective release properties. Furthermore, the ester compound content in the resin composition of this embodiment is preferably 5.0 parts by mass or less, more preferably 4.5 parts by mass or less, more preferably 4.0 parts by mass or less, even more preferably 3.5 parts by mass or less, even more preferably 3.0 parts by mass or less, and even more preferably 2.5 parts by mass or less, based on 100 parts by mass of the thermoplastic resin component. Setting the content below the upper limit allows for effective suppression of gas generation. The resin composition of this embodiment may contain only one ester compound or two or more. When it contains two or more, it is preferable that the total amount is within the above range.

[0058] <Other ingredients> The resin composition of this embodiment may contain, in addition to a polycarbonate resin, other thermoplastic resins (such as (meth)acrylate polymers), a glass filler, and a predetermined ester compound, other components as needed, provided that they do not significantly impair the desired physical properties. Examples of other components include various resin additives. Examples of resin additives include colorants, stabilizers (heat stabilizers, antioxidants, etc.), ultraviolet absorbers, antistatic agents, flame retardants, flame retardant enhancers, antifogging agents, lubricants, antiblocking agents, flow improvers, plasticizers, dispersants, and antibacterial agents. The resin additive may contain only one type, or two or more types in any combination and ratio. Further details can be found in paragraphs 0059-0080 of Japanese Patent Publication No. 2014-065901 and paragraphs 0069-0093 of Japanese Patent Publication No. 2018-165017, the contents of which are incorporated herein by reference. The resin composition of this embodiment is prepared so that the total of the polycarbonate resin, other thermoplastic resins (such as (meth)acrylate polymers), glass fillers, a predetermined ester compound, and resin additives (e.g., stabilizers) added as needed is 100% by mass.

[0059] The resin composition of this embodiment may contain a stabilizer. Examples of stabilizers include heat stabilizers and antioxidants. As a heat stabilizer, phosphorus-based stabilizers are 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 polyphosphate; acidic pyrophosphate metal salts such as sodium acidic pyrophosphate, potassium acidic pyrophosphate, and calcium acidic pyrophosphate; phosphates of Group 1 or Group 2B metals such as potassium phosphate, sodium phosphate, cesium phosphate, and zinc phosphate; and organic phosphate compounds, organic phosphite compounds, and organic phosphonite compounds, with organic phosphite compounds being particularly preferred.

[0060] Hindered phenol-based stabilizers are preferably used as antioxidants. 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, thiodiethylenebis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], N,N'-hexane-1,6-diylbis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionamide], 2,4-dimethyl-6-(1-methylpentadecyl)phenol, diethyl[[3,5-bis(1,1-dimethylethyl)-4-hydroxyphenyl]methyl]phosphate, and 3,3',3'',5,5',5''-hexa-tert-butyl-a,a',a''-(methylpentadecyl) (2,4,6-triyl)tri-p-cresol, 4,6-bis(octylthiomethyl)-o-cresol, ethylenebis(oxyethylene)bis[3-(5-tert-butyl-4-hydroxy-m-tolyl)propionate], hexamethylenebis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], 1,3,5-tris(3,5-di-tert-butyl) Examples include -4-hydroxybenzyl)-1,3,5-triazine-2,4,6(1H,3H,5H)-trione, 2,6-di-tert-butyl-4-(4,6-bis(octylthio)-1,3,5-triazine-2-ylamino)phenol, and 2-[1-(2-hydroxy-3,5-di-tert-pentylphenyl)ethyl]-4,6-di-tert-pentylphenyl acrylate.

[0061] Examples of such hindered phenol-based stabilizers include, for example, BASF's "Irganox (registered trademark; hereinafter the same) 1010" and "Irganox 1076," and ADEKA's "ADEKA Stab AO-50" and "ADEKA Stab AO-60."

[0062] The stabilizer content in the resin composition of this embodiment is typically 0.001 parts by mass or more, preferably 0.005 parts by mass or more, more preferably 0.01 parts by mass or more, and typically 1 part by mass or less, preferably 0.5 parts by mass or less, more preferably 0.3 parts by mass or less, per 100 parts by mass of the thermoplastic resin component. By setting the stabilizer content within the above range, the effect of adding the stabilizer is more effectively exhibited. The resin composition of this embodiment may contain only one stabilizer or two or more stabilizers. When two or more stabilizers are included, it is preferable that the total amount is within the above range.

