阅读说明：本技术 聚碳酸酯共聚物 (Polycarbonate copolymer ) 是由 常守秀幸 今里健太 山中克浩 于 2018-06-20 设计创作，主要内容包括：本发明提供一种比重低且具有高表面硬度的聚碳酸酯共聚物。本发明的聚碳酸酯共聚物含有下述式(1-1)或(1-2)所示的单元(A)和下述式(3)所示的单元(B)。(式(1-1)中,R<Sub>1</Sub>和R<Sub>2</Sub>各自独立地表示氢原子、碳原子数1～10的可以含有芳香族基团的烃基或卤素原子。Y表示由下述式(2)构成的二价的有机残基。)(式(2)中,C<Sub>m</Sub>表示亚环烷基,m表示3～20的整数。另外,R<Sub>3</Sub>表示氢原子、卤素原子、碳原子数1～20的烷基或碳原子数3～20的环烷基,n表示1～10的整数。)(式(1-2)中,R<Sub>1</Sub>’和R<Sub>2</Sub>’各自独立地表示氢原子、碳原子数1～10的可以含有芳香族基团的烃基或卤素原子。W表示单键、碳原子、氧原子或硫原子。)(式(3)中,R<Sub>4</Sub>、R<Sub>5</Sub>、R<Sub>6</Sub>、R<Sub>7</Sub>各自独立地表示氢原子、卤素原子、碳原子数1～20的烷基或碳原子数3～20的环烷基。)。<Image he="941" wi="700" file="DDA0002356658550000011.GIF" imgContent="drawing" imgFormat="GIF" orientation="portrait" inline="no"></Image>(The present invention provides a polycarbonate copolymer having a low specific gravity and a high surface hardness. The polycarbonate copolymer of the present invention contains a unit (A) represented by the following formula (1-1) or (1-2) and a unit (B) represented by the following formula (3). (in the formula (1-1), R 1 And R 2 Each independently represents a hydrogen atom, a hydrocarbon group having 1 to 10 carbon atoms which may contain an aromatic group, or a halogen atom. Y represents a divalent organic residue represented by the following formula (2). ) (in the formula (2), C m Represents a cycloalkylene group, m represents 3 to 20An integer number. In addition, R 3 Represents a hydrogen atom, a halogen atom, an alkyl group having 1 to 20 carbon atoms or a cycloalkyl group having 3 to 20 carbon atoms, and n represents an integer of 1 to 10. ) (in the formula (1-2), R 1 ' and R 2 ' each independently represents a hydrogen atom, a hydrocarbon group having 1 to 10 carbon atoms which may contain an aromatic group, or a halogen atom. W represents a single bond, a carbon atom, an oxygen atom or a sulfur atom. ) (in the formula (3), R 4 、R 5 、R 6 、R 7 Each independently represents a hydrogen atom, a halogen atom, an alkyl group having 1 to 20 carbon atoms, or a cycloalkyl group having 3 to 20 carbon atoms. ).)

1. A polycarbonate copolymer comprising a unit (A) represented by the following formula (1-1) or (1-2) and a unit (B) represented by the following formula (3):

in the formula (1-1), R₁And R₂Each independently represents a hydrogen atom, a hydrocarbon group having 1 to 10 carbon atoms which may contain an aromatic group, or a halogen atom, Y represents a divalent organic residue represented by the following formula (2),

in the formula (2), C_mRepresents a cycloalkylene group, m represents an integer of 3 to 20, and R represents₃Represents a hydrogen atom, a halogen atom, an alkyl group having 1 to 20 carbon atoms or a cycloalkyl group having 3 to 20 carbon atoms, n represents an integer of 1 to 10,

in the formula (1-2), R₁' and R₂' each independently represents a hydrogen atom, a hydrocarbon group having 1 to 10 carbon atoms which may contain an aromatic group, or a halogen atom, W represents a single bond, a carbon atom, an oxygen atom or a sulfur atom,

in the formula (3), R₄、R₅、R₆、R₇Each independently represents a hydrogen atom, a halogen atom, an alkyl group having 1 to 20 carbon atoms, or a cycloalkyl group having 3 to 20 carbon atoms.

2. The polycarbonate copolymer according to claim 1, wherein the number average molecular weight as converted to polystyrene by gel permeation chromatography is in the range of 10000 to 100000, and the molecular weight distribution Mw/Mn is in the range of 1.5 to 3.5.

3. The polycarbonate copolymer according to claim 1 or 2, wherein the dihydroxy compound from which the unit (B) is derived is a cis-trans isomer mixture, and the cis isomer ratio in the mixture is 50% or more.

4. The polycarbonate copolymer as claimed in any one of claims 1 to 3, wherein APHA, which is the degree of blackness when the dihydroxy compound from which the unit (B) is derived is melted at 220 ℃ in a nitrogen atmosphere, is 100 or less.

5. The polycarbonate copolymer as claimed in any one of claims 1 to 4, wherein the viscosity average molecular weight is 10000 to 40000.

6. The polycarbonate copolymer according to any one of claims 1 to 5, which comprises a unit represented by the following formula (4) as the unit (A),

in the formula (4), R₈、R₉Each independently represents a hydrogen atom, a C1-10 hydrocarbon group which may contain an aromatic group, or a halogen atom, R₁₀Represents a hydrogen atom, a halogen atom, an alkyl group having 1 to 20 carbon atoms or a cycloalkyl group having 3 to 20 carbon atoms, and p represents an integer of 1 to 10.

7. The polycarbonate copolymer according to any one of claims 1 to 6, wherein a unit derived from 1, 1-bis (4-hydroxyphenyl) -3,3, 5-trimethylcyclohexane is contained as the unit (A).

8. The polycarbonate copolymer according to any one of claims 1 to 5, wherein a unit derived from 6,6 '-dihydroxy-3, 3, 3', 3 '-tetramethyl-1, 1' -spirobiindan is contained as the unit (A).

9. The polycarbonate copolymer according to any one of claims 1 to 8, wherein a unit derived from 2,2,4, 4-tetramethyl-1, 3-cyclobutanediol is contained as the unit (B).

10. The polycarbonate copolymer according to any one of claims 1 to 9, further comprising at least 1 constituent unit derived from a diol having a cyclic acetal structure, wherein the diol has an aliphatic dihydroxy compound, an alicyclic dihydroxy compound, an oxyalkylene diol, or a cyclic acetal structure.

11. The polycarbonate copolymer as claimed in claim 1, which comprises a unit (A) represented by the formula (1-1) and a unit (B) represented by the formula (2) as main constituent units, and the molar ratio A/B of the unit (A) to the unit (B) is 5/95 to 50/50.

12. The polycarbonate copolymer according to claim 1, which comprises a unit (A) represented by the formula (1-2) and a unit (B) represented by the formula (2) as main constituent units, has a glass transition temperature of 126 to 175 ℃, and has a specific gravity of 1.10 or less as measured by a method described in JIS 7112.

13. A resin molded article comprising the polycarbonate copolymer according to any one of claims 1 to 12.

14. An automobile interior part or an automobile exterior part comprising the resin molded article according to claim 13.

15. A method for producing a polycarbonate copolymer according to any one of claims 1 to 12, comprising an ester interchange reaction between a dihydroxy compound and a carbonic acid diester in the presence of an alkali metal catalyst and/or an alkaline earth metal catalyst, wherein the alkali metal catalyst and/or the alkaline earth metal catalyst is used in an amount in the range of 0.1 to 500. mu. mol based on 1 mol of the dihydroxy compound.

Technical Field

The present invention relates to a polycarbonate copolymer and a polycarbonate resin composition which are suitably used for producing an automotive interior part such as an in-vehicle display, an automobile navigation system, an automobile audio system, a console panel, an instrument panel or a door trim, and an exterior part such as a head lamp lens, a rear door, a bumper, a fender, a door handle, a sign, a glass window or an outer panel of a motorcycle. More specifically, the present invention provides a novel polycarbonate copolymer and a polycarbonate resin composition having excellent surface hardness, heat resistance, weather resistance and solvent resistance and a low specific gravity.

Background

In recent years, in the field of automobiles, there is a growing need to make automobile parts lighter for the purpose of reducing carbon dioxide emissions and improving fuel efficiency. In particular, polycarbonate resin having excellent transparency, heat resistance and impact resistance can be used as a resin glazing instead of glass, and since the glass has a lower specific gravity than glass, has a high degree of freedom in shape by selecting a processing method such as injection molding, and can integrate a plurality of members, weight reduction of a vehicle body, design of a vehicle body appearance, and improvement in productivity can be expected.

On the other hand, a molded article molded using a polycarbonate resin has the following disadvantages: the surface is soft and therefore easily scratched, and if the composition is used outdoors for a long period of time, it is easily yellowed by sunlight, and the chemical resistance to organic solvents such as gasoline is poor.

Therefore, as automobiles become more lightweight, there is a need for a polycarbonate resin having a low specific gravity and excellent surface hardness, weather resistance and chemical resistance while maintaining excellent transparency and heat resistance which are possessed by conventional polycarbonate resins.

