阅读说明：本技术 聚碳酸酯树脂组合物及使用其的光学透镜 (Polycarbonate resin composition and optical lens using same ) 是由 石原健太朗 西森克吏 加藤宣之 铃木章子 于 2020-02-06 设计创作，主要内容包括：根据本发明,能够提供包含下述式(1)所示的结构单元、下述式(2)所示的结构单元和下述通式(3)所示的结构单元的聚碳酸酯树脂组合物。(通式(3)中,R-1～R-4分别独立地表示氢原子、氟原子、氯原子、溴原子、碘原子、碳原子数1～6的烷基、或可以包含选自氧原子、氮原子和硫原子中的杂环原子的碳原子数6～20的芳基、碳原子数2～6的烯基、碳原子数1～6的烷氧基或碳原子数7～17的芳烷基,p、q、r和s分别独立表示0～4的整数,i表示1～10的整数,ii表示0～10的整数。)。(According to the present invention, a polycarbonate resin composition comprising a structural unit represented by the following formula (1), a structural unit represented by the following formula (2), and a structural unit represented by the following general formula (3) can be provided. (in the general formula (3), R 1 ～R 4 Each independently represents a hydrogen atom, a fluorine atom, a chlorine atom, a bromine atom, an iodine atom, an alkyl group having 1 to 6 carbon atoms, or an aryl group having 6 to 20 carbon atoms, an alkenyl group having 2 to 6 carbon atoms, an alkoxy group having 1 to 6 carbon atoms, or an aralkyl group having 7 to 17 carbon atoms, which may contain a heterocyclic atom selected from an oxygen atom, a nitrogen atom, and a sulfur atom, p, q, r, and s independently represent an integer of 0 to 4, i represents an integer of 1 to 10, and ii represents an integer of 0 to 10. ).)

1. A polycarbonate resin composition characterized by:

comprising a structural unit represented by the following formula (1), a structural unit represented by the following formula (2), and a structural unit represented by the following general formula (3), and further comprising an antioxidant,

in the general formula (3), R₁～R₄Each independently represents a hydrogen atom, a fluorine atom, a chlorine atom, a bromine atom, an iodine atom, an alkyl group having 1 to 6 carbon atoms, or an aryl group having 6 to 20 carbon atoms which may contain a heterocyclic atom selected from an oxygen atom, a nitrogen atom and a sulfur atom, an alkenyl group having 2 to 6 carbon atoms, an alkoxy group having 1 to 6 carbon atoms or an aralkyl group having 7 to 17 carbon atoms,

p, q, r and s each independently represent an integer of 0 to 4,

i represents an integer of 1 to 10, and ii represents an integer of 0 to 10.

2. The polycarbonate resin composition according to claim 1, wherein:

the antioxidant is contained in the polycarbonate resin composition in an amount of 0.50% by mass or less.

3. The polycarbonate resin composition according to claim 1 or 2, wherein:

the antioxidant is contained in the polycarbonate resin composition in an amount of 0.10 to 0.40 mass%.

4. The polycarbonate resin composition according to any one of claims 1 to 3, wherein:

the antioxidant is selected from triethylene glycol-bis [ 3- (3-tert-butyl-5-methyl-4-hydroxyphenyl) propionate ], 1, 6-hexanediol-bis [ 3- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionate ], pentaerythritol-tetrakis [ 3- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionate ], octadecyl-3- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionate, 1,3, 5-trimethyl-2, 4, 6-tris (3, 5-di-tert-butyl-4-hydroxybenzyl) benzene, N-hexamethylenebis (3, 5-di-tert-butyl-4-hydroxy-hydrocinnamide), 3, 5-di-tert-butyl-4-hydroxy-benzylphosphonate-diethyl ester, tris (3, 5-di-tert-butyl-4-hydroxybenzyl) isocyanurate, and 3, 9-bis {1, 1-dimethyl-2- [ beta- (3-tert-butyl-4-hydroxy-5-methylphenyl) propionyloxy ] ethyl } -2, 4,8, 10-tetraoxaspiro (5,5) undecane.