[0063] <Difference in refractive index> In this embodiment, the difference in refractive index between the thermoplastic resin component and the glass filler contained in the resin composition is adjusted to be 0.0150 or less. Note that the difference in refractive index refers to the absolute value. By adopting this configuration, the transmittance of the resulting molded product can be improved, and a molded product with excellent gloss can be obtained. The upper limit of the difference in refractive index is preferably 0.0130 or less, more preferably 0.0080 or less, even more preferably 0.0060 or less, even more preferably 0.0040 or less, even more preferably 0.0030 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, and 0.0008 or less. The lower limit of the difference in refractive index is ideally 0, but for example, 0.0001 or more, and even 0.0003 or more, can sufficiently satisfy the required performance.

[0064] <Coefficient of Dynamic Friction> The resin composition of this embodiment preferably has a dynamic friction coefficient of 0.40 or less, according to ISO 19252, for the composition obtained by removing the glass filler from the resin composition. This dynamic friction coefficient is mainly achieved by using a polycarbonate resin containing the constituent units represented by formula (1) and by blending a predetermined ester compound. That is, by using a polycarbonate resin containing the constituent units represented by formula (1) and a predetermined ester compound, the fluidity of the glass filler in the resin composition is improved, and the floating of the glass filler on the surface of the resulting molded product can be effectively suppressed. Furthermore, by blending a predetermined ester compound, the glass transition temperature of the thermoplastic resin component is increased, and the floating of the glass filler can be effectively suppressed. As a result, the dynamic friction coefficient of the surface of the resulting molded product can be reduced.

[0065] More specifically, a test specimen measuring 90 mm in length, 50 mm in width, and 2 mm in thickness, formed from the resin composition of this embodiment with the glass filler removed, preferably has a dynamic friction coefficient of 0.40 or less, more preferably 0.37 or less, even more preferably 0.35 or less, even more preferably 0.33 or less, and even more preferably 0.32 or less, according to ISO 19252, when loaded with 30 N. Ideally, the lower limit of the dynamic friction coefficient should be 0, but values ​​of 0.01 or higher, and even 0.10 or higher, are at a practical level. The method for measuring the dynamic friction coefficient follows the description in the examples below.

[0066] <Other physical properties of resin compositions> The resin composition of this embodiment preferably exhibits low haze. Specifically, the resin composition of this embodiment preferably has a haze of 30% or less when molded at a mold temperature of 80°C, more preferably 29% or less, even more preferably 28% or less, even more preferably 27% or less, even more preferably 26% or less, and even more preferably 25% or less. The lower limit of the haze is ideally 0%, but 1% or more is practical. The above haze is measured according to the example described below.

[0067] <Method for producing resin compositions> There are no limitations on the manufacturing method of the resin composition of this embodiment, and a wide range of known methods for manufacturing polycarbonate resin compositions can be used. For example, the polycarbonate resin, other thermoplastic resins, glass fillers, and a predetermined ester compound, as well as other components that may be added as needed, are pre-mixed using various mixers such as a tumbler or a Henschel mixer, and then melt-kneaded using a mixer such as a Banbury mixer, rolls, brabender, single-screw extruder, twin-screw extruder, or kneader. While there are no specific restrictions on the melting and mixing temperature, it is typically in the range of 240 to 320°C.

[0068] <Molded products> The resin composition described above (for example, pellets) is molded into a molded product using various molding methods. That is, the molded product of this embodiment is molded from the resin composition of this embodiment. There are no particular restrictions on the shape of the molded product, and it can be appropriately selected according to the application and purpose of the molded product. Examples include film-shaped, rod-shaped, cylindrical, annular, circular, elliptical, polygonal, irregularly shaped, hollow, frame-shaped, box-shaped, and panel-shaped products. Among these, panel-shaped products are preferred, with a thickness of, for example, about 1 mm to 5 mm. The molded articles of this embodiment are preferably formed by die molding. In particular, the resin composition of this embodiment is preferably molded at a mold temperature in the range of 75 to 105°C, and more preferably in the range of 75 to 95°C. Normally, excellent release properties can be achieved by lowering the mold temperature, but transparency can be improved by raising the mold temperature. In this embodiment, excellent release properties and transparency can be achieved even at high mold temperatures.

