Environment-friendly polycarbonate resin composition and article produced therefrom

Abstract

A polycarbonate resin composition according to the present invention comprises: about 100 parts by weight of a base resin including about 1 to about 96 wt% of a polycarbonate resin, about 2 to about 90 wt% of a recycled polycarbonate resin including polymethyl methacrylate, and about 2 to about 97 wt% of a polysiloxane-polycarbonate copolymer resin; about 1 to about 15 parts by weight of a phosphazene compound; about 0.3 to about 3 parts by weight of a phenylmethylsiloxane compound; and about 0.1 to about 2 parts by weight of a polydimethylsiloxane having a terminal reactive group and having a kinematic viscosity of about 5 to about 200 cSt as measured at 40°C according to ASTM D445. The polycarbonate resin composition has excellent environmental friendliness, (thin film) flame retardancy, chemical resistance, and impact resistance, and an excellent balance of said physical properties.

Description

Eco-friendly polycarbonate resin composition and molded article formed therefrom

[0001] The present invention relates to an eco-friendly polycarbonate resin composition and a molded article formed therefrom. More specifically, the present invention relates to a polycarbonate resin composition having excellent eco-friendliness, (thin film) flame retardancy, chemical resistance, impact resistance, and a balance of these physical properties, and a molded article formed therefrom.

[0002]

[0003] Various electronics manufacturers are using materials incorporating recycled plastics as part of eco-friendly marketing strategies to enhance consumer interest as well as improve device specifications; more recently, there is a growing need to use recycled materials to achieve carbon neutrality. Among these recycled materials, there is a growing trend to use eco-friendly products made with recycled polycarbonate resin, as the quality of recycled polycarbonate resin is relatively better managed compared to other high-heat-resistant plastics.

[0004] However, it is difficult to stably supply high-quality recycled polycarbonate resin, leading to situations where low-quality recycled polycarbonate resin mixed with polymethyl methacrylate (PMMA), which is easily confused with polycarbonate resin in appearance, must be used. Since such PMMA-mixed recycled polycarbonate resin can cause a decline in flame retardancy, chemical resistance, and impact resistance, it is difficult to apply it to applications such as electronic device housings that require high impact resistance or thin-film flame retardant properties.

[0005] Therefore, there is a need to develop a recycled polycarbonate resin composition that is eco-friendly by applying recycled polycarbonate resin, and which exhibits excellent (thin film) flame retardancy, chemical resistance, impact resistance, and a balance of these physical properties even when using recycled materials.

[0006] The background technology of the present invention is disclosed in Korean Published Patent No. 10-2022-0056273, etc.

[0007]

[0008] The objective of the present invention is to provide a polycarbonate resin composition having excellent eco-friendliness, (thin film) flame retardancy, chemical resistance, impact resistance, and a balance of these physical properties.

[0009] Another objective of the present invention is to provide a molded article formed from the polycarbonate resin composition.

[0010] The above and other objectives of the present invention can all be achieved by the present invention described below.

[0011]

[0012] 1. One aspect of the present invention relates to a polycarbonate resin composition. The polycarbonate resin composition comprises about 100 parts by weight of a base resin comprising about 1 to about 96 parts by weight of a polycarbonate resin, about 2 to about 90 parts by weight of a regenerated polycarbonate resin containing polymethyl methacrylate, and about 2 to about 97 parts by weight of a polysiloxane-polycarbonate copolymer resin; about 1 to about 15 parts by weight of a phosphazene compound; about 0.3 to about 3 parts by weight of a phenylmethylsiloxane compound; and about 0.1 to about 2 parts by weight of a polydimethylsiloxane having terminal reactive groups having a kinematic viscosity of about 5 to about 200 cSt measured at 40°C according to ASTM D445.

[0013] 2. In the above 1 embodiment, the recycled polycarbonate resin may be a recycled polycarbonate resin derived from an automobile headlamp having a polymethyl methacrylate content of about 0.1 to about 50 weight%.

[0014] 3. In the above 1 or 2 embodiments, the polycarbonate-polysiloxane copolymer resin may comprise about 70 to about 99 weight% of a polycarbonate block and about 1 to about 30 weight% of a polysiloxane block.

[0015] 4. In the above 1 to 3 embodiments, the phosphazene compound may be a cyclic phosphazene compound.

[0016] 5. In the above 1 to 4 embodiments, the phenylmethylsiloxane compound may have a kinematic viscosity of about 5 to about 5,000 cSt as measured at 25°C according to ASTM D445.

[0017] 6. In the above 1 to 5 embodiments, the terminal reactive group of the polydimethylsiloxane having the terminal reactive group may include one or more of a hydroxyl group, an epoxy group, and a maleic anhydride group.

[0018] 7. In the above 1 to 6 embodiments, the weight ratio of the sum of the recycled polycarbonate resin, the phosphazene compound, and the phenylmethylsiloxane compound (recycled polycarbonate resin : phosphazene compound + phenylmethylsiloxane compound) may be about 1 : 0.05 to about 1 : 2.5.