5. The polycarbonate resin composition according to any one of claims 1 to 4, wherein:

the polycarbonate resin composition contains a polycarbonate resin having a phenol content of 0.1 to 3000 ppm.

6. The polycarbonate resin composition according to any one of claims 1 to 5, wherein:

the polycarbonate resin composition contains a polycarbonate resin having a carbonic acid diester content of 0.1 to 1000 ppm.

7. The polycarbonate resin composition according to any one of claims 1 to 6, wherein:

(structural unit (mol) represented by the formula (1))/(structural unit (mol) represented by the formula (1) + structural unit (mol) represented by the formula (2) + structural unit (mol) represented by the general formula (3)) × 100 is 8 to 32 mol%.

8. The polycarbonate resin composition according to any one of claims 1 to 7, wherein:

(the structural unit (mol) represented by the formula (2))/(the structural unit (mol) represented by the formula (1) + the structural unit (mol) represented by the formula (2) + the structural unit (mol) represented by the general formula (3)) × 100 is 28 to 52 mol%.

9. The polycarbonate resin composition according to any one of claims 1 to 8, wherein:

(the structural unit (mol) represented by the general formula (3))/(the structural unit (mol) represented by the formula (1) + the structural unit (mol) represented by the formula (2) + the structural unit (mol) represented by the general formula (3)) × 100 is 28 to 52 mol%.

10. The polycarbonate resin composition according to any one of claims 1 to 9, wherein:

the structural unit shown in the general formula (3) is

11. The polycarbonate resin composition according to any one of claims 1 to 10, wherein:

the glass transition temperature (Tg) is 140-200 ℃.

12. The polycarbonate resin composition according to any one of claims 1 to 11, wherein:

the refractive index (nD) is 1.565-1.600, and the Abbe number (v) is 26-32.

13. The polycarbonate resin composition according to any one of claims 1 to 12, wherein:

the refractive index (nD) and Abbe number (v) satisfy the following relation:

－0.0130v+1.9480＜nD＜－0.0130v+1.9900。

14. the polycarbonate resin composition according to any one of claims 1 to 13, wherein:

the weight average molecular weight (Mw) is 10,000-70,000.

15. An optical lens, characterized in that:

comprising the polycarbonate resin composition according to any one of claims 1 to 14.

16. The optical lens of claim 15 wherein:

the thickness is 0.01-30 mm.

Technical Field

The present invention relates to a polycarbonate resin composition having a well-balanced refractive index and abbe number, and an optical lens using the same.

Background

Polycarbonate resins (hereinafter, sometimes referred to as "PC") are polymers in which dihydric phenols are linked by carbonates, and among them, polycarbonate resins obtained from 2, 2-bis (4-hydroxyphenyl) propane (generally referred to as "bisphenol a") are used in many fields because they are excellent in transparency and heat resistance and also have excellent mechanical properties such as impact resistance. In the optical fields of various lenses, optical disks, and the like, characteristics such as impact resistance, transparency, low water absorption, and the like have been drawing attention, and they are an important position as materials for optical applications.

Particularly in the field of lenses, PC as a thermoplastic resin has attracted attention because of its high productivity, and there is an increasing demand for a substitute for a thermosetting resin represented by CR-39 (diethylene glycol bis allyl carbonate), which has been the mainstream of plastic lenses so far.

However, a polycarbonate resin obtained by reacting bisphenol a with a carbonate precursor such as phosgene or diphenyl carbonate has a high refractive index and a low abbe number, and therefore has a problem of easy occurrence of chromatic aberration and a disadvantage of poor balance between the refractive index and the abbe number. Further, there is a disadvantage that the photoelastic constant is large and the birefringence of the molded article becomes large.

In order to solve the drawbacks of such polycarbonate resins, some copolymerized polycarbonate resins of an aromatic dihydroxy compound and an aliphatic diol have been proposed (patent documents 1 to 5). These techniques have problems such as a low refractive index and Abbe number, a large photoelastic constant, a large birefringence of a molded article, insufficient moldability and heat resistance, and unsatisfactory molding or coloring.