In addition, polycarbonate copolymers of 2,2,4, 4-tetramethyl-1, 3-cyclobutanediol (hereinafter referred to as TMCB) and an aliphatic diol or a bisphenol have been reported (patent documents 1 to 5). Polycarbonates having structural units derived from TMCB are excellent in heat resistance and surface hardness, but when bisphenols are copolymerized, they have difficulties in weatherability and solvent resistance. In addition, copolymerization with an aliphatic diol has a problem of poor heat resistance and surface hardness, although excellent in weather resistance.

Disclosure of Invention

The purpose of the present invention is to provide a polycarbonate copolymer and a polycarbonate resin composition which have excellent surface hardness, heat resistance, weather resistance and solvent resistance and a low specific gravity. Further, an object of the present invention is to provide a polycarbonate resin composition which is particularly suitable for automotive interior and exterior parts.

The present inventors have made extensive studies and as a result, have surprisingly found that the above object can be achieved by using a polycarbonate copolymer containing a specific structural unit even in a polycarbonate resin. The present invention has been completed as a result of studies based on this situation.

That is, according to the present invention, the following (configurations 1) to 15) are provided.

(constitution 1)

A polycarbonate copolymer comprising a unit (A) represented by the following formula (1-1) or (1-2) and a unit (B) represented by the following formula (3):

(in the formula (1-1), R₁And R₂Each independently represents a hydrogen atom, a hydrocarbon group having 1 to 10 carbon atoms which may contain an aromatic group, or a halogen atom. Y represents a divalent organic residue represented by the following formula (2). )

(in the formula (2), C_mRepresents a cycloalkylene group, and m represents an integer of 3 to 20. In addition, R₃Represents a hydrogen atom, a halogen atom, an alkyl group having 1 to 20 carbon atoms or a cycloalkyl group having 3 to 20 carbon atoms, and n represents an integer of 1 to 10. )

(in the formula (1-2), R₁' and R₂' each independently represents a hydrogen atom, a hydrocarbon group having 1 to 10 carbon atoms which may contain an aromatic group, or a halogen atom. W represents a single bond, a carbon atom, an oxygen atom or a sulfur atom. )

(in the formula (3), R₄、R₅、R₆、R₇Each independently represents a hydrogen atom, a halogen atom, an alkyl group having 1 to 20 carbon atoms, or a cycloalkyl group having 3 to 20 carbon atoms. ).

(constitution 2)

The polycarbonate copolymer according to constitution 1, wherein the number average molecular weight in terms of polystyrene by gel permeation chromatography is in the range of 10000 to 100000, and the molecular weight distribution (Mw/Mn) is in the range of 1.5 to 3.5.

(constitution 3)

The polycarbonate copolymer according to constitution 1 or 2, wherein the dihydroxy compound from which the unit (B) is derived is a cis-trans isomer mixture, and the cis isomer ratio in the mixture is 50% or more.

(constitution 4)

The polycarbonate copolymer according to any one of constitutions 1 to 3, wherein a degree of blackness (APHA) when the dihydroxy compound from which the unit (B) is derived is melted at 220 ℃ in a nitrogen atmosphere is 100 or less.

(constitution 5)

The polycarbonate copolymer according to any one of constitutions 1 to 4, wherein the viscosity average molecular weight is 10000 to 40000.

(constitution 6)

The polycarbonate copolymer according to any one of constitutions 1 to 5, which comprises a unit represented by the following formula (4) as a unit (A).

(in the formula (4), R₈、R₉Each independently represents a hydrogen atom, a hydrocarbon group having 1 to 10 carbon atoms which may contain an aromatic group, or a halogen atom. R₁₀Represents a hydrogen atom, a halogen atom, an alkyl group having 1 to 20 carbon atoms or a cycloalkyl group having 3 to 20 carbon atoms, and p represents an integer of 1 to 10. )

(constitution 7)

The polycarbonate copolymer according to any one of constitutions 1 to 6, which comprises a unit derived from 1, 1-bis (4-hydroxyphenyl) -3,3, 5-trimethylcyclohexane as the unit (A).

(constitution 8)

The polycarbonate copolymer according to any one of constitutions 1 to 5, which comprises a unit derived from 6,6 '-dihydroxy-3, 3, 3', 3 '-tetramethyl-1, 1' -spirobiindan as the unit (A).

(constitution 9)

The polycarbonate copolymer according to any one of constitutions 1 to 8, which comprises a unit derived from 2,2,4, 4-tetramethyl-1, 3-cyclobutanediol as a unit (B).

(constitution 10)

The polycarbonate copolymer according to any one of constitutions 1 to 9, further comprising at least 1 constituent unit derived from at least one compound selected from the group consisting of an aliphatic dihydroxy compound, an alicyclic dihydroxy compound, an oxyalkylene glycol, and a diol having a cyclic acetal structure.

(constitution 11)

The polycarbonate copolymer according to constitution 1, which comprises a unit (A) represented by the formula (1-1) and a unit (B) represented by the formula (2) as main constituent units, and the molar ratio (A/B) of the unit (A) to the unit (B) is 5/95 to 50/50.

(constitution 12)

The polycarbonate copolymer according to constitution 1, which comprises a unit (A) represented by formula (1-2) and a unit (B) represented by formula (2) as main constituent units, has a glass transition temperature of 126 to 175 ℃ and a specific gravity of 1.10 or less as measured by the method described in JIS 7112.

(constitution 13)

A resin molded article comprising the polycarbonate copolymer described in any one of constitutions 1 to 12.

(constitution 14)

An automotive interior part or an automotive exterior part comprising the resin molded article of constitution 13.

(constitution 15)

A method for producing a polycarbonate copolymer according to any one of constitutions 1 to 12, comprising an ester interchange reaction between a dihydroxy compound and a carbonic acid diester in the presence of an alkali metal catalyst and/or an alkaline earth metal catalyst, wherein the alkali metal catalyst and/or the alkaline earth metal catalyst is used in an amount in the range of 0.1 to 500. mu. mol based on 1 mol of the dihydroxy compound.

The polycarbonate copolymer of the present invention is excellent in surface hardness, heat resistance, weather resistance and solvent resistance and has a low specific gravity, and therefore, is suitably used for automotive interior parts and automotive exterior parts. Therefore, the industrial effect is particularly excellent.

Detailed Description

The present invention will be described in detail below.

< polycarbonate copolymer >

The polycarbonate copolymer of the present invention comprises a unit (A) represented by the following formula (1-1) or (1-2) and a unit (B) represented by the following formula (3):

(in the formula (1-1), R₁And R₂Each independently represents a hydrogen atom, a hydrocarbon group having 1 to 10 carbon atoms which may contain an aromatic group, or a halogen atom. Y represents a divalent organic residue represented by the following formula (2). )

(in the formula (2), C_mRepresents a cycloalkylene group, and m represents an integer of 3 to 20. In addition, R₃Represents a hydrogen atom, a halogen atom, an alkyl group having 1 to 20 carbon atoms or a cycloalkyl group having 3 to 20 carbon atoms, and n represents an integer of 1 to 10. )

(in the formula (1-2), R₁' and R₂' each independently represents a hydrogen atom, a hydrocarbon group having 1 to 10 carbon atoms which may contain an aromatic group, or a halogen atom. W represents a single bond, a carbon atom, an oxygen atom or sulfurAn atom. )

(in the formula (3), R₄、R₅、R₆、R₇Each independently represents a hydrogen atom, a halogen atom, an alkyl group having 1 to 20 carbon atoms, or a cycloalkyl group having 3 to 20 carbon atoms. ).

The present inventors have found that a polycarbonate copolymer comprising a unit (A) having the formula (1-1) or the formula (1-2) and a unit (B) represented by the formula (3) is excellent in surface hardness, heat resistance, weather resistance and solvent resistance and has a low specific gravity. Polycarbonate copolymers having such characteristics cannot be obtained in the prior art, and the polycarbonate copolymer of the present invention is very useful.

Although a polycarbonate copolymer containing the unit (B) has been known in the past, it has not been known that the specific gravity is low when the polycarbonate copolymer contains the unit (B). Therefore, it is unexpected that the polycarbonate copolymer of the present invention containing the unit (B) has a low specific gravity.

In general, it is known that a polycarbonate copolymer containing a large amount of aliphatic moieties has excellent weather resistance but low heat resistance, and a polycarbonate copolymer containing a large amount of aromatic moieties has excellent heat resistance but low weather resistance. Further, it is known that a polycarbonate copolymer having a bisphenol skeleton tends to have poor solvent resistance when a structure in which 2 phenols are linked is aliphatic.

However, it is unexpected that the polycarbonate copolymer containing the unit (A) and the unit (B) is excellent in the balance among weather resistance, heat resistance and solvent resistance, and that the polycarbonate copolymer of the present invention has high surface hardness.

In a first aspect, the polycarbonate copolymer of the present invention contains, as main constituent units, a unit (A) represented by the following formula (1-1) and a unit (B) represented by the following formula (3):

(in the formula (1-1), R₁And R₂Each independently represents a hydrogen atom, a hydrocarbon group having 1 to 10 carbon atoms which may contain an aromatic group, or a halogen atom. Y represents a single bond or a divalent organic residue represented by the following formula (2). )

(in the formula (2), C_mRepresents a cycloalkylene group, and m represents an integer of 3 to 20. In addition, R₃Represents a hydrogen atom, a halogen atom, an alkyl group having 1 to 20 carbon atoms or a cycloalkyl group having 3 to 20 carbon atoms, and n represents an integer of 1 to 10. )

(in the formula (3), R₄、R₅、R₆、R₇Each independently represents a hydrogen atom, a halogen atom, an alkyl group having 1 to 20 carbon atoms, or a cycloalkyl group having 3 to 20 carbon atoms. ).