[0069] The method for molding the molded product is not particularly limited, and conventionally known molding methods can be employed. Examples include injection molding, injection compression molding, extrusion molding, shape extrusion, transfer molding, hollow molding, gas-assisted hollow molding, blow molding, extrusion blow molding, IMC (in-mold coating) molding, rotational molding, multilayer molding, two-color molding, insert molding, sandwich molding, foam molding, and pressure molding. In particular, the resin composition of this embodiment is suitable for molded products obtained by injection molding, injection compression molding, and extrusion molding. However, it goes without saying that the resin composition of this embodiment is not limited to molded products obtained by these methods.

[0070] The molded products of this embodiment are suitably used in electrical and electronic equipment, office automation equipment, personal digital assistants, machine parts, home appliances, vehicle parts, various containers, lighting equipment, and other components. Among these, they are particularly suitable for display components, personal digital assistant components, household electrical appliances, or interior furnishings. [Examples]

[0071] The present invention will be described in more detail below with reference to examples. The materials, amounts used, proportions, processing content, and processing procedures shown in the following examples can be modified as appropriate, 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. If the measuring instruments used in the examples are difficult to obtain due to discontinuation or other reasons, measurements can be taken using other instruments with equivalent performance.

[0072] 1.Raw materials The raw materials shown in Table 1 below were used. [Table 1]

[0073] <Manufacturing Example 1: Manufacturing of Polycarbonate Resin A1-1> 26.14 moles (6.75 kg) of bisphenol C (BPC) and 26.79 moles (5.74 kg) of diphenyl carbonate were placed in an aluminum (SUS) reactor (internal volume 10 liters) equipped with a stirrer and a distillation condenser. After replacing the reactor with nitrogen gas, the temperature was raised to 220°C over 30 minutes under a nitrogen gas atmosphere. Next, the reaction mixture in the reactor is stirred, and cesium carbonate (Cs2CO3) is added to the molten reaction mixture as a transesterification catalyst at a rate of 1.5 × 10⁻¹⁶ per mole of BPC. -6 The mixture was added to form moles, and the reaction mixture was stirred and matured at 220°C for 30 minutes under a nitrogen gas atmosphere. Next, the pressure in the reactor was reduced to 100 Torr over 40 minutes at the same temperature, and the reaction was continued for another 100 minutes to distill off the phenol. Next, the temperature inside the reactor was raised to 284°C over 60 minutes, and the pressure was reduced to 3 Torr, allowing almost the entire theoretical amount of phenol to be distilled off. Then, the pressure inside the reactor was maintained at less than 1 Torr at the same temperature, and the reaction was continued for another 60 minutes to complete the polycondensation reaction. At this time, the stirring speed of the stirrer was 38 revolutions per minute, the reaction solution temperature just before the end of the reaction was 289°C, and the stirring power was 1.00 kW. Next, the molten reaction mixture was fed into a twin-screw extruder, and 4 times the molar amount of butyl p-toluenesulfonate relative to cesium carbonate was supplied from the first feed port of the twin-screw extruder and kneaded with the reaction mixture. Then, the reaction mixture was extruded in strand form through the die of the twin-screw extruder and cut with a cutter to obtain pellets of polycarbonate resin A1-1.

[0074] <Measurement of viscosity-average molecular weight (Mv) of polycarbonate resin> The viscosity-average molecular weight (Mv) of polycarbonate resin was calculated using Schnell's viscosity formula, after determining the intrinsic viscosity (η) (unit: dL / g) at 20°C using an Ubbelohde viscometer with methylene chloride as the solvent. η = 1.23 × 10 -4 Mv 0.83

[0075] <Measurement of pencil hardness of polycarbonate resin> After drying polycarbonate resin pellets at 100°C for 5 hours, flat test specimens (150 mm × 100 mm × 2 mm thick) were fabricated using an injection molding machine (FANUC Corporation "α-2000i-150B") with a cylinder temperature of 260°C, a mold temperature of 70°C, a screw rotation speed of 100 rpm, and an injection speed of 30 mm / second. The pencil hardness of these flat test specimens was determined using a pencil hardness tester (Toyo Seiki Co., Ltd.) with a 750 g load, in accordance with ISO 15184.