Documents of the prior art

Patent document

Patent document 1: japanese laid-open patent publication No. 1-66234

Patent document 2: japanese laid-open patent publication No. 10-120777

Patent document 3: japanese laid-open patent publication No. 11-228683

Patent document 4: japanese laid-open patent publication No. 11-349676

Patent document 5: japanese patent laid-open No. 2000-63506

Disclosure of Invention

Technical problem to be solved by the invention

The technical problem of the present invention is to solve at least one of the above-mentioned existing problems. Further, the present invention has an object to provide a polycarbonate resin composition having a refractive index and an abbe number in a well-balanced manner, and an optical lens using the polycarbonate resin composition. Further, the present invention has an object to provide a polycarbonate resin composition excellent in heat resistance and molding cycle properties, and an optical lens using the polycarbonate resin composition.

Technical solution for solving technical problem

As a result of intensive studies, the inventors of the present invention have found that at least one of the above-mentioned technical problems can be solved by using a diol compound having a specific structure in combination.

Namely, the present invention is as follows.

< 1 > a polycarbonate resin composition comprising a structural unit represented by the following formula (1), a structural unit represented by the following formula (2) and a structural unit represented by the following general formula (3),

(in the general formula (3), R₁～R₄Each independently represents a hydrogen atom, a fluorine atom, a chlorine atom, a bromine atom, an iodine atom, an alkyl group having 1 to 6 carbon atoms, or an aryl group having 6 to 20 carbon atoms which may contain a heterocyclic atom selected from an oxygen atom, a nitrogen atom and a sulfur atom, an alkenyl group having 2 to 6 carbon atoms, an alkoxy group having 1 to 6 carbon atoms or an aralkyl group having 7 to 17 carbon atoms,

p, q, r and s each independently represent an integer of 0 to 4,

i represents an integer of 1 to 10, and ii represents an integer of 0 to 10. )

< 2 > the polycarbonate resin composition according to the above < 1 >, wherein the antioxidant is contained in the polycarbonate resin composition in an amount of 0.50% by mass or less.

< 3 > the polycarbonate resin composition as defined in the above < 1 > or < 2 >, wherein the antioxidant is contained in the polycarbonate resin composition in an amount of 0.10 to 0.40 mass%.

< 4 > the polycarbonate resin composition as described in any one of above < 1 > to < 3 >, wherein the antioxidant is selected from triethylene glycol-bis [ 3- (3-tert-butyl-5-methyl-4-hydroxyphenyl) propionate ], 1, 6-hexanediol-bis [ 3- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionate ], pentaerythritol-tetrakis [ 3- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionate ], octadecyl-3- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionate, 1,3, 5-trimethyl-2, 4, 6-tris (3, 5-di-tert-butyl-4-hydroxybenzyl) benzene, N-hexamethylenebis (3, 5-di-tert-butyl-4-hydroxy-hydrocinnamide), 3, 5-di-tert-butyl-4-hydroxy-benzylphosphonate-diethyl ester, Tris (3, 5-di-tert-butyl-4-hydroxybenzyl) isocyanurate and 3, 9-bis {1, 1-dimethyl-2- [ β - (3-tert-butyl-4-hydroxy-5-methylphenyl) propionyloxy ] ethyl } -2, 4,8, 10-tetraoxaspiro (5,5) undecane.

< 5 > the polycarbonate resin composition according to any one of the above < 1 > to < 4 >, wherein the polycarbonate resin composition contains 0.1 to 3000ppm of phenol.

< 6 > the polycarbonate resin composition according to any one of the above < 1 > to < 5 >, wherein the polycarbonate resin composition contains a carbonic acid diester in an amount of 0.1 to 1000 ppm.

< 7 > the polycarbonate resin composition according to any one of the above < 1 > to < 6 >, wherein (mol) of the structural unit represented by the above formula (1))/(mol of the structural unit represented by the above formula (1) + mol of the structural unit represented by the above formula (2) + mol of the structural unit represented by the above general formula (3)) × 100 is 8 to 32 mol%.

< 8 > the polycarbonate resin composition according to any one of the above < 1 > to < 7 >, wherein (mol) of the structural unit represented by the above formula (2))/(mol of the structural unit represented by the above formula (1) + mol of the structural unit represented by the above formula (2) + mol of the structural unit represented by the above general formula (3)) × 100 is 28 to 52 mol%.