In a second embodiment, the polycarbonate copolymer of the present invention comprises, as main constituent units, a unit (A) represented by the following formula (1-2) and a unit (B) represented by the following formula (3):

(in the formula (1-2), R₁' and R₂' each independently represents a hydrogen atom, a hydrocarbon group having 1 to 10 carbon atoms which may contain an aromatic group, or a halogen atom. W represents a single bond, a carbon atom, an oxygen atom or a sulfur atom. )

(in the formula (3), R₃、R₄、R₅、R₆Each independently represents a hydrogen atom, a halogen atom, or carbonAn alkyl group having 1 to 20 carbon atoms or a cycloalkyl group having 3 to 20 carbon atoms. ).

In a third embodiment, the polycarbonate copolymer of the present invention comprises, as main constituent units, the unit (A) represented by the above formula (1-1), the unit (A) represented by the above formula (1-2), and the unit (B) represented by the above formula (3). These constituent elements can be referred to the following descriptions of the first and second embodiments.

Here, "mainly" means that the total carbonate constituent unit excluding the terminal is preferably 70 mol% or more, more preferably 80 mol% or more, further preferably 90 mol% or more, particularly preferably 95 mol% or more, and most preferably 100 mol% of the total carbonate constituent unit.

(Unit (A))

The unit (A) represented by the formula (1-1) wherein R is₁And R₂Each independently represents a hydrogen atom, a hydrocarbon group having 1 to 10 carbon atoms which may contain an aromatic group, or a halogen atom. R₁And R₂Each independently preferably represents a hydrogen atom or an alkyl group having 1 to 6 carbon atoms, more preferably a hydrogen atom or an alkyl group having 1 to 3 carbon atoms, and most preferably a hydrogen atom.

In the above formula (2), wherein C is_mRepresents a cycloalkylene group having 3 to 20 carbon atoms. Preferably a cycloalkylene group having 3 to 15 carbon atoms, more preferably a cycloalkylene group having 3 to 12 carbon atoms, still more preferably a cycloalkylene group having 4 to 8 carbon atoms, and most preferably a cyclohexylene group having 6 carbon atoms.

In the above formula (2), R₃Represents a hydrogen atom, a halogen atom, an alkyl group having 1 to 20 carbon atoms or a cycloalkyl group having 3 to 20 carbon atoms, and n represents an integer of 1 to 10. R₃Preferably a hydrogen atom or an alkyl group having 1 to 6 carbon atoms, and more preferably a methyl group. n is preferably 1 to 5, more preferably 1 to 3.

As the unit (A) represented by the formula (1-1), a unit represented by the above formula (4) is preferable, wherein R is₈And R₉Each independently preferably represents a hydrogen atom or an alkyl group having 1 to 6 carbon atoms, more preferably a hydrogen atom or an alkyl group having 1 to 3 carbon atoms, and most preferably a hydrogen atom.

Examples of the dihydric phenol from which the unit (A) represented by the formula (1-1) is derived include 1, 1-bis (4-hydroxyphenyl) cyclopentane, 1-bis (4-hydroxyphenyl) cyclohexane, 1-bis (4-hydroxyphenyl) cyclododecane, 1-bis (4-hydroxy-3-methylphenyl) cyclohexane, 1-bis (4-hydroxyphenyl) -4-methylcyclohexane, 1-bis (4-hydroxyphenyl) -3,3, 5-trimethylcyclohexane, 1-bis (4-hydroxy-3-methylphenyl) -3,3, 5-trimethylcyclohexane, 1-bis (4-hydroxyphenyl) -4-isopropylcyclohexane, And 1, 1-bis (3-cyclohexyl-4-hydroxyphenyl) cyclohexane, and the like. The most suitable dihydric phenol is 1, 1-bis (4-hydroxyphenyl) -3,3, 5-trimethylcyclohexane. These dihydric phenols may be used in combination of two or more.

The unit (A) represented by the formula (1-2) wherein R is₁' and R₂' each independently represents a hydrogen atom, a hydrocarbon group having 1 to 10 carbon atoms which may contain an aromatic group, or a halogen atom. Examples of the hydrocarbon group include an alkyl group having 1 to 10 carbon atoms, a cycloalkyl group having 5 to 10 carbon atoms, an aryl group having 6 to 10 carbon atoms, an aralkyl group having 7 to 10 carbon atoms, and an alkenyl group having 1 to 10 carbon atoms. Examples of the halogen atom include a fluorine atom, a chlorine atom, and a bromine atom. R₁' and R₂' independently of each other, a hydrogen atom or an alkyl group having 1 to 6 carbon atoms is preferable, a hydrogen atom or an alkyl group having 1 to 3 carbon atoms is more preferable, and a hydrogen atom is most preferable. W represents a single bond, a carbon atom, an oxygen atom or a sulfur atom, and more preferably a single bond.

The dihydroxy compound from which the unit (a) of the second embodiment is derived is preferably 6,6 '-dihydroxy-3, 3, 3', 3 '-tetramethyl-1, 1' -spirobiindane or spirobicyclohexane, and most preferably 6,6 '-dihydroxy-3, 3, 3', 3 '-tetramethyl-1, 1' -spirobiindane.

(Unit (B))

The unit (B) is represented by the formula (3) above, wherein R is₄、R₅、R₆、R₇Each independently represents a hydrogen atom, a halogen atom, an alkyl group having 1 to 20 carbon atoms, or a cycloalkyl group having 3 to 20 carbon atoms. R₄、R₅、R₆、R₇Each independently preferably represents a hydrogen atom, an alkyl group having 1 to 6 carbon atoms, or a cycloalkane having 3 to 6 carbon atomsMore preferably methyl.

Examples of the dihydroxy compound from which the unit (B) is derived include 2-methyl-1, 3-cyclobutanediol, 2, 4-dimethyl-1, 3-cyclobutanediol, 2,4, 4-tetramethyl-1, 3-cyclobutanediol, 2-ethyl-1, 3-cyclobutanediol, 2, 4-diethyl-1, 3-cyclobutanediol, and 2,2,4, 4-tetrabutyl-1, 3-cyclobutanediol. The most preferred dihydroxy compound is 2,2,4, 4-tetramethyl-1, 3-cyclobutanediol. These dihydroxy compounds may be used in combination of two or more.

The dihydroxy compound from which unit (B) is derived is typically a mixture of cis-trans isomers. Although the ratio is not limited, the cis isomer ratio is preferably 50% or more, more preferably 60% or more, and still more preferably 70% or more. When the cis-isomer ratio is not less than the above ratio, the obtained polycarbonate copolymer has good impact resistance, and can be preferably used in applications requiring impact resistance. Japanese Kokoku publication Sho-39-1546 discloses that when the trans-isomer content is 50% or less, decomposition is less likely to occur during molding and an excellent resin molded article is easily obtained. The cis-trans isomer ratio can be calculated by measuring the cis-trans isomer ratio by proton NMR of JNM-AL400 manufactured by electronic official Japan.

The black color (APHA) of the dihydroxy compound from which the unit (B) is derived when it is melted at 220 ℃ under a nitrogen atmosphere is preferably 100 or less, more preferably 80 or less, and still more preferably 60 or less. When the degree of blackness is less than the above value, the polymer is preferable because the color tone is good and the transparency is excellent.

The diol compound from which the other copolymerized constituent unit is derived may be either an aliphatic diol compound or an alicyclic diol compound, and examples thereof include the diol compounds described in pamphlet of international publication No. 2004/111106 and pamphlet of international publication No. 2011/021720, oxyalkylene glycols such as diethylene glycol, triethylene glycol, tetraethylene glycol, and polyethylene glycol, and diols having a cyclic acetal structure.

Examples of the aliphatic diol compound include 1, 3-propanediol, 1, 4-butanediol, 1, 5-pentanediol, 1, 6-hexanediol, 1, 8-octanediol, 1, 9-nonanediol, 1, 10-decanediol, 1, 12-dodecanediol, 2-methyl-1, 3-propanediol, neopentyl glycol, 3-methyl-1, 5-pentanediol, 2-n-butyl-2-ethyl-1, 3-propanediol, 2-diethyl-1, 3-propanediol, 2, 4-diethyl-1, 5-pentanediol, 1, 2-hexanediol, 1, 2-octanediol, 2-ethyl-1, 3-hexanediol, 2, 3-diisobutyl-1, 3-propanediol, 2-diisoamyl-1, 3-propanediol, 2-methyl-2-propyl-1, 3-propanediol, and the like. These dihydric phenols may be used in combination of two or more.

Examples of the alicyclic diol compound include cyclohexanedimethanol, tricyclodecanedimethanol, adamantanediol, pentacyclopentadecane dimethanol, 3, 9-bis (2-hydroxy-1, 1-dimethylethyl) -2,4,8, 10-tetraoxaspiro [5.5] undecane, and the like. These dihydric phenols may be used in combination of two or more.