[0076] <Weight-average molecular weight (Mw) of (meth)acrylate polymers> The weight-average molecular weight of the (meth)acrylate polymer was measured using gel permeation chromatography with chloroform as the solvent and expressed as a polystyrene (PS) equivalent value.

[0077] <Method for measuring the melting point of ester compounds> The melting point of an ester compound is a value measured by differential scanning calorimetry (DSC), and refers to the peak temperature (°C) of the main melting peak. Specifically, the temperature (°C) of the peak top of the endothermic main peak detected when the temperature was increased from 30°C to the expected melting point + 40°C at a rate of 20°C / min was measured.

[0078] 2. Examples 1-12, Comparative Examples 1-20 <Manufacturing of resin composition pellets> Each component listed in Table 1 above (excluding the glass filler) was blended in the proportions shown in Tables 2 to 7 below (expressed in parts by mass unless otherwise specified), and after being uniformly mixed in a tumbler mixer, one vent was supplied to a twin-screw extruder (Shibaura Machine Co., Ltd., TEM26SX) from the upstream feeder. The glass filler was then supplied from the middle of the barrel (3 / 5 downstream of the barrel length L from the upstream (hopper) part of the extruder), and the mixture was fed into the extruder from the barrel upstream of the extruder at a cylinder temperature of 260°C, screw rotation speed of 250 rpm, and discharge rate of 25 kg / hr. The mixture was then melt-kneaded to obtain resin composition pellets.

[0079] <Haze> The haze at a mold temperature of 80°C was measured as follows. After drying the resin composition pellets obtained above 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 (Japan Steel Works Ltd. "J55-60H") under the following conditions: cylinder temperature set to 280°C, mold temperature to 80°C, screw rotation speed to 100 rpm, and injection speed to 100 mm / s. The haze of the flat test specimens obtained as described above was measured at 23°C using a haze meter in accordance with JIS K-7105. A haze meter, model NDH-2000, manufactured by Nippon Denshoku Industries Co., Ltd., was used. The haze is expressed in percentages. Furthermore, if the haze level was 90% or higher, it was indicated as cloudy.

[0080] <Release Resistance> After drying the resin composition pellets obtained above at 100°C for 5 hours, a box-shaped product (30 mm high, 54 mm wide, 34 mm deep, 1.5 mm thick) was molded using an injection molding machine (Japan Steel Works Ltd. "J55-60H") under the following conditions: cylinder temperature 260°C, mold temperature 80°C, screw rotation speed 100 rpm, and injection speed 100 mm / second. The resin was injected through a side gate (gate thickness 1.5 mm x gate width 3 mm) located near the center of the frontmost front of the left side wall of the box-shaped product, and the release properties during injection molding were evaluated. A: Molded product without ejector pin marks. B: Other than those mentioned in A above, for example, molded products that have cracked due to being penetrated by an ejector pin, etc.

[0081] <Gas properties> In the production of the above-mentioned resin composition pellets, the amount of gas generated was visually evaluated as follows. A: Gas generation amount is standard or below. B: Gas generation is higher than standard.

[0082] <Coefficient of kinetic friction (30N)> Using the resin composition pellets obtained above, the glass filler was removed, and the process was carried out in the same manner to obtain composition pellets without the glass filler. After drying the composition pellets at 100°C for 5 hours, a 100mm × 100mm × 2mm thick flat test piece was injection molded using an injection molding machine (Japan Steel Works Ltd. "J55-60H") under the following conditions: cylinder temperature 260°C, mold temperature 70°C, screw rotation speed 100 rpm, and injection speed 30 mm / second. For the obtained flat test piece, the coefficient of dynamic friction was determined in accordance with ISO 19252, using a scratch tester (Kato Tech Co., Ltd.) with a load of 30N.

[0083] <Method for measuring refractive index> The refractive indices of various resins, thermoplastic resin components, and glass fillers were measured as follows. The refractive indices of various resins and thermoplastic resin components were determined by the following method. A flat test specimen (90 mm x 50 mm x 1 mm thick) was manufactured for refractive index measurement, and the refractive index at a wavelength of 486 nm was measured. For the measurement of the refractive index, we used the "MODEL2010 prism coupler" manufactured by Seki Technotron. Flat test specimens (90 mm x 50 mm x 1 mm thick) for refractive index measurement were prepared by drying a resin or thermoplastic resin component manufactured in the same manner as described above at 100°C for 5 hours, and then injection molding them using an injection molding machine (Japan Steel Works Ltd. "J55-60H") at a cylinder 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 manufacturing a flat test piece of a mixture of the thermoplastic resin component and the glass filler, and then subtracting the refractive index of the thermoplastic resin component from the refractive index of the test piece. Furthermore, the refractive index difference (refractive index of the thermoplastic resin component - refractive index of the glass filler, absolute value) was calculated from the obtained refractive index.