< 9 > the polycarbonate resin composition according to any one of the above < 1 > to < 8 >, wherein (mol) of the structural unit represented by the above general formula (3))/(mol of the structural unit represented by the above general formula (1) + mol of the structural unit represented by the above general formula (2) + mol of the structural unit represented by the above general formula (3)) × 100 is 28 to 52 mol%.

< 10 > the polycarbonate resin composition according to any one of the above < 1 > to < 9 >, wherein the structural unit represented by the above general formula (3) is

< 11 > the polycarbonate resin composition according to any one of the above < 1 > to < 10 >, wherein the glass transition temperature (Tg) is 140 ℃ to 200 ℃.

< 12 > the polycarbonate resin composition according to any one of the above < 1 > to < 11 >, wherein the refractive index (nD) is 1.565 to 1.600 and the Abbe number (v) is 26 to 32.

< 13 > the polycarbonate resin composition according to any one of the above < 1 > to < 12 >, wherein the refractive index (nD) and Abbe number (v) satisfy the following relation:

－0.0130v+1.9480＜nD＜－0.0130v+1.9900。

< 14 > the polycarbonate resin composition according to any one of the above < 1 > to < 13 >, wherein the weight average molecular weight (Mw) is 10,000 to 70,000.

< 15 > an optical lens comprising the polycarbonate resin composition described in any one of the above < 1 > to < 14 >.

The thickness of the optical lens is less than 16 and less than 15, and the thickness of the optical lens is 0.01-30 mm.

ADVANTAGEOUS EFFECTS OF INVENTION

According to the present invention, a polycarbonate resin composition having a refractive index and an Abbe number in a well-balanced manner can be obtained, and particularly, a polycarbonate resin composition having excellent heat resistance and molding cycle properties can be obtained at a specific copolymerization ratio. The polycarbonate resin composition of the present invention is most suitable for optical lenses.

Drawings

FIG. 1 is a graph showing the relationship between Abbe number and refractive index of polycarbonate resin compositions obtained in examples and comparative examples.

Detailed Description

The present invention will be described in detail below.

< polycarbonate resin composition >

The polycarbonate resin composition of the present invention comprises at least a polycarbonate resin containing a structural unit represented by the above formula (1), a structural unit represented by the above formula (2), and a structural unit represented by the above general formula (3). These structural units are derived from a diol compound represented by the following formula (1 '), a diol compound represented by the following formula (2 '), and a diol compound represented by the following general formula (3 '), respectively.

Among them, the diol compound represented by the above formula (1') is called SPG (spiroglycol: 3, 9-bis (1, 1-dimethyl-2-hydroxyethyl) -2, 4,8, 10-tetraoxaspiro [5.5] undecane), and in the present invention, commercially available products or synthesized ones can be used.

Among them, the diol compound represented by the above formula (2') is a diol compound called Bis-TMC (1, 1-Bis (4-hydroxyphenyl) -3, 3, 5-trimethylcyclohexane), and commercially available products or synthesized products can be used in the present invention.

In the general formula (3'), R₁～R₄Each independently represents a hydrogen atom, a fluorine atom, a chlorine atom, a bromine atom, an iodine atom, an alkyl group having 1 to 6 carbon atoms, or an aryl group having 6 to 20 carbon atoms, an alkenyl group having 2 to 6 carbon atoms, an alkoxy group having 1 to 6 carbon atoms, or an aralkyl group having 7 to 17 carbon atoms, which may contain a heterocyclic atom selected from an oxygen atom, a nitrogen atom, and a sulfur atom. Preferably R₁And R₂Each independently represents a hydrogen atom, a methyl group, an ethyl group or a phenyl group, R₃And R₄Each independently represents a hydrogen atom or a phenyl group.

p, q, r and s each independently represent an integer of 0 to 4, preferably p and q represent 1, and r and s represent 0.

i represents an integer of 1 to 10, preferably an integer of 1 to 4, and more preferably 2.

ii represents an integer of 0 to 10, preferably an integer of 1 to 3, and more preferably 1.