[0019] 8. In the above 1 to 7 embodiments, the weight ratio of the phosphazene compound and the phenylmethylsiloxane compound may be about 1:0.03 to about 1:1.

[0020] 9. In the above 1 to 8 embodiments, the weight ratio of the phenylmethylsiloxane compound and the polydimethylsiloxane having terminal reactive groups may be about 1:0.1 to about 1:3.

[0021] 10. In the above 1 to 9 embodiments, the polycarbonate resin composition may have a flame retardancy of V-1 or higher on a 0.6 mm thick specimen measured by the UL-94 vertical test method.

[0022] 11. In the above 1 to 10 embodiments, the polycarbonate resin composition may have a fracture height of about 40 cm or more when a specimen with a thickness of 2 mm is immersed in a thinner solution for 2 minutes and 30 seconds, dried at 80°C for 20 minutes, left at room temperature for 24 hours, and then impacted by a drop weight evaluation device using a Dupont drop test method with a weight of 2 kg.

[0023] 12. In the above 1 to 11 embodiments, the polycarbonate resin composition may have a notched Izod impact strength of about 50 kgf·cm / cm or more of a 1 / 8" thick specimen measured according to ASTM D256.

[0024] 13. Another aspect of the present invention relates to a molded article. The molded article is characterized by being formed from a polycarbonate resin composition according to any one of 1 to 12.

[0025]

[0026] The present invention has the effect of providing a polycarbonate resin composition having excellent eco-friendliness, (thin film) flame retardancy, chemical resistance, impact resistance, and a balance of these physical properties, and a molded article formed therefrom.

[0027]

[0028] The present invention will be described in detail below.

[0029] The polycarbonate resin composition according to the present invention is characterized by comprising (A) a polycarbonate resin; (B) a regenerated polycarbonate resin; (C) a polysiloxane-polycarbonate copolymer resin; (D) a phosphazene compound; (E) a polymethylsiloxane compound; and (F) a polydimethylsiloxane having terminal reactive groups.

[0030] In this specification, "a to b" indicating a numerical range is defined as "≥a and ≤b".

[0031]

[0032] (A) Polycarbonate resin

[0033] As the polycarbonate resin according to one embodiment of the present invention, a polycarbonate resin used in conventional thermoplastic resin compositions may be used. For example, an aromatic polycarbonate resin prepared by reacting diphenols (aromatic diol compounds) with a carbonate precursor such as phosgene, halogen formate, or carbonate diester may be used.

[0034] In a specific example, the above diphenols may be exemplified as 4,4'-biphenol, 2,2-bis(4-hydroxyphenyl)propane, 2,4-bis(4-hydroxyphenyl)-2-methylbutane, 1,1-bis(4-hydroxyphenyl)cyclohexane, 2,2-bis(3-chloro-4-hydroxyphenyl)propane, 2,2-bis(3,5-dichloro-4-hydroxyphenyl)propane, 2,2-bis(3-methyl-4-hydroxyphenyl)propane, 2,2-bis(3,5-dimethyl-4-hydroxyphenyl)propane, etc., but are not limited thereto. For example, 2,2-bis(4-hydroxyphenyl)propane, 2,2-bis(3,5-dichloro-4-hydroxyphenyl)propane, 2,2-bis(3-methyl-4-hydroxyphenyl)propane, 2,2-bis(3,5-dimethyl-4-hydroxyphenyl)propane, or 1,1-bis(4-hydroxyphenyl)cyclohexane may be used, and specifically, 2,2-bis(4-hydroxyphenyl)propane called bisphenol-A may be used.

[0035] In a specific example, examples of the carbonate precursors include dimethyl carbonate, diethyl carbonate, dibutyl carbonate, dicyclohexyl carbonate, diphenyl carbonate, ditoryl carbonate, bis(chlorophenyl)carbonate, m-cresyl carbonate, dinaphthyl carbonate, carbonyl chloride (phosgene), diphosgene, triphosgene, carbonyl bromide, bishaloformate, etc. These may be used individually or in a mixture of two or more.

[0036] The above polycarbonate resin may be used having branched chains, and may be prepared, for example, by adding about 0.05 to about 2 mol% of a trivalent or higher polyfunctional compound, specifically a compound having a trivalent or higher phenolic group, to the total amount of diphenols used in the polymerization.

[0037] The above polycarbonate resin can be used in the form of a homopolycarbonate resin, a copolycarbonate resin, or a blend thereof. In addition, the above polycarbonate resin may be partially or entirely replaced with an aromatic polyester-carbonate resin obtained by polymerizing in the presence of an ester precursor, for example, a difunctional carboxylic acid.

[0038] In a specific example, the polycarbonate resin may have a weight-average molecular weight (Mw) measured by gel permeation chromatography (GPC) of about 10,000 to about 200,000 g / mol, for example, about 15,000 to about 40,000 g / mol. Within this range, the mechanical properties, heat resistance, etc. of the polycarbonate resin composition may be excellent.