[0084] [Table 2]

[0085] [Table 3]

[0086] [Table 4]

[0087] [Table 5]

[0088] [Table 6]

[0089] [Table 7]

[0090] In Tables 2 to 7 above, the resin refractive index refers to the refractive index of the thermoplastic resin component at a wavelength of 486 nm, and the GF refractive index refers to the refractive index of the glass filler at a wavelength of 486 nm. Furthermore, the refractive index difference refers to the difference between the refractive index of the thermoplastic resin component and the refractive index of the glass filler at a wavelength of 486 nm. As is clear from the above results, the molded articles formed from the resin composition of this embodiment exhibited high transparency, excellent release properties, and effectively suppressed gas generation.

Claims

1. A resin composition comprising a polycarbonate resin containing a structural unit represented by formula (1), another thermoplastic resin other than the polycarbonate resin containing the structural unit represented by formula (1), a glass filler, and an ester compound, The mixture contains 5 to 100 parts by mass of glass filler per 100 parts by mass of the total of the polycarbonate resin and other thermoplastic resins. The difference between the refractive index of the thermoplastic resin component contained in the resin composition and the refractive index of the glass filler is 0.0150 or less. The mixture contains 0.8 to 5.0 parts by mass of an ester compound per 100 parts by mass of the polycarbonate resin and other thermoplastic resins combined. The ester compound has 40 or more carbon atoms and a melting point of 60°C or higher. Resin composition. Formula (1) 【Chemistry 1】 (In formula (1), R １ represents a methyl group, R ２ represents a hydrogen atom or a methyl group, X １ This represents one of the following expressions: 【Chemistry 2】 R ３ and R ４ Each of these independently represents a hydrogen atom or a methyl group, and Z represents a group that, when bonded to C, forms an alicyclic hydrocarbon having 6 to 12 carbon atoms, which may have substituents.

2. The polycarbonate resin further includes a constituent unit represented by formula (2), The resin composition according to claim 1. Formula (2) 【Transformation 3】 (In formula (2), X ２ This represents one of the following expressions: 【Chemistry 4】 R ３ and R ４ Each of these independently represents a hydrogen atom or a methyl group, and Z represents a group that, when bonded to C, forms an alicyclic hydrocarbon having 6 to 12 carbon atoms, which may have substituents.

3. The resin composition according to claim 1 or 2, wherein the refractive index of the other thermoplastic 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 constituent unit represented by formula (1) in the polycarbonate resin is 5% by mass or more.

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

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

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

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

9. The resin composition according to any one of claims 1 to 8, wherein the ester compound comprises an ester compound of an aliphatic carboxylic acid having 10 to 26 carbon atoms and an aliphatic alcohol having 22 carbon atoms or less.

10. The resin composition according to any one of claims 1 to 9, wherein the ester compound comprises an ester compound of an aliphatic saturated monocarboxylic acid having 16 to 26 carbon atoms and a monohydric aliphatic saturated alcohol having 16 to 22 carbon atoms, and / or a full ester compound of an aliphatic saturated monocarboxylic acid having 16 to 26 carbon atoms and a polyhydric alcohol having 2 to 12 carbon atoms.

11. The resin composition according to any one of claims 1 to 10, wherein the dynamic friction coefficient of the composition obtained by removing the glass filler from the resin composition is 0.40 or less in accordance with ISO 19252.

12. The resin composition according to any one of claims 1 to 11, wherein the proportion of the constituent unit represented by formula (1) in the polycarbonate resin containing the constituent unit represented by formula (1) is 50% by mass or more.

13. The resin composition according to any one of claims 1 to 12, wherein the melting point of the ester compound is less than 70°C.

14. The resin composition according to any one of claims 1 to 13, wherein the ester compound has 90 or fewer carbon atoms.

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

16. The molded article according to claim 15, wherein the molded article is a display component, a mobile information terminal component, a household electrical appliance, or an interior furnishing.

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