Examples of the oxyalkylene glycol include diethylene glycol, triethylene glycol, tetraethylene glycol, and polyethylene glycol. These compounds may be used alone in 1 kind, or may be used in combination in 2 or more kinds.

Examples of the diol having a cyclic acetal structure include spiroglycol and diethylene glycol

Alkylene glycols, and the like.

The above-mentioned exemplary compound is an example of the dihydroxy compound that can be used as a constituent unit of the polycarbonate copolymer in the present invention, and is not limited to any of these.

(composition)

The polycarbonate copolymer of the present invention contains a unit (A) and a unit (B), and the molar ratio (A/B) of the units (A) to (B) may be 5/95 to 50/50. A molar ratio (A/B) in the range of 5/95 to 50/50 is preferable from the viewpoint of heat resistance, weather resistance, etc. The molar ratio (A/B) of the unit (A) to the unit (B) is preferably 10/80 to 50/50, more preferably 20/80 to 50/50. The molar ratio (A/B) of the unit (A) to the unit (B) is more preferably 10/90 to 40/60, and still more preferably 15/85 to 35/65. When the unit (a) is in such a range, the balance of heat resistance, surface hardness, weather resistance, chemical resistance, and the like tends to be favorable. The molar ratio (A/B) can be calculated by measuring the molar ratio by proton NMR of JNM-AL400 manufactured by Kokai electronic division, Japan.

In the third embodiment, the molar ratio of the unit (A) represented by the formula (1-1) to the unit (A) represented by the formula (1-2) is not particularly limited, and may be 5/95 to 95/5, 10/90 to 90/10, 20/80 to 80/20, 30/70 to 70/30, or 40/60 to 60/40.

When an aliphatic dihydroxy compound, an alicyclic dihydroxy compound, an oxyalkylene glycol, or a diol having a cyclic acetal structure is further copolymerized, the copolymerization ratio of these dihydroxy compounds is not particularly limited, and may be selected at an arbitrary ratio. These copolymerized units are preferably 30 mol% or less, more preferably 20 mol% or less, further preferably 10 mol% or less, and particularly preferably 5 mol% or less, of 100 mol% of all carbonate constituent units excluding the terminal.

(method for producing polycarbonate copolymer)

The polycarbonate copolymer of the present invention is produced by a reaction method known per se for producing a usual polycarbonate resin, for example, a method of reacting a carbonate precursor such as a carbonic acid diester with a dihydroxy component. Next, basic means of these manufacturing methods will be briefly described.

The transesterification reaction using a carbonic diester as a carbonate precursor substance is carried out by the following method: an aromatic dihydroxy component and a carbonic acid diester in a predetermined ratio are stirred while heating in an inert gas atmosphere, and the produced alcohol or phenol is distilled off. The reaction temperature varies depending on the boiling point of the alcohol or phenol to be produced, and is usually within a range of 120 to 300 ℃. The reaction is completed by distilling off the alcohol or phenol produced under reduced pressure from the initial stage. Further, a chain terminator, an antioxidant and the like may be added as necessary.

Examples of the carbonic acid diester used for the transesterification reaction include esters such as aryl and aralkyl groups having 6 to 12 carbon atoms which may be substituted. Specific examples thereof include diphenyl carbonate, ditolyl carbonate, bis (chlorophenyl) carbonate and m-cresyl carbonate. Among them, diphenyl carbonate is particularly preferable. The amount of diphenyl carbonate used is preferably 0.97 to 1.10 mol, more preferably 1.00 to 1.06 mol, based on 1 mol of the total of dihydroxy compounds.

In the melt polymerization method, a polymerization catalyst may be used in order to increase the polymerization rate, and examples of the polymerization catalyst include alkali metal compounds, alkaline earth metal compounds, nitrogen-containing compounds, metal compounds, and the like.

As such a compound, an organic acid salt, an inorganic salt, an oxide, a hydroxide, a hydride, an alkoxide, a quaternary ammonium hydroxide, or the like of an alkali metal or an alkaline earth metal can be preferably used, and these compounds may be used alone or in combination.

Examples of the alkali metal compound include sodium hydroxide, potassium hydroxide, cesium hydroxide, lithium hydroxide, sodium hydrogen carbonate, sodium carbonate, potassium carbonate, cesium carbonate, lithium carbonate, sodium acetate, potassium acetate, cesium acetate, lithium acetate, sodium stearate, potassium stearate, cesium stearate, lithium stearate, sodium borohydride, sodium benzoate, potassium benzoate, cesium benzoate, lithium benzoate, disodium hydrogen phosphate, dipotassium hydrogen phosphate, dilithium hydrogen phosphate, disodium phenyl phosphate, disodium salt, dipotassium salt, dicesium salt, dilithium salt, sodium salt, potassium salt, cesium salt, and lithium salt of phenol.

Examples of the alkaline earth metal compound include magnesium hydroxide, calcium hydroxide, strontium hydroxide, barium hydroxide, magnesium carbonate, calcium carbonate, strontium carbonate, barium carbonate, magnesium diacetate, calcium diacetate, strontium diacetate, and barium diacetate.

Examples of the nitrogen-containing compound include quaternary ammonium hydroxides having an alkyl group, an aryl group, and the like, such as tetramethylammonium hydroxide, tetraethylammonium hydroxide, tetrapropylammonium hydroxide, tetrabutylammonium hydroxide, and trimethylbenzylammonium hydroxide. Further, tertiary amines such as triethylamine, dimethylbenzylamine and triphenylamine, and imidazoles such as 2-methylimidazole, 2-phenylimidazole and benzimidazole may be mentioned. Further, there may be exemplified an alkali or basic salt such as ammonia, tetramethylammonium borohydride, tetrabutylammonium tetraphenylborate and tetraphenylammonium tetraphenylborate.

Examples of the metal compound include a zinc-aluminum compound, a germanium compound, an organotin compound, an antimony compound, a manganese compound, a titanium compound, and a zirconium compound. These compounds may be used in combination of 1 or 2 or more.

The amount of the polymerization catalyst to be used is preferably 0.1 to 500. mu. mol, more preferably 0.5 to 300. mu. mol, and still more preferably 1 to 100. mu. mol, based on 1 mol of the dihydroxy component.

In addition, a catalyst deactivator may be added at the latter stage of the reaction. As the catalyst deactivator to be used, known catalyst deactivators can be effectively used, but among them, ammonium salts of sulfonic acids, and the like are preferable,

And (3) salt. Further preferred is tetrabutyl dodecylbenzenesulfonate

Salts of dodecylbenzenesulfonic acid such as dodecyl benzene sulfonate, and salts of p-toluenesulfonic acid such as tetrabutylammonium p-toluenesulfonic acid.

Further, as the ester of sulfonic acid, methyl benzenesulfonate, ethyl benzenesulfonate, butyl benzenesulfonate, octyl benzenesulfonate, phenyl benzenesulfonate, methyl p-toluenesulfonate, ethyl p-toluenesulfonate, butyl p-toluenesulfonate, octyl p-toluenesulfonate, phenyl p-toluenesulfonate and the like can be preferably used. Among them, tetrabutyl dodecylbenzenesulfonate is most preferably used

And (3) salt.

When at least 1 kind of polymerization catalyst selected from the group consisting of alkali metal compounds and/or alkaline earth metal compounds is used, the amount of the catalyst deactivator may be preferably 0.5 to 50 mol, more preferably 0.5 to 10 mol, and still more preferably 0.8 to 5 mol based on 1 mol of the catalyst.

(number average molecular weight)

The number average molecular weight (Mn) of the polycarbonate copolymer of the present invention may be 10000 or more, 15000 or more, 18000 or more, or 20000 or more, 100000 or less, 80000 or less, 50000 or less, 30000 or less, 20000 or less, or 18000 or less. Similarly, the weight average molecular weight (Mw) may be 15000 or more, 20000 or more, 30000 or more, or 50000 or more, and may be 200000 or less, 150000 or less, 100000 or less, 80000 or less, 50000 or less, or 30000 or less. Further, the molecular weight distribution (Mw/Mn) may be 1.5 or more, 1.8 or more, 2.0 or more, or 2.3 or more, and may be 3.5 or less, 3.0 or less, 2.5 or less, or 2.3 or less. Here, the number average molecular weight (Mn) and the weight average molecular weight (Mw) are values obtained in terms of polystyrene based on a Gel Permeation Chromatography (GPC) method. Specifically, the following measurement apparatus and measurement conditions were used:

the measuring machine comprises: HLC-8220GPC made by Tosoh

Column: shodex KF-G + KF-805 Lx 2 root + KF-800D

Eluent: THF (tetrahydrofuran)

Temperature: column thermostat 40.0 deg.C

Flow rate: 1.0mL/min

Concentration: 0.1 wt/vol%

Injection amount: 100 μ L

Pretreatment: filtering with 0.2 μm filter

A detector: differential Refractometer (RI)

(viscosity average molecular weight)

The viscosity average molecular weight (Mv) of the polycarbonate copolymer of the present invention is preferably 10000 to 40000, more preferably 12000 to 35000, and further preferably 15000 to 30000. When the viscosity average molecular weight is not less than the lower limit, sufficient toughness and impact resistance tend to be obtained. Further, when the viscosity average molecular weight is not more than the above upper limit, a high molding temperature is not required, and a special molding method is not required, so that the general applicability tends to be excellent. Further, the decrease in melt viscosity may make it easy to eliminate the dependence on the injection rate, thereby improving the yield of defective appearance and the like.