[0039] In a specific example, the polycarbonate resin may be included in an amount of about 1 to about 96 weight%, for example, about 1 to about 60 weight%, of a base resin (A+B+C) comprising (A) polycarbonate resin, (B) recycled polycarbonate resin, and (C) polysiloxane-polycarbonate copolymer resin, in an amount of about 1 to about 96 weight%. If the amount falls outside this range, there is a risk that the eco-friendliness, chemical resistance, impact resistance, fluidity, etc., of the thermoplastic resin composition may be reduced.

[0040]

[0041] (B) Recycled polycarbonate resin

[0042] A recycled polycarbonate resin according to one embodiment of the present invention is a recycled material capable of imparting eco-friendliness, and can be applied together with polycarbonate resin, polysiloxane-polycarbonate copolymer resin, phosphazene compound, polymethylsiloxane compound and polydimethylsiloxane having terminal reactive groups, etc., to improve the eco-friendliness, (thin film) flame retardancy, chemical resistance, impact resistance, and the balance of physical properties thereof of a polycarbonate resin composition, and a recycled polycarbonate resin containing polymethyl methacrylate can be used.

[0043] In a specific example, the recycled polycarbonate resin may be a recycled polycarbonate resin derived from an automobile headlamp having a polymethyl methacrylate content of about 0.1 to about 50 weight%.

[0044] In a specific example, the recycled polycarbonate resin may have a melt flow index (MI) of about 5 to about 35 g / 10 min, for example, about 10 to about 30 g / 10 min, measured according to ASTM D1238 at 300°C and a 1.2 kg load. Within this range, the mechanical properties and fluidity of the polycarbonate resin composition may be excellent.

[0045] In a specific example, the recycled polycarbonate resin may be included in an amount of about 2 to about 90 weight%, for example, about 5 to about 85 weight%, of 100 weight% of the base resin. If the content of the recycled polycarbonate resin is less than about 2 weight% of 100 weight% of the base resin, the content of the recycled material is below the range of the present invention and does not satisfy the eco-friendly conditions of the present invention, and if it exceeds about 90 weight%, there is a risk that the chemical resistance, impact resistance, etc. of the polycarbonate resin composition may be reduced.

[0046]

[0047] (C) Polysiloxane-polycarbonate copolymer resin

[0048] A polysiloxane-polycarbonate copolymer resin according to one embodiment of the present invention is applied together with a polycarbonate resin, a recycled polycarbonate resin, a phosphazene compound, a polymethylsiloxane compound, and a polydimethylsiloxane having terminal reactive groups, etc., to improve the eco-friendliness, (thin film) flame retardancy, chemical resistance, impact resistance, and the balance of physical properties thereof of a polycarbonate resin composition, and comprises a polycarbonate block and a polysiloxane block. For example, it may be a triblock copolymer of a polycarbonate block / polysiloxane block / polycarbonate block, but is not limited thereto.

[0049] In a specific example, the polysiloxane-polycarbonate copolymer resin may be a polysiloxane-polycarbonate copolymer resin prepared by reacting a siloxane compound represented by the following chemical formula 1, an aromatic dihydroxy compound, and a carbonate precursor.

[0050] [Chemical Formula 1]

[0051]

[0052] In the above formula 1, R1 and R2 are each independently a C1-C10 alkyl group, a C6-C18 aryl group, or a C1-C10 alkyl group or a C6-C18 aryl group having a halogen atom or an alkoxy group; A is each independently a substituted or unsubstituted C2-C20 hydrocarbon group, or a substituted or unsubstituted C2-C20 hydrocarbon group having -O- or -S-; Y is each independently a hydrogen atom, a halogen atom, a C1-C18 alkyl halide group, a cyano group (-CN), or an ester group; and m can be 2 to 1,000, for example 4 to 120, specifically 10 to 100.

[0053] In a specific example, the aromatic dihydroxy compound (diphenol) may be an aromatic dihydroxy compound used in the manufacture of conventional polycarbonate resins, such as 4,4'-biphenol, 2,2-bis(4-hydroxyphenyl)propane, 2,4-bis(4-hydroxyphenyl)-2-methylbutane, 1,1-bis(4-hydroxyphenyl)cyclohexane, 2,2-bis(3-chloro-4-hydroxyphenyl)propane, 2,2-bis(3,5-dichloro-4-hydroxyphenyl)propane, etc., but is not limited thereto. Specifically, 2,2-bis(4-hydroxyphenyl)propane, 2,2-bis(3,5-dichloro-4-hydroxyphenyl)propane, 1,1-bis(4-hydroxyphenyl)cyclohexane, etc. can be used, and preferably, 2,2-bis(4-hydroxyphenyl)propane, also known as bisphenol A, can be used.