In one embodiment of the present invention, the structural unit represented by the above general formula (3) is

When used as an optical lens, the optical lens is preferable because the balance between the refractive index and the abbe number is good.

The above-mentioned structural units are derived from BPEF (9, 9-bis [ 4- (2-hydroxyethoxy) phenyl ] fluorene) represented by the following structural formula and BPPEF (9, 9-bis [ 4- (2-hydroxyethoxy) -3-phenylphenyl ] fluorene) represented by the following structural formula, respectively, and commercially available or synthesized ones can be used in the present invention.

In one embodiment of the present invention, the ratio of the structural unit represented by the formula (1), (the structural unit (mol) represented by the formula (1))/(the structural unit (mol) represented by the formula (1) + the structural unit (mol) represented by the formula (2) + the structural unit (mol) represented by the formula (3)) × 100 is preferably 8 to 32 mol%, more preferably 10 to 30 mol%, and particularly preferably 15 to 25 mol%.

Further, regarding the proportion of the structural unit represented by the formula (2), (the structural unit (mol) represented by the formula (2))/(the structural unit (mol) represented by the formula (1) + the structural unit (mol) represented by the formula (2) + the structural unit (mol) represented by the general formula (3)) × 100 is preferably 28 to 52 mol%, more preferably 30 to 48 mol%, and particularly preferably 33 to 42 mol%.

Further, regarding the proportion of the structural unit represented by the general formula (3), (the structural unit (mol) represented by the general formula (3))/(the structural unit (mol) represented by the formula (1) + the structural unit (mol) represented by the formula (2) + the structural unit (mol) represented by the general formula (3)) × 100 is preferably 28 to 52 mol%, more preferably 32 to 50 mol%, and particularly preferably 38 to 48 mol%.

By setting the copolymerization ratio as described above, a polycarbonate resin composition having excellent heat resistance and molding cycle properties can be obtained.

The polycarbonate resin used in the polycarbonate resin composition of the present invention may be a ternary resin prepared using, as monomers, the diol compound represented by the above formula (1 '), the diol compound represented by the above formula (2 '), and the diol compound represented by the above general formula (3 '), or may contain a diol compound other than these diol compounds. Examples of such other diol compounds include:

4,4 ' -biphenyldiol, bis (4-hydroxyphenyl) methane, bis (2-hydroxyphenyl) methane, 2,4 ' -dihydroxydiphenylmethane, bis (4-hydroxyphenyl) ether, bis (4-hydroxyphenyl) sulfone, 2,4 ' -dihydroxydiphenylsulfone, bis (2-hydroxyphenyl) sulfone, bis (4-hydroxy-3-methylphenyl) sulfone, bis (4-hydroxyphenyl) sulfoxide, bis (4-hydroxyphenyl) sulfide, bis (4-hydroxyphenyl) ketone, 1-bis (4-hydroxyphenyl) ethane, 1-bis (4-hydroxyphenyl) -1-phenylethane, bis (4-hydroxyphenyl) diphenylmethane, 2-bis (4-hydroxyphenyl) propane, 2-bis (4-hydroxy-3-methylphenyl) propane, 1-bis (4-hydroxy-3-methylphenyl) ethane, bis (4-hydroxy-3-methylphenyl) methane, 2, 2-bis (4-hydroxy-3-tert-butylphenyl) propane, 2-bis (4-hydroxyphenyl) butane, 1-bis (4-hydroxyphenyl) cyclohexane, 1-bis (4-hydroxy-3-methylphenyl) cyclohexane, 1-bis (4-hydroxyphenyl) cycloundecane, 1-bis (4-hydroxyphenyl) cyclododecane, 2-bis (4-hydroxy-3-allylphenyl) propane, 3, 5-trimethyl-1, 1-bis (4-hydroxyphenyl) cyclohexane, α, ω -bis [ 3- (o-hydroxyphenyl) propyl ] polydimethyldiphenyl random copolysiloxane-loxane, α, ω -bis [ 3- (o-hydroxyphenyl) propyl ] polydimethylsiloxane, 4 '- [1, 4-phenylenebis (1-methylethylidene) ] bisphenol, 4' - [1, 3-phenylenebis (1-methylethylidene) ] bisphenol, 1, 3-adamantanediol, 2-bis (4-hydroxyphenyl) butane, 1-bis (4-hydroxyphenyl) -2-ethylhexane, 1-bis (4-hydroxyphenyl) -2-methylpropane, 2-bis (4-hydroxyphenyl) -4-methylpentane, 1-bis (4-hydroxyphenyl) decane, 1, 3-bis (4-hydroxyphenyl) -5, 7-dimethyladamantane, 2-bis (4- (2-hydroxyethoxy) phenyl) propane, 4-bis (2-hydroxyethoxy) biphenyl, 2 ' - (1, 4-phenylene) bis (ethane-1-ol), 2 ' - (1, 4-phenylene) bis (methane-1-ol), 2 ' - (1, 4-phenylenebis (oxy)) bis (ethane-1-ol), 1-bis (4-hydroxyphenyl) cyclododecane, 1, 1-bis (4-hydroxy-3-methylphenyl) cyclododecane, 1-bis (4-hydroxy-3-phenylphenyl) cyclododecane, 1-bis (4-hydroxy-3-tert-butylphenyl) cyclododecane, 1-bis (4-hydroxy-3-sec-butylphenyl) cyclododecane, 1-bis (4-hydroxy-3-allylphenyl) cyclododecane, 1-bis (4-hydroxy-3, 5-dimethylphenyl) cyclododecane, 1-bis (4-hydroxy-3-fluorophenyl) cyclododecane, 1-bis (4-hydroxy-3-chlorophenyl) cyclododecane, 1-bis (4-hydroxy-3-bromophenyl) cyclododecane, 7-ethyl-1, 1-bis (4-hydroxyphenyl) cyclododecane, 5, 6-dimethyl-1, 1-bis (4-hydroxyphenyl) cyclododecane, Pentacyclopentadecane dimethanol, 1, 4-cyclohexane dimethanol, 1, 3-adamantane dimethanol, decahydronaphthalene-2, 6-dimethanol, tricyclodecane, dimethanol fluorene diol, fluorene diethanol, isosorbide and the like, but are not limited thereto. The above-mentioned other diol compound is preferably 2, 2-bis (4-hydroxyphenyl) propane. The amount of the other diol compound can be appropriately adjusted within a range not impairing the effects of the present invention.

In one embodiment of the present invention, the polycarbonate resin composition may include any of a random copolymer structure, a block copolymer structure, and an alternating copolymer structure.

In one embodiment of the present invention, the polycarbonate resin composition may preferably have a polystyrene-reduced weight average molecular weight (Mw) of 10,000 to 70,000. The weight average molecular weight (Mw) of the polycarbonate resin composition in terms of polystyrene is more preferably 20,000 to 50,000, and particularly preferably 30,000 to 45,000. When the polystyrene-equivalent weight average molecular weight (Mw) of the polycarbonate resin composition is within the above range, the molded article can be prevented from becoming brittle, the melt viscosity is not excessively high, the resin after production can be easily taken out, and further the fluidity can be improved, and injection molding in a molten state can be easily performed.

In another embodiment of the present invention, the polycarbonate resin composition may be blended with another resin to produce an optical lens. Examples of the other resin include, but are not limited to, polyester carbonates, polyamides, polyacetals, modified polyphenylene ethers, polyesters (e.g., polyethylene terephthalate, polybutylene terephthalate), and the like.

(other Components)

In one embodiment of the present invention, an antioxidant and a mold release agent can be contained as additives in the polycarbonate resin composition.