The viscosity average molecular weight of the polycarbonate copolymer of the present invention is calculated by the following formula from a solution obtained by dissolving 0.7g of a polycarbonate resin in 100ml of methylene chloride at 20 ℃ using an Ostwald viscometerSpecific viscosity (η)_SP)，

Specific viscosity (η)_SP)＝(t-t₀)/t₀

[t₀The number of seconds of methylene chloride falling, and t is the number of seconds of sample solution falling]

From the determined specific viscosity (η)_SP) The viscosity average molecular weight Mv was calculated by the following equation.

η_SP/c＝[η]+0.45×[η]²c (wherein, [ η ]]To intrinsic viscosity)

[η]＝1.23×10^-4Mv^0.83

c＝0.7

(glass transition temperature)

The polycarbonate copolymer of the present invention shows a single glass transition temperature (hereinafter abbreviated as Tg) when subjected to Differential Scanning Calorimetry (DSC). The Tg is preferably 125 to 175 ℃, more preferably 130 to 160 ℃. In addition, Tg may be 126 to 175 ℃, preferably 128 to 170 ℃, more preferably 130 to 160 ℃. When the glass transition temperature (Tg) is not lower than the lower limit, the heat resistance is sufficient, and when it is not higher than the upper limit, the moldability is good, so that it is preferable.

Tg can be measured by using DSC model 2910 manufactured by TA Instruments Japan, at a temperature rising rate of 20 ℃/min.

(specific gravity)

The specific gravity of the polycarbonate copolymer of the present invention is preferably 1.10 or less, more preferably 1.08 or less, and still more preferably 1.06 or less. The specific gravity was measured based on the method for measuring the density and specific gravity of JIS 7112 plastic-non-foamed plastic (method C float-sink method). The smaller the specific gravity is, the more preferable the weight is from the viewpoint of weight reduction.

(Pencil hardness)

The polycarbonate copolymer of the present invention preferably has a pencil hardness of HB or more or F or more. From the viewpoint of excellent scratch resistance, H or more is more preferable, and 2H or more is further preferable. Note that the pencil hardness is 4H or less and has a sufficient function. The pencil hardness can be hardened by increasing the composition ratio of the unit (B) based on the total carbonate units. In the present invention, the pencil hardness is a hardness at which no scratch is left even when a resin is rubbed with a pencil (Hi-uni manufactured by mitsubishi pencil) having a specific pencil hardness after processing the copolymer of the present invention into a plate shape, and it is preferable to use the pencil hardness used in the surface hardness test of a coating film, which can be measured according to JIS K-5600, as an index. The pencil hardness was softened in the order of 9H, 8H, 7H, 6H, 5H, 4H, 3H, 2H, F, HB, B, 2B, 3B, 4B, 5B, 6B, the hardest being 9H, the softest being 6B.

(reagent resistance)

In a reagent resistance test using regular gasoline, the polycarbonate copolymer of the present invention preferably has a limit strain at which solvent cracking occurs of 0.5% or more, more preferably 1.0% or more. If the limit deformation is not less than the above value, the gasoline resistance is good, so that it is preferable. The chemical resistance test was conducted by mounting a test piece (square plate having a thickness of 1 mm) on an oval jig of Peyer 1/4 having different curvatures at each portion, immersing the test piece in ordinary gasoline, and measuring the strain at the end point of crack generation after 1 hour.

(impact resistance)

The polycarbonate copolymer of the present invention has an impact energy of preferably 25J or more, more preferably 30J or more, in a high-speed surface impact test measured in accordance with JIS K7211-2. Furthermore, the fracture mode is preferably ductile fracture. When the impact energy is not less than the above value, the impact resistance is good and the fracture morphology is ductile fracture, which is preferable.

(content of aromatic monohydroxy Compound)

The content of the aromatic monohydroxy compound in the polycarbonate copolymer of the present invention is preferably 1500ppm or less, more preferably 1200ppm or less, and still more preferably 1000ppm or less. The polycarbonate copolymer having a smaller content of the aromatic monohydroxy compound is preferable because the color tone thereof is better. The lower limit is not particularly limited, and is usually 5ppm or more.

< ingredient other than polycarbonate copolymer >

The polycarbonate copolymer of the present invention contains functional agents known per se, such as a mold release agent, a heat stabilizer, an ultraviolet absorber, a flow modifier, and an antistatic agent, within a range not impairing the effects of the present invention.

(i) Release agent

The polycarbonate copolymer of the present invention may be used in combination with a mold release agent within a range not impairing the effects of the present invention. Examples of the release agent include fatty acid esters, polyolefin waxes (polyethylene waxes, 1-olefin polymers, and the like, and those modified with a functional group-containing compound such as acid modification can also be used), fluorine compounds (fluorine oils represented by polyfluoroalkyl ethers, and the like), paraffin waxes, and beeswax. Among these, fatty acid esters are preferable from the viewpoint of availability, releasability, and transparency. The content of the release agent is preferably 0.001 to 2 parts by weight, more preferably 0.005 to 1 part by weight, still more preferably 0.007 to 0.5 part by weight, and particularly preferably 0.01 to 0.3 part by weight based on 100 parts by weight of the polycarbonate copolymer. When the content is not less than the lower limit of the above range, the effect of improving the mold releasability can be clearly exhibited, and when the content is not more than the upper limit, the adverse effect such as mold contamination at the time of molding is preferably reduced.

The fatty acid ester used as a preferable release agent among the above is described in further detail. The fatty acid ester is an ester of an aliphatic alcohol and an aliphatic carboxylic acid. The aliphatic alcohol may be a monohydric alcohol or a dihydric or higher polyhydric alcohol. The number of carbon atoms of the alcohol is preferably in the range of 3 to 32, and more preferably in the range of 5 to 30. Examples of the monohydric alcohol include dodecanol, tetradecanol, hexadecanol, octadecanol, eicosanol, tetracosanol, hexacosanol, and triacontanol. Examples of the polyhydric alcohol include pentaerythritol, dipentaerythritol, tripentaerythritol, polyglycerols (triglycerol to hexaglycerol), ditrimethylolpropane, xylitol, sorbitol, and mannitol. Among the fatty acid esters, polyhydric alcohols are more preferable.

On the other hand, the aliphatic carboxylic acid is preferably an aliphatic carboxylic acid having 3 to 32 carbon atoms, and particularly preferably 10to 22 carbon atoms. Examples of the aliphatic carboxylic acid include saturated aliphatic carboxylic acids such as capric acid, undecanoic acid, lauric acid, tridecanoic acid, myristic acid, pentadecanoic acid, palmitic acid (palmitic acid), margaric acid, stearic acid (stearic acid), nonadecanoic acid, arachic acid, and behenic acid (behenic acid), and unsaturated aliphatic acids such as palmitoleic acid, oleic acid, linoleic acid, linolenic acid, eicosenoic acid, eicosapentaenoic acid, and cetylenic acid. The aliphatic carboxylic acid preferably has 14 to 20 carbon atoms. Among them, saturated aliphatic carboxylic acids are preferable. The aliphatic carboxylic acid is usually produced from natural oils and fats such as animal fats and oils (beef tallow, lard, etc.) and vegetable fats and oils (palm oil, etc.), and therefore, these aliphatic carboxylic acids are usually mixtures containing other carboxylic acid components having different carbon numbers. Therefore, the aliphatic carboxylic acid is also produced from the natural oils and fats, and is composed of a mixture containing other carboxylic acid components. The acid value of the fatty acid ester is preferably 20 or less (may be 0 in practice). However, in the case of a full ester (fullerene), it is preferable to contain not less free fatty acids in order to improve the mold release property, and from this point of view, the acid value of the full ester is preferably in the range of 3 to 15. The iodine value of the fatty acid ester is preferably 10 or less (may be 0 in practice). These properties can be determined by the method specified in JIS K0070.

The fatty acid ester may be any of partial esters and full esters. From the viewpoint of more favorable mold release properties and durability, partial esters are preferable, and monoglycerides are particularly preferable. The monoglyceride is a monoester of glycerin and a fatty acid as a main component, and preferable fatty acids include saturated fatty acids such as stearic acid, palmitic acid, behenic acid, arachidic acid, montanic acid, and lauric acid, unsaturated fatty acids such as oleic acid, linoleic acid, and sorbic acid, and particularly preferable fatty acids include monoglyceride of stearic acid, behenic acid, and palmitic acid as a main component. The fatty acid is synthesized from natural fatty acids, and is a mixture as described above. Even in such a case, the proportion of monoglyceride in the fatty acid ester is preferably 60% by weight or more.

From the viewpoint of thermal stability, partial esters are often inferior to full esters. In order to improve the thermal stability of the partial ester, the partial ester is preferably set to a sodium metal content of less than 20ppm, more preferably less than 5ppm, and still more preferably less than 1 ppm. The fatty acid partial ester having a sodium metal content of less than 1ppm can be produced by producing a fatty acid partial ester by a usual method and then purifying the fatty acid partial ester by molecular distillation or the like.