[0054] In a specific example, the carbonate precursor may be exemplified as phosgene, triphosgene, diaryl carbonate, mixtures thereof, etc. Additionally, the diaryl carbonate may be exemplified as diphenyl carbonate, ditoryl carbonate, bis(chlorophenyl) carbonate, m-cresyl carbonate, dinaphthyl carbonate, bis(diphenyl) carbonate, diethyl carbonate, dimethyl carbonate, dibutyl carbonate, dicyclohexyl carbonate, etc., but is not limited thereto. These may be used alone or in combination of two or more, and for example, diphenyl carbonate, etc. may be used.

[0055] In a specific example, the polycarbonate-polysiloxane copolymer may comprise about 70 to about 99 weight%, for example, about 80 to about 97 weight% of a polycarbonate block derived from the aromatic dihydroxy compound, and about 1 to about 30 weight%, for example, about 3 to about 25 weight% of a polysiloxane block derived from the siloxane compound. Within this range, the impact resistance, chemical resistance, flame retardancy, etc. of the polycarbonate resin composition may be excellent.

[0056] In a specific example, the polycarbonate-polysiloxane copolymer may have a weight-average molecular weight (Mw) measured by gel permeation chromatography (GPC) of about 10,000 to about 50,000 g / mol, for example, about 15,000 to about 40,000 g / mol. Within this range, the impact resistance, chemical resistance, (thin film) flame retardancy, moldability, etc. of the polycarbonate resin composition may be excellent.

[0057] In a specific example, the polycarbonate-polysiloxane copolymer can be prepared by conventional methods. For example, the aromatic dihydroxy compound, carbonate precursor, and siloxane compound can be copolymerized using interfacial condensation polymerization, emulsion polymerization, etc. Additionally, a commercially available product may be used as the polycarbonate-polysiloxane copolymer.

[0058] In a specific example, the polysiloxane-polycarbonate copolymer resin may be included in an amount of about 2 to about 97 weight%, for example, about 5 to about 90 weight%, of 100 weight% of the base resin. If the content of the polysiloxane-polycarbonate copolymer resin is less than about 2 weight% of 100 weight% of the base resin, there is a risk that the chemical resistance, impact resistance, etc. of the polycarbonate resin composition may be reduced.

[0059]

[0060] (D) Phosphazene compound

[0061] A phosphazene compound according to one embodiment of the present invention can be applied together with polycarbonate resin, recycled polycarbonate resin, polysiloxane-polycarbonate copolymer resin, polymethylsiloxane compound, and polydimethylsiloxane having terminal reactive groups, and can improve the eco-friendliness, (thin film) flame retardancy, chemical resistance, impact resistance, and balance of physical properties of the polycarbonate resin composition, and for example, a cyclic phosphazene compound may be used.

[0062] In a specific example, the phosphazene compound may be a compound represented by the following chemical formula 2.

[0063] [Chemical Formula 2]

[0064]

[0065] In the above formula 2, R1, R2, R3, R4, R5, and R6 are each independently a hydrogen atom, a halogen atom, a substituted or unsubstituted alkyl group having 1 to 20 carbon atoms, a substituted or unsubstituted alkenyl group having 2 to 7 carbon atoms, a substituted or unsubstituted cycloalkyl group having 3 to 20 carbon atoms, a substituted or unsubstituted heterocycloalkyl group having 2 to 20 carbon atoms, an alkoxy group having 1 to 20 carbon atoms, an aryl group having 6 to 20 carbon atoms, an aryloxy group having 6 to 20 carbon atoms, a heteroaryl group having about 5 to about 20 carbon atoms, a substituted or unsubstituted alkoxycarbonylalkyl group having 3 to 20 carbon atoms, a substituted or unsubstituted carbonylalkyl group having 2 to 10 carbon atoms, an amino group, or a hydroxyl group.

[0066] Here, the term "substitution" means that a hydrogen atom is substituted with a substituent such as an alkyl group having 1 to 10 carbon atoms, a halogen atom, a nitro group, a cyano group, a hydroxyl group, an amino group, an aryl group having 6 to 10 carbon atoms, a cycloalkyl group having 3 to 10 carbon atoms, a heterocycloalkyl group having 3 to 10 carbon atoms, a heteroaryl group having 4 to 10 carbon atoms, or a combination thereof.

[0067] In addition, the substituents comprising the "alkyl," "alkoxy," and other "alkyl" portions include both straight-chain and pulverized forms, the "alkenyl" includes both straight-chain and pulverized forms having 2 to 8 carbon atoms and containing one or more double bonds, and the "cycloalkyl" includes both saturated monocyclic or saturated bicyclic ring structures having 3 to 20 carbon atoms. The "aryl" is an organic radical derived from an aromatic hydrocarbon by the removal of one hydrogen atom and comprises a single or fused ring system having 4 to 7, preferably 5 or 6, ring atoms in each ring, suitably. Specifically, examples may include, but are not limited to, phenyl, naphthyl, biphenyl, tolyl, etc.