Specifically, the following methods are mentioned: removing gas components and low boiling point substances by a nozzle type degasser, removing polyol components such as glycerin by using a falling film type distillation device under the conditions of a distillation temperature of 120-150 ℃ and a vacuum degree of 0.01-0.03 kPa, and obtaining high-purity fatty acid partial ester as a distillate component under the conditions of a distillation temperature of 160-230 ℃ and a vacuum degree of 0.01-0.2 Torr by using a centrifugal type molecular distillation device, wherein sodium metal can be removed as a distillation residue. The purity of the obtained distillate component can be further improved by repeating molecular distillation, and a fatty acid partial ester having a smaller sodium metal content can be obtained. It is also important to sufficiently clean the inside of the molecular distillation apparatus in advance by an appropriate method and to prevent the mixing of the sodium metal component from the external environment by improving the airtightness or the like. The fatty acid ester can be obtained from a professional (e.g., riken vitamin co.).

(ii) Phosphorus-based stabilizer

In the polycarbonate copolymer of the present invention, it is preferable to further blend various phosphorus stabilizers for the main purpose of improving the thermal stability during molding. Examples of the phosphorus-based stabilizer include phosphorous acid, phosphoric acid, phosphonous acid, phosphonic acid, and esters thereof. Further, the phosphorus-based stabilizer comprises a tertiary phosphine.

Specific examples of the phosphite compound include triphenyl phosphite, tris (nonylphenyl) phosphite, tridecyl phosphite, trioctyl phosphite, trioctadecyl phosphite, didecylmonophenyl phosphite, dioctylmonophenyl phosphite, diisopropylmonophenyl phosphite, monobutyldiphenyl phosphite, monodecyldiphenyl phosphite, monooctyldiphenyl phosphite, 2-methylenebis (4, 6-di-t-butylphenyl) octyl phosphite, tris (diethylphenyl) phosphite, tris (diisopropylphenyl) phosphite, tris (di-n-butylphenyl) phosphite, tris (2, 4-di-t-butylphenyl) phosphite, tris (2, 6-di-t-butylphenyl) phosphite, distearylpentaerythritol diphosphite, bis (2, 4-di-t-butylphenyl) pentaerythritol diphosphite, bis (2, 6-di-t-butyl-4-methylphenyl) pentaerythritol diphosphite, bis (2, 6-di-t-butyl-4-ethylphenyl) pentaerythritol diphosphite, phenyl bisphenol A pentaerythritol diphosphite, bis (nonylphenyl) pentaerythritol diphosphite, dicyclohexylpentaerythritol diphosphite, and the like.

In addition, as other phosphite compounds, phosphite compounds having a cyclic structure by reacting with diphenols may also be used. Examples thereof include 2,2 '-methylenebis (4, 6-di-t-butylphenyl) (2, 4-di-t-butylphenyl) phosphite, 2' -methylenebis (4, 6-di-t-butylphenyl) (2-t-butyl-4-methylphenyl) phosphite, 2 '-methylenebis (4-methyl-6-t-butylphenyl) (2-t-butyl-4-methylphenyl) phosphite, and 2, 2' -ethylidenebis (4-methyl-6-t-butylphenyl) (2-t-butyl-4-methylphenyl) phosphite.

Examples of the phosphate ester compound include tributyl phosphate, trimethyl phosphate, tricresyl phosphate, triphenyl phosphate, tricresyl phosphate, triethyl phosphate, diphenylcresyl phosphate, diphenylmonoortho-biphenyl phosphate, tributoxyethyl phosphate, dibutyl phosphate, dioctyl phosphate, diisopropyl phosphate, and the like, and triphenyl phosphate and trimethyl phosphate are preferable.

The phosphonite compounds include tetrakis (2, 4-di-tert-butylphenyl) -4,4 '-biphenylene diphosphonite, tetrakis (2, 4-di-tert-butylphenyl) -4, 3' -biphenylene diphosphonite, tetrakis (2, 4-di-tert-butylphenyl) -3,3 '-biphenylene diphosphonite, tetrakis (2, 6-di-tert-butylphenyl) -4, 4' -biphenylene diphosphonite, tetrakis (2, 6-di-tert-butylphenyl) -4,3 '-biphenylene diphosphonite, tetrakis (2, 6-di-tert-butylphenyl) -3, 3' -biphenylene diphosphonite, bis (2, 4-di-tert-butylphenyl) -4-phenyl phosphonite, and mixtures thereof, Bis (2, 4-di-tert-butylphenyl) -3-phenyl-phenylphosphonite, bis (2, 6-di-n-butylphenyl) -3-phenyl-phenylphosphonite, bis (2, 6-di-tert-butylphenyl) -4-phenyl-phenylphosphonite, bis (2, 6-di-tert-butylphenyl) -3-phenyl-phenylphosphonite and the like, preferably tetrakis (di-tert-butylphenyl) -biphenylene diphosphonite, bis (di-tert-butylphenyl) -phenyl-phenylphosphonite, more preferably tetrakis (2, 4-di-tert-butylphenyl) -biphenylene diphosphonite, bis (2, 4-di-tert-butylphenyl) -phenyl-phenylphosphonite. This phosphite compound is preferably used in combination with the above-mentioned phosphite compound having an aryl group substituted with 2 or more alkyl groups.

Examples of the phosphonate compound include dimethyl phenylphosphonate, diethyl phenylphosphonate, dipropyl phenylphosphonate, and the like.

Examples of the tertiary phosphine include triethylphosphine, tripropylphosphine, tributylphosphine, trioctylphosphine, tripentylphosphine, dimethylphenylphosphine, dibutylphenylphosphine, diphenylmethylphosphine, diphenyloctylphosphine, triphenylphosphine, tri-p-tolylphosphine, trinaphthylphosphine, and diphenylbenzylphosphine. A particularly preferred tertiary phosphine is triphenylphosphine.

The phosphorus-based stabilizer may be used not only in 1 kind but also in a mixture of 2 or more kinds. Among the above phosphorus-based stabilizers, phosphite compounds and phosphonite compounds are preferable. Particular preference is given to tris (2, 4-di-tert-butylphenyl) phosphite, tetrakis (2, 4-di-tert-butylphenyl) -4, 4' -biphenylene diphosphonite and bis (2, 4-di-tert-butylphenyl) -phenyl phosphonite. In addition, the use of these in combination with a phosphate compound is also a preferable mode.

(iii) Hindered phenol stabilizers (antioxidants)

The polycarbonate copolymer of the present invention may contain a hindered phenol-based stabilizer mainly for the purpose of improving the heat stability and heat aging resistance during the molding process, for example, α -tocopherol, butylhydroxytoluene, sinapyl alcohol, vitamin E, N-octadecyl- β - (4 '-hydroxy-3', 5 '-di-tert-butylphenyl) propionate, 2-tert-butyl-6- (3' -tert-butyl-5 '-methyl-2' -hydroxybenzyl) -4-methylphenyl acrylate, 2, 6-di-tert-butyl-4- (N, N-dimethylaminomethyl) phenol, 3, 5-di-tert-butyl-4-hydroxybenzylphosphonate diethyl ester, 2 '-methylenebis (4-methyl-6-tert-butylphenol), 2' -methylenebis (4-ethyl-6-tert-butylphenol), 4 '-methylenebis (2, 6-di-tert-butylphenol), 2' -methylenebis (4-methyl-6-cyclohexylphenol), 2 '-dimethylenebis (6-methyl-6-tert-butylphenol), tris (3, 5-butyl-4-2-hydroxy-propylidene) -2, 5-2' -bis (3-di-tert-butyl-4-5-2-hydroxyphenyl) propionate, 3, 5-di-tert-butyl-4-5-methyl-5-butyl-4-methyl-4-butyl-phenyl) propionate, 2, 5-4-tert-5-butyl-methyl-4-butyl-4-methyl-4-phenyl-methyl-4-butyl-phenyl) phenol, 3, 5-methyl-4-methyl-butyl-4-methyl-4-methyl-butyl-4-methyl-4-phenyl-butyl-phenyl-4-methyl-phenyl-butyl-phenyl-4-phenyl ethyl-methyl-phenyl-methyl-phenyl) propionate, 3, 2, 5-tert-methyl-4-butyl-4-methyl-butyl-4-butyl-4-hydroxy-4-butyl-4-hydroxybenzyl-butyl-methyl-4-butyl-methyl-4-butyl-4-methyl-4-phenyl) isocyanurate, 2, 5-4-butyl-4-methyl-4-butyl-4-tert-butyl-methyl-butyl-4-tert-4-butyl-4-hydroxy-4-hydroxy-butyl-4-hydroxy-butyl-4-butyl-methyl-butyl-4-butyl-methyl-phenyl) phenol, 2,3, 2, 5-4-methyl-4-butyl-4-methyl-4-butyl-methyl-butyl-4-methyl-4-methyl-butyl-methyl-phenyl) benzene, 2,3, 5-4-butyl-.