[0068] The above "heterocycloalkyl" refers to a cycloalkyl group comprising 1 to 3 heteroatoms selected from N, O, and S as saturated cyclic hydrocarbon backbone atoms, wherein the remaining saturated monocycloalkyl or bicyclic ring backbone atoms are carbon, and includes pyrrolidinyl, azetidinyl, pyrazolidinyl, oxazolidinyl, piperidinyl, piperazinyl, morpholinyl, thiomophorinyl, thiazolidinyl, hydantoinyl, valerolactamil, oxiranil, oxetanil, dioxolanil, dioxanil, oxathionil, oxatianil, dithianil, dihydrofuranil, tetrahydrofuranil, dihydropyranil, tetrahydropyranil, tetrahydropyridinyl, tetrahydropyrimidinyl, tetrahydrothiophenyl, tetrahydrothiopyranil, diazepanil, and azepanil Examples of the back can be given.

[0069] The above "heteroaryl" refers to an aryl group comprising one to three heteroatoms selected from N, O, and S as aromatic ring backbone atoms, wherein the remaining aromatic ring backbone atoms are carbons. The heteroaryl group comprises a divalent aryl group in which the heteroatoms within the ring are oxidized or quaternized to form, for example, N-oxide or a quaternary salt. Specifically, examples may include, but are not limited to, furyl, thiophenyl, pyrrolyl, pyranyl, imidazolyl, pyrazolyl, thiazolyl, thiadiazolyl, isothiazolyl, isoxazolyl, oxazolyl, oxadiazolyl, triazinyl, tetrazinyl, triazolyl, tetrazolyl, furazanyl, pyridyl, pyrazinyl, pyrimidinyl, pyridazinyl, etc.

[0070] In a specific example, the phosphazene compound may be included in an amount of about 1 to about 15 parts by weight, for example, about 4 to about 12 parts by weight, with respect to about 100 parts by weight of the base resin. If the content of the phosphazene compound is less than about 1 part by weight with respect to about 100 parts by weight of the base resin, there is a risk that the (thin film) flame retardancy of the polycarbonate resin composition may be reduced, and if it exceeds about 15 parts by weight, there is a risk that the chemical resistance, impact resistance, etc. of the polycarbonate resin composition may be reduced.

[0071]

[0072] (E) Phenylmethylsiloxane compound

[0073] A phenylmethylsiloxane compound according to one embodiment of the present invention can be applied together with polycarbonate resin, recycled polycarbonate resin, polysiloxane-polycarbonate copolymer resin, phosphazene compound, and polydimethylsiloxane having terminal reactive groups, and can improve the eco-friendliness, (thin film) flame retardancy, chemical resistance, impact resistance, and balance of physical properties of the polycarbonate resin composition, and liquid phenylmethylsiloxane-based flame retardants can be used.

[0074] In a specific example, the phenylmethylsiloxane compound may have a kinematic viscosity of about 5 to about 5,000 cSt, for example, about 10 to about 100 cSt, measured at 25°C according to ASTM D445. Within this range, the fluidity of the polycarbonate resin composition may be excellent.

[0075] In a specific example, the phenylmethylsiloxane compound may be included in an amount of about 0.3 to about 3 parts by weight, for example, about 0.5 to about 2 parts by weight, per about 100 parts by weight of the base resin. If the content of the phenylmethylsiloxane compound is less than about 0.3 parts by weight per about 100 parts by weight of the base resin, there is a risk that the (thin film) flame retardancy, impact resistance, etc. of the polycarbonate resin composition may be reduced, and if it exceeds about 3 parts by weight, there is a risk that the chemical resistance, impact resistance, etc. of the polycarbonate resin composition may be reduced.

[0076] In a specific example, the weight ratio of the sum of the recycled polycarbonate resin, the phosphazene compound, and the phenylmethylsiloxane compound (recycled polycarbonate resin : phosphazene compound + phenylmethylsiloxane compound) may be about 1 : 0.05 to about 1 : 2.5, for example, about 1 : 0.08 to about 1 : 2.5, specifically about 1 : 0.1 to about 1 : 1.9. Within the above range, the flame retardancy, chemical resistance, impact resistance, etc. of the polycarbonate resin composition (thin film) may be superior.

[0077] In a specific example, the weight ratio of the phosphazene compound and the phenylmethylsiloxane compound may be about 1:0.03 to about 1:1, for example, about 1:0.05 to about 1:0.5, specifically about 1:0.06 to about 1:0.3. Within this range, the flame retardancy, chemical resistance, impact resistance, etc. of the polycarbonate resin composition (thin film) may be superior.

[0078]

[0079] (F) Polydimethylsiloxane having terminal reactive groups

[0080] A polydimethylsiloxane having terminal reactive groups according to one embodiment of the present invention can be applied together with polycarbonate resin, recycled polycarbonate resin, polysiloxane-polycarbonate copolymer resin, phosphazene compound and polymethylsiloxane compound, etc., to improve the eco-friendliness, (thin film) flame retardancy, chemical resistance, impact resistance, and balance of physical properties of the polycarbonate resin composition. In accordance with ASTM D445, a polydimethylsiloxane having terminal reactive groups having a kinematic viscosity of about 5 to about 200 cSt measured at 40°C can be used.