The amount of the phosphorus stabilizer (ii) and/or the hindered phenol antioxidant (iii) is preferably 0.0001 to 1 part by weight, more preferably 0.001 to 0.5 part by weight, and still more preferably 0.005 to 0.1 part by weight, based on 100 parts by weight of the polycarbonate copolymer. When the amount of the stabilizer is not less than the above range, a good stabilizing effect can be obtained, and when the amount is not more than the above range, the physical properties of the material are less likely to be deteriorated and the mold is less likely to be contaminated during molding, which is preferable.

In the polycarbonate copolymer of the present invention, an antioxidant other than the above-mentioned hindered phenol-based antioxidant can be suitably used. Examples of the other antioxidant include pentaerythritol tetrakis (3-mercaptopropionate), pentaerythritol tetrakis (3-laurylthiopropionate), and glycerol-3-stearylthiopropionate. The amount of the other antioxidant used is preferably 0.001 to 0.05 part by weight based on 100 parts by weight of the polycarbonate copolymer.

(iv) Ultraviolet absorber

The polycarbonate copolymer used in the present invention may contain an ultraviolet absorber. Specific examples of the ultraviolet absorber include benzophenone series, such as 2, 4-dihydroxybenzophenone, 2-hydroxy-4-methoxybenzophenone, 2-hydroxy-4-octyloxybenzophenone, 2-hydroxy-4-benzyloxybenzophenone, 2-hydroxy-4-methoxy-5-sulfoxy (sulfoxy) benzophenone, 2-hydroxy-4-methoxy-5-sulfoxy trihydrate benzophenone, 2 '-dihydroxy-4-methoxybenzophenone, 2', 4,4 '-tetrahydroxybenzophenone, 2' -dihydroxy-4, 4 '-dimethoxybenzophenone, 2' -dihydroxy-4, 4 '-dimethoxy-5-sodium thiobenzophenones, bis (5-benzoyl-4-hydroxy-2-methoxyphenyl) methane, 2-hydroxy-4-n-dodecyloxybenzophenone, and 2-hydroxy-4-methoxy-2' -carboxybenzophenone, and the like.

Specific examples of the ultraviolet absorber include benzotriazole compounds such as 2- (2-hydroxy-5-methylphenyl) benzotriazole, 2- (2-hydroxy-5-tert-octylphenyl) benzotriazole, 2- (2-hydroxy-3, 5-diisopropylphenyl) phenylbenzotriazole, 2- (2-hydroxy-3-tert-butyl-5-methylphenyl) -5-chlorobenzotriazole, and 2, 2' -methylenebis [4- (1,1,3, 3-tetramethylbutyl) -6- (2H-benzotriazol-2-yl) phenol]2- (2-hydroxy-3, 5-di-tert-butylphenyl) benzotriazole, 2- (2-hydroxy-3, 5-di-tert-butylphenyl) -5-chlorobenzotriazole, 2- (2-hydroxy-3, 5-di-tert-amylphenyl) benzotriazole, 2- (2-hydroxy-5-tert-octylphenyl) benzotriazole, 2- (2-hydroxy-3, 5-di-tert-amylphenyl) benzotriazolePhenyl-5-tert-butylphenyl) benzotriazole, 2- (2-hydroxy-4-octyloxyphenyl) benzotriazole, 2 '-methylenebis (4-cumyl-6-benzotriazolylphenyl), 2' -p-phenylenebis (1, 3-benzophenonebe)

Oxazin-4-one) and 2- [ 2-hydroxy-3- (3,4,5, 6-tetrahydrophthalimidomethyl) -5-methylphenyl]Examples of the benzotriazole include polymers having a 2-hydroxyphenyl-2H-benzotriazole skeleton, such as a copolymer of 2- (2 '-hydroxy-5-methacryloyloxyethylphenyl) -2H-benzotriazole and a vinyl monomer copolymerizable with the above monomer, and a copolymer of 2- (2' -hydroxy-5-acryloyloxyethylphenyl) -2H-benzotriazole and a vinyl monomer copolymerizable with the above monomer.

As the ultraviolet absorber, specifically, in the case of hydroxyphenyl triazine series, examples thereof include 2- (4, 6-diphenyl-1, 3, 5-triazin-2-yl) -5-hexyloxyphenol, 2- (4, 6-diphenyl-1, 3, 5-triazin-2-yl) -5-methoxyphenol, 2- (4, 6-diphenyl-1, 3, 5-triazin-2-yl) -5-ethoxyphenol, 2- (4, 6-diphenyl-1, 3, 5-triazin-2-yl) -5-propoxyphenol, and 2- (4, 6-diphenyl-1, 3, 5-triazin-2-yl) -5-butoxyphenol. Examples of the compound include compounds in which the phenyl group of the above-exemplified compounds is changed to a 2, 4-dimethylphenyl group, such as 2- (4, 6-bis (2, 4-dimethylphenyl) -1,3, 5-triazin-2-yl) -5-hexyloxyphenol.

As the ultraviolet absorber, specifically, for the cyclic imino ester, for example, 2' -p-phenylenebis (3, 1-benzo)

Oxazin-4-one), 2 '- (4, 4' -diphenylene) bis (3, 1-benzo

Oxazin-4-ones) and 2, 2' - (2, 6-naphthalene) bis (3, 1-benzo

Oxazin-4-one).

Specific examples of the ultraviolet absorber include cyanoacrylate compounds such as 1, 3-bis- [ (2 ' -cyano-3 ', 3 ' -diphenylacryloyl) oxy ] -2, 2-bis [ (2-cyano-3, 3-diphenylacryloyl) oxy ] methyl) propane and 1, 3-bis- [ (2-cyano-3, 3-diphenylacryloyl) oxy ] benzene.

The ultraviolet absorber may be a polymer type ultraviolet absorber obtained by copolymerizing the ultraviolet absorbing monomer and/or the light-stable monomer having a hindered amine structure with a monomer such as alkyl (meth) acrylate by adopting a structure of a radical polymerizable monomer compound. As the ultraviolet absorbing monomer, a compound containing a benzotriazole skeleton, a benzophenone skeleton, a triazine skeleton, a cyclic imino ester skeleton, and a cyanoacrylate skeleton in an ester substituent of a (meth) acrylate is preferably exemplified.

Among the above, benzotriazole-based and hydroxyphenyltriazine-based are preferable from the viewpoint of ultraviolet absorption ability. From the viewpoint of heat resistance and color tone, cyclic imino ester esters and cyanoacrylate esters are preferable. The ultraviolet absorber may be used alone or in combination of 2 or more.

The content of the ultraviolet absorber is 0.01 to 2 parts by weight, preferably 0.03 to 2 parts by weight, more preferably 0.04 to 1 part by weight, and still more preferably 0.05 to 0.5 part by weight, based on 100 parts by weight of the polycarbonate copolymer.

(v) Flow modifier

The polycarbonate copolymer of the present invention may contain a flow modifier within a range not impairing the effects of the present invention. As the flow modifier, styrene-based oligomers, polycarbonate oligomers (including highly branched, hyperbranched and cyclic oligomer types), polyalkylene terephthalate oligomers (including highly branched, hyperbranched and cyclic oligomer types), highly branched and hyperbranched aliphatic polyester oligomers, terpene resins, polycaprolactone, and the like can be preferably exemplified. The flow modifier is preferably 0.1 to 30 parts by weight, more preferably 1 to 20 parts by weight, and still more preferably 2to 15 parts by weight, based on 100 parts by weight of the polycarbonate copolymer. Particularly preferably polycaprolactone, and the composition ratio is 2to 7 parts by weight relative to 100 parts by weight of the polycarbonate copolymer. The molecular weight of polycaprolactone is 1000-70000, preferably 1500-40000, more preferably 2000-30000, and further preferably 2500-15000 in number average molecular weight.

(vi) Antistatic agent

The polycarbonate copolymer of the present invention may be compounded with an antistatic agent for the main purpose of improving antistatic properties. As antistatic agents, sulfonic acids can be used

Salts, phosphites, caprolactone-based polymers, and the like, sulfonic acids are preferably used

And (3) salt. As the sulfonic acid

Specific examples of the salt include tetrabutyl dodecylsulfonate

Dodecyl benzene sulfonic acid tetrabutyl

Dodecyl benzene sulfonic acid tributyl octyl

Dodecyl benzene sulfonic acid tetraoctylOctadecyl benzene sulfonic acid tetraethyl

Tributyl methyl dibutylbenzenesulfonate

Dibutyl naphthyl sulfonic acid triphenyl

Diisopropyl naphthyl sulfonic acid trioctyl methyl

And the like. Among them, tetrabutyl dodecylbenzenesulfonate is preferable from the viewpoint of compatibility with polycarbonate and ready availability

The amount of the antistatic agent is preferably 0.1 to 5.0 parts by weight, more preferably 0.2to 3.0 parts by weight, still more preferably 0.3 to 2.0 parts by weight, and particularly preferably 0.5 to 1.8 parts by weight, based on 100 parts by weight of the polycarbonate copolymer. When the amount is 0.1 parts by weight or more, an antistatic effect can be obtained, and when the amount is 5.0 parts by weight or less, transparency and mechanical strength are excellent, and the surface of a molded article is not silvery white or peeled off, and appearance defects are not easily caused.