[0081] In a specific example, the polydimethylsiloxane having the terminal reactive group may have a kinematic viscosity of about 5 to about 200 cSt, for example 10 to 100 cSt, measured at 40°C according to ASTM D445. If the kinematic viscosity of the polydimethylsiloxane having the terminal reactive group falls outside the above range, there is a risk that the thermal stability, moldability, impact resistance, and / or chemical resistance of the polycarbonate resin composition may be reduced.

[0082] In a specific example, the terminal reactive group of the polydimethylsiloxane having the terminal reactive group may include one or more of a hydroxyl group, an epoxy group, and a maleic anhydride group.

[0083] In a specific example, the polydimethylsiloxane having the terminal reactive group may be included in an amount of about 0.1 to about 2 parts by weight, for example, about 0.3 to about 1.5 parts by weight, per about 100 parts by weight of the base resin. If the content of the polydimethylsiloxane having the terminal reactive group is less than about 0.1 parts by weight per about 100 parts by weight of the base resin, there is a risk that the flame retardancy, chemical resistance, impact resistance, etc. of the polycarbonate resin composition (thin film) will be reduced, and if it exceeds about 2 parts by weight, there is a risk that the impact resistance, etc. of the polycarbonate resin composition will be reduced.

[0084] In a specific example, the weight ratio of the phenylmethylsiloxane compound and the polydimethylsiloxane having terminal reactive groups may be about 1:0.1 to about 1:3, for example, about 1:0.2 to about 1:2, for example, about 1:0.25 to about 1:1.5. Within the above range, the flame retardancy, chemical resistance, impact resistance, etc. of the polycarbonate resin composition (thin film) may be superior.

[0085]

[0086] A polycarbonate resin composition according to one embodiment of the present invention may further include conventional additives as needed. Examples of such additives include antioxidants, release agents, lubricants, nucleating agents, antistatic agents, stabilizers, pigments, dyes, mixtures thereof, etc. When using such additives, the content may be about 0.001 to about 10 parts by weight per about 100 parts by weight of the base resin, but is not limited thereto.

[0087]

[0088] A polycarbonate resin composition according to one embodiment of the present invention can be prepared by a known method for preparing a polycarbonate resin composition. For example, after mixing the above components and, if necessary, other additives, the composition can be prepared in the form of pellets by melt-extruding using a conventional twin-screw extruder at about 200 to about 300°C, for example, about 250 to about 280°C.

[0089] In a specific example, the polycarbonate resin composition may have a flame retardancy of V-1 or higher, for example, V-0 or V-1, of a 0.6 mm thick specimen measured by the UL-94 vertical test method.

[0090] In a specific example, the polycarbonate resin composition may have a thickness of 2 mm, which is immersed in a thinner solution for 2 minutes and 30 seconds, dried at 80°C for 20 minutes, left at room temperature for 24 hours, and then impacted by a drop weight evaluation device using a Dupont drop test method with a weight of 2 kg, so that the height at which the specimen breaks is about 40 cm or more, for example, about 40 to about 80 cm.

[0091] In a specific example, the polycarbonate resin composition may have a notched Izod impact strength of about 50 kgf·cm / cm or more, for example, about 51 to about 80 kgf·cm / cm, of a 1 / 8" thick specimen measured according to ASTM D256.

[0092]

[0093] The molded article according to the present invention is formed from the polycarbonate resin composition. For example, the polycarbonate resin composition can be used to manufacture various molded articles (products) through various molding methods such as injection molding, extrusion molding, vacuum molding, and casting molding. Such molding methods are well known to those skilled in the art to which the present invention pertains. Since the molded article exhibits excellent eco-friendliness, (thin film) flame retardancy, chemical resistance, impact resistance, and a balance of these physical properties, it is particularly useful as an interior or exterior material for (mobile) electrical / electronic products.

[0094]

[0095] Hereinafter, the structure and operation of the present invention will be explained in more detail through preferred embodiments of the present invention. However, these are presented as preferred examples of the present invention and should not be interpreted in any way as limiting the present invention.

[0096]

[0097] Examples

[0098] The specifications of each component used in the following examples and comparative examples are as follows.

[0099] (A) Polycarbonate resin

[0100] Bisphenol-A-based polycarbonate resin (weight-average molecular weight (Mw): approximately 22,000 g / mol) was used.

[0101] (B) Recycled polycarbonate resin

[0102] Recycled polycarbonate resin derived from automotive headlamps (PMMA content: 20 wt%, MI: 20±5 g / 10 min) was used.

[0103] (C) Polysiloxane-polycarbonate copolymer resin

[0104] A polysiloxane-polycarbonate copolymer resin with a polydimethylsiloxane (PDMS) content of 6 wt% and a weight-average molecular weight (Mw) of about 22,000 g / mol was used.

[0105] (D) Phosphazene compound

[0106] A cyclic phosphazene compound (Manufacturer: Pharmicell Co. Ltd., Product name: Phoretar 201) was used.

[0107] (E) Phenylmethylsiloxane compound

[0108] A liquid phenylmethylsiloxane compound (Manufacturer: Momentive, Product name: SFR320, Kinematic viscosity: approximately 80 cSt) was used.

[0109] (F) Polydimethylsiloxane

[0110] (F1) Polydimethylsiloxane having terminal reactive groups (hydroxyl groups) (kinematic viscosity: about 40 cSt) was used.

[0111] (F2) Polydimethylsiloxane (Manufacturer: Momentive, Product name: PDMS-200, Kinematic viscosity: approximately 40 cSt) was used.

[0112]

[0113] Examples 1 to 10 and Comparative Examples 1 to 9

[0114] Each of the above components was added in the amounts listed in Tables 1, 2, 3, and 4 below, and pellets were prepared by extrusion at approximately 280°C. A twin-screw extruder with L / D=36 and a diameter of 45 mm was used for extrusion. The prepared pellets were dried at 80°C for at least 5 hours, and then injection molded in a 6 oz injection molding machine (molding temperature: approximately 310°C) to produce specimens. The physical properties of the prepared specimens were evaluated by the following method, and the results are shown in Tables 1, 2, 3, and 4 below.

[0115]

[0116] Methods for measuring physical properties

[0117] (1) Flame resistance: The flame resistance of a 0.6 mm thick specimen was measured using the UL-94 vertical test method.

[0118] (2) Evaluation of chemical resistance (impact resistance after coating): A 2 mm thick specimen was immersed in a thinner solution for 2 minutes and 30 seconds, dried at 80°C for 20 minutes, left at room temperature for 24 hours, and then subjected to a drop test using a 2 kg weight, and the height at which the specimen broke (unit: cm) was measured.

[0119] (3) Notched Izod impact strength (unit: kgf·cm / cm): The notched Izod impact strength of a 1 / 8" thick specimen was measured according to ASTM D256.

[0120]

[0121] Example 12345(A) (Weight%) 1010101010(B) (Weight%) 3535353535(C) (Weight%) 55555555555(D) (Parts by weight) 481288(E) (Parts by weight) 1110.52(F1) (Parts by weight) 0.50.50.50.50.50.5(F2) (Parts by weight)-----Flame Retardancy V-1 V-0 V-0 V-0 V-0 Specimen Break Height (cm) 6255515551 Notch Izod Impact Strength (kgf·cm / cm) 6260586357

[0122] * Parts by weight: Parts by weight relative to 100 parts by weight of base resin (A+B+C)

[0123]

[0124] Example 678910(A) (Weight%) 10101605(B) (Weight%) 353584355(C) (Weight%) 555515590(D) (Parts by weight) 88888(E) (Parts by weight) 11111(F1) (Parts by weight) 0.31.50.50.50.50.5(F2) (Parts by weight)-----Flame Retardancy V-0V-0V-0V-0V-0 Specimen Break Height (cm) 5065424975 Notch Izod Impact Strength (kgf·cm / cm) 6067515558

[0125] * Parts by weight: Parts by weight relative to 100 parts by weight of base resin (A+B+C)

[0126]

[0127] Comparative Example 1234(A) (Weight%) 1221010(B) (Weight%) 91773535(C) (Weight%) 81555(D) (Parts by weight) 880.520(E) (Parts by weight) 1111(F1) (Parts by weight) 0.50.50.50.50.5(F2) (Parts by weight) ---- Flame Retardancy V-1 V-1 HB V-0 Specimen Fracture Height (cm) 1510658 Notched Izod Impact Strength (kgf·cm / cm) 1010609

[0128] * Parts by weight: Parts by weight relative to 100 parts by weight of base resin (A+B+C)

[0129]

[0130] Comparative Example 56789(A) (Weight%) 1010101010(B) (Weight%) 3535353535(C) (Weight%) 5555555555(D) (Parts by weight) 88888(E) (Parts by weight) 0.14111(F1) (Parts by weight) 0.50.50.013-(F2) (Parts by weight) 0.5 Flame retardancy V-2V-0V-2V-0V-1 Specimen fracture height (cm) 5210184534 Notch Izod impact strength (kgf·cm / cm) 51684355

[0131] * Parts by weight: Parts by weight relative to 100 parts by weight of base resin (A+B+C)

[0132]

[0133] From the above results, it can be seen that the polycarbonate resin composition according to the present invention is excellent in terms of eco-friendliness (containing at least 2% by weight of recycled polycarbonate resin in 100% by weight of base resin), flame retardancy (flame retardancy), chemical resistance (specimen fracture height), and impact resistance (notched Izod impact strength).