The polycarbonate copolymer of the present invention may contain various additives such as a bluing agent, a fluorescent dye, a flame retardant, and a dye pigment. They may be appropriately selected and contained within a range not impairing the effects of the present invention.

The bluing agent is preferably contained in the polycarbonate copolymer in an amount of 0.05 to 3.0ppm by weight. Typical examples of the bluing agent include Macrolex Violet B and Macrolex Blue RR manufactured by Bayer corporation and Polysynthren Blue RLS manufactured by Clariant corporation.

Examples of the fluorescent dye (including the fluorescent whitening agent) include coumarin fluorescent dyes, benzopyran fluorescent dyes, perylene fluorescent dyes, anthraquinone fluorescent dyes, thioindigo fluorescent dyes, xanthene ketone fluorescent dyes, thioxanthene fluorescent dyes, thioxanthone fluorescent dyes, thiazine fluorescent dyes, and diaminostilbene fluorescent dyes. The amount of the fluorescent dye (including the fluorescent whitening agent) is preferably 0.0001 to 0.1 part by weight based on 100 parts by weight of the polycarbonate copolymer.

Examples of the flame retardant include a metal sulfonate flame retardant, a halogen compound flame retardant, a phosphorus compound flame retardant, and a silicon compound flame retardant. Among these, sulfonic acid metal salt-based flame retardants are preferable. The amount of the flame retardant is usually in the range of preferably 0.01 to 1 part by weight, more preferably 0.05 to 1 part by weight, based on 100 parts by weight of the polycarbonate copolymer.

The polycarbonate copolymer of the present invention may contain other components than those described above as long as the effects of the present invention are not significantly impaired. Examples of the other components include resins other than polycarbonate copolymers. The other components may be contained in 1 kind, or may be contained in 2 or more kinds in an arbitrary combination and ratio. Examples of the other resin include thermoplastic polyester resins such as polyethylene terephthalate resin (PET resin), polytrimethylene terephthalate resin (PTT resin), and polybutylene terephthalate resin (PBT resin); styrene resins such AS polystyrene resin (PS resin), high impact polystyrene resin (HIPS), acrylonitrile-styrene copolymer (AS resin), acrylonitrile-butadiene-styrene copolymer (ABS resin), acrylonitrile-styrene-acrylic rubber copolymer (ASA resin), and acrylonitrile-ethylene propylene rubber-styrene copolymer (AES resin); polyolefin resins such as polyethylene resin (PE resin), polypropylene resin (PP resin), cyclic cycloolefin resin (COP resin), and cyclic cycloolefin Copolymer (COP) resin; polyamide resin (PA resin); polyimide resin (PI resin); polyetherimide resins (PEI resins); a polyurethane resin (PU resin); polyphenylene ether resin (PPE resin); polyphenylene sulfide resin (PPS resin); polysulfone resin (PSU resin); polymethacrylate resin (PMMA resin); and the like.

The method for blending an additive or the like to the polycarbonate copolymer of the present invention is not particularly limited, and a known method can be used. The most common method includes the following methods: the polycarbonate copolymer and the additive are premixed, and then fed into an extruder to be melt-kneaded, and the extruded strand is cooled and cut by a pelletizer to produce a pelletized molding material.

The extruder used in the above method may be either a single-screw extruder or a twin-screw extruder, and is preferably a twin-screw extruder from the viewpoint of productivity and kneading properties. A typical example of the twin-screw extruder is ZSK (trade name, manufactured by Werner & Pfleiderer). Specific examples of the same type include TEX (trade name, manufactured by Nippon Steel works Co., Ltd.), TEM (trade name, manufactured by Toshiba mechanical Co., Ltd.), KTX (trade name, manufactured by Kiyoki Steel works Co., Ltd.), and the like. As the extruder, an extruder having a vent capable of degassing moisture in the raw material and a volatile gas generated from the melt-kneaded resin can be preferably used. It is preferable to provide a vacuum pump for efficiently discharging moisture and volatile gas generated from the exhaust port to the outside of the extruder. Further, a screen for removing foreign matter or the like mixed in the extrusion material may be provided in a region in front of the die opening of the extruder to remove the foreign matter from the resin composition. Examples of the mesh include a metal mesh, a screen changer, and a sintered metal plate (such as a disc filter).

Further, the additives may be supplied to the extruder independently, but are preferably premixed with the resin raw material as described above. Examples of the premixing apparatus include a nauta mixer, a V-type mixer, a henschel mixer, a mechanochemical apparatus, and an extrusion mixer. A more preferable method is, for example, a method in which a part of the raw material resin and the additive are mixed by a high-speed mixer such as a henschel mixer to prepare a base, and then the base is mixed with the remaining whole amount of the resin raw material by a non-high-speed mixer such as a nauta mixer.

The polycarbonate resin composition extruded from the extruder is pelletized by direct cutting, or after forming a strand, the strand is cut by a pelletizer and pelletized. When it is necessary to reduce the influence of external dust and the like, it is preferable to purge the atmosphere around the extruder. In the production of the pellets, it is preferable to narrow the shape distribution of the pellets, further reduce the amount of cut-off, further reduce the amount of fine powder generated during transportation or conveyance, and reduce the amount of air bubbles (vacuum bubbles) generated in the strands or pellets by using various methods which have been proposed for polycarbonate resins for optical disks. As a method for reducing the false cutting, there are a method of controlling the temperature of the strand when the strand is cut by the pelletizer, a method of blowing ion wind when the strand is cut, a method of optimizing the front angle of the pelletizer, and a method of appropriately blending the release agent, and a method of filtering a mixture of cut pellets and water to separate the pellets from the water and the false cutting. An example of the measuring method is disclosed in, for example, Japanese patent laid-open publication No. 2003-200421. By using these formulations, the molding cycle can be increased and the proportion of defects such as silver white can be reduced.

The amount of miscut of the molding material (pellets) is preferably 10ppm or less, more preferably 5ppm or less. Here, the miscut means a powder or granule finer than a desired size of a particle passing through a JIS standard sieve having a mesh opening of 1.0 mm. The shape of the particles may be a general shape such as a cylinder, prism, or sphere, but is more preferably a cylinder (including an elliptic cylinder), and the diameter of the cylinder is preferably 1.5 to 4mm, more preferably 2to 3.5 mm. The ratio of the minor axis to the major axis in the elliptic cylinder is preferably 60% or more, and more preferably 65% or more. On the other hand, the length of the cylinder is preferably 2to 4mm, and more preferably 2.5 to 3.5 mm.

< polycarbonate resin molded article >

The method for producing the molded article comprising the polycarbonate copolymer or resin composition of the present invention is not particularly limited, and a molding method generally used for polycarbonate resins can be arbitrarily employed. Examples thereof include injection molding, ultrahigh-speed injection molding, injection compression molding, two-color molding, hollow molding such as gas assist molding, molding using a heat-insulating mold, molding using a rapid-heating mold, foam molding (including supercritical fluid), insert molding, IMC (in-mold coating molding) molding, extrusion molding, sheet molding, thermoforming, rotational molding, lamination molding, press molding, and the like. Further, a molding method using a hot runner system may be used.

The polycarbonate copolymer or the resin composition of the present invention can be molded into a sheet or film by a method such as melt extrusion or solution casting (casting). Specific examples of the melt extrusion method include the following methods: the polycarbonate copolymer or the resin composition is quantitatively supplied to an extruder, heated and melted, the melted resin is extruded in a sheet form from the tip of a T-die onto a mirror surface roll, extracted while being cooled by a plurality of rolls, and cut into an appropriate size or wound up at the time of solidification. As a specific method of the solution casting method, for example, the following method can be used: a solution (concentration: 5% to 40%) obtained by dissolving a polycarbonate copolymer or a resin composition in methylene chloride was cast from a T die onto a mirror-polished stainless steel plate, and the sheet was peeled off while passing through an oven with stepwise temperature control, and the solvent was removed, followed by cooling and winding.

The polycarbonate copolymer or the resin composition of the present invention may be molded to form a laminate. The laminate can be produced by any method, and is particularly preferably produced by a hot press bonding method or a co-extrusion method. As the thermocompression bonding method, any method can be used, and for example, a method of thermocompression bonding a sheet of a polycarbonate copolymer or a resin composition by a laminator or a press, a method of thermocompression bonding immediately after extrusion, and particularly a method of continuously thermocompression bonding a sheet immediately after extrusion are preferable industrially.

< interior and exterior parts of automobile >

The polycarbonate copolymer or the resin composition of the present invention is excellent in surface hardness, heat resistance, weather resistance and solvent resistance and has a low specific gravity, and therefore, it can be suitably used, for example, in various display devices such as instrument panels, center consoles, car navigation parts, car audio parts, car mobile computer parts, display instrument covers, instrument tablets, various switches, display front panels, heat control panels, instrument panels, center consoles, center panels, interior lenses, head-up displays, automobile interior parts such as protective parts and light transmitting parts, headlamps, rear door panels, door handles, signs, glass windows, fenders, bumpers, instruments, door panels, side trims, brackets, radiator grilles, side shields, side trim, rear shields, rear trim, various spoilers, valve covers, roofs, trunk covers, The automobile exterior parts such as a detachable top plate, a windshield, a rearview mirror cover, an outer door handle and the like.