[0134] On the other hand, in Comparative Example 1, where the content of recycled polycarbonate resin exceeds the range of the present invention, it can be seen that chemical resistance, impact resistance, etc. are reduced, and in Comparative Example 2, where the content of polysiloxane-polycarbonate copolymer resin is less than the range of the present invention, it can be seen that chemical resistance, impact resistance, etc. are reduced. In Comparative Example 3, where the content of phosphazene compound is less than the range of the present invention, it can be seen that (thin film) flame retardancy, etc. is reduced, and in Comparative Example 4, where the content of phosphazene compound exceeds the range of the present invention, it can be seen that chemical resistance, impact resistance, etc. are reduced. In Comparative Example 5, where the content of polymethylsiloxane compound is less than the range of the present invention, it can be seen that (thin film) flame retardancy, etc. is reduced, and in Comparative Example 6, where the content of polymethylsiloxane compound exceeds the range of the present invention, it can be seen that chemical resistance, impact resistance, etc. are reduced. In addition, in Comparative Example 7, where the content of polydimethylsiloxane having terminal reactive groups is less than the range of the present invention, it can be seen that the flame retardancy, chemical resistance, impact resistance, etc. (thin film) is reduced, and in Comparative Example 8, where the content of polydimethylsiloxane having terminal reactive groups exceeds the range of the present invention, it can be seen that the impact resistance, etc. is reduced. In addition, in Comparative Example 9, where polydimethylsiloxane (F2) is applied instead of the polydimethylsiloxane having terminal reactive groups of the present invention, it can be seen that the chemical resistance, etc. is reduced.

[0135]

[0136] The present invention has been described above with reference to embodiments. Those skilled in the art will understand that the present invention may be embodied in modified forms without departing from the essential characteristics of the invention. Therefore, the disclosed embodiments should be considered in an illustrative rather than a restrictive sense. The scope of the invention is defined by the claims, not by the foregoing description, and all variations within the scope of equivalents should be interpreted as being included in the invention.

Claims

1. About 100 parts by weight of a base resin comprising about 1 to about 96 weight% of a polycarbonate resin, about 2 to about 90 weight% of a recycled polycarbonate resin containing polymethyl methacrylate, and about 2 to about 97 weight% of a polysiloxane-polycarbonate copolymer resin; About 1 to about 15 parts by weight of a phosphazene compound; About 0.3 to about 3 parts by weight of a phenylmethylsiloxane compound; and A polycarbonate resin composition characterized by comprising about 0.1 to about 2 parts by weight of a polydimethylsiloxane having terminal reactive groups, having a kinematic viscosity of about 5 to about 200 cSt measured at 40°C according to ASTM D445.

2. A polycarbonate resin composition according to claim 1, characterized in that the recycled polycarbonate resin is a recycled polycarbonate resin derived from an automobile headlamp having a polymethyl methacrylate content of about 0.1 to about 50 weight%.

3. A polycarbonate resin composition according to claim 1 or 2, characterized in that the polycarbonate-polysiloxane copolymer resin comprises about 70 to about 99 weight% of a polycarbonate block and about 1 to about 30 weight% of a polysiloxane block.

4. A polycarbonate resin composition characterized in that, in any one of claims 1 to 3, the phosphazene compound is a cyclic phosphazene compound.

5. A polycarbonate resin composition according to any one of claims 1 to 4, wherein the phenylmethylsiloxane compound has a kinematic viscosity of about 5 to about 5,000 cSt as measured at 25°C in accordance with ASTM D445.

6. A polycarbonate resin composition according to any one of claims 1 to 5, characterized in that the terminal reactive group of the polydimethylsiloxane having the terminal reactive group comprises one or more of a hydroxyl group, an epoxy group, and a maleic anhydride group.

7. A polycarbonate resin composition characterized in that, in any one of claims 1 to 6, the weight ratio of the sum of the recycled polycarbonate resin, the phosphazene compound, and the phenylmethylsiloxane compound is about 1:0.05 to about 1:2.

5.

8. A polycarbonate resin composition characterized in that, in any one of claims 1 to 7, the weight ratio of the phosphazene compound and the phenylmethylsiloxane compound is about 1:0.03 to about 1:

1.

9. A polycarbonate resin composition characterized in that, in any one of claims 1 to 8, the weight ratio of the phenylmethylsiloxane compound and the polydimethylsiloxane having terminal reactive groups is about 1:0.1 to about 1:

3.

10. A polycarbonate resin composition according to any one of claims 1 to 9, characterized in that the polycarbonate resin composition has a flame retardancy of V-1 or higher for a 0.6 mm thick specimen measured by the UL-94 vertical test method.

11. A polycarbonate resin composition according to any one of claims 1 to 10, wherein the height at which a specimen is destroyed, measured by impacting a specimen with a thickness of 2 mm with a drop weight evaluation device using a Dupont drop test method with a weight of 2 kg, is about 40 cm or more.

12. A polycarbonate resin composition according to any one of claims 1 to 11, characterized in that the polycarbonate resin composition has a notched Izod impact strength of about 50 kgf·cm / cm or more of a 1 / 8" thick specimen measured according to ASTM D256.

13. A molded article formed from a polycarbonate resin composition according to any one of claims 1 to 12.

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