As the antioxidant, triethylene glycol-bis [ 3- (3-tert-butyl-5-methyl-4-hydroxyphenyl) propionate ], 1, 6-hexanediol-bis [ 3- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionate ], pentaerythritol-tetrakis [ 3- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionate ], octadecyl-3- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionate, 1,3, 5-trimethyl-2, 4, 6-tris (3, 5-di-tert-butyl-4-hydroxybenzyl) benzene, N-hexamethylenebis (3, 5-di-tert-butyl-4-hydroxy-hydrocinnamide), 3, 5-di-tert-butyl-4-hydroxy-benzylphosphonate-diethyl ester, tris (3, 5-di-tert-butyl-4-hydroxybenzyl) isocyanurate and 3, 9-bis {1, 1-dimethyl-2- [ beta- (3-tert-butyl-4-hydroxy-5-methylphenyl) propionyloxy ] ethyl } -2, 4,8, 10-tetraoxaspiro (5,5) undecane, and the like.

The content of the antioxidant is preferably 0.50% by mass or less, more preferably 0.05 to 0.40% by mass, even more preferably 0.05 to 0.20% by mass or 0.10 to 0.40% by mass, and particularly preferably 0.20 to 0.40% by mass in the polycarbonate resin composition.

The release agent is preferably an ester of an alcohol and a fatty acid in an amount of 90 wt% or more. Specific examples of the ester of an alcohol and a fatty acid include an ester of a monohydric alcohol and a fatty acid, and a partial or full ester of a polyhydric alcohol and a fatty acid. The ester of a monohydric alcohol and a fatty acid is preferably an ester of a monohydric alcohol having 1 to 20 carbon atoms and a saturated fatty acid having 10 to 30 carbon atoms. The partial ester or full ester of a polyhydric alcohol and a fatty acid is preferably a partial ester or full ester of a polyhydric alcohol having 1 to 25 carbon atoms and a saturated fatty acid having 10 to 30 carbon atoms.

Specifically, examples of the ester of a monohydric alcohol and a saturated fatty acid include stearyl stearate, palmityl palmitate, butyl stearate, methyl laurate, and isopropyl palmitate. Examples of the partial or full esters of polyhydric alcohols and saturated fatty acids include full or partial esters of dipentaerythritol such as glycerol monostearate, glycerol distearate, glycerol tristearate, sorbitan stearate (ステアリン acid モノソルビテート), glycerol monobehenate, glycerol monocaprate, glycerol monolaurate, pentaerythritol monostearate, pentaerythritol tetrastearate, pentaerythritol tetrapelargonate, propylene glycol monostearate, biphenyl ester, sorbitan monostearate, 2-ethylhexyl stearate, and dipentaerythritol hexastearate.

The content of the release agent is preferably 0.50% by mass or less, more preferably 0.01 to 0.10% by mass, even more preferably 0.02 to 0.05% by mass, and particularly preferably 0.03 to 0.05% by mass in the polycarbonate resin composition.

In addition, as other additives, a processing stabilizer, an ultraviolet absorber, a fluidity modifier, a crystal nucleating agent, a reinforcing agent, a dye, an antistatic agent, a bluing agent, an antibacterial agent, and the like may be added to the polycarbonate resin composition of the present invention.

(impurities)

In the polycarbonate resin of the present invention, phenol produced during production and diol or carbonic acid diester which is a monomer remaining without reaction may be present as impurities. The content of phenol in the polycarbonate resin is preferably 0.1 to 3000ppm, more preferably 0.1 to 2000ppm, and particularly preferably 1 to 1000ppm, 1 to 800ppm, 1 to 500ppm, or 1 to 300 ppm. The content of the diol in the polycarbonate resin is preferably 0.1 to 5000ppm, more preferably 1 to 3000ppm, still more preferably 1 to 1000ppm, and particularly preferably 1 to 500 ppm. The content of the carbonic acid diester in the polycarbonate resin is preferably 0.1 to 1000ppm, more preferably 0.1 to 500ppm, and particularly preferably 1 to 100 ppm. By adjusting the amounts of the phenol and the carbonic acid diester contained in the polycarbonate resin, a resin having physical properties suitable for the purpose can be obtained. The content of the phenol and the carbonic acid diester can be adjusted as appropriate by changing the conditions and the apparatus for the polycondensation. Further, the conditions of the extrusion step after polycondensation can be adjusted.

If the content of the phenol or the carbonic acid diester exceeds the above range, problems such as a decrease in strength of the obtained resin molded article and generation of odor occur. On the other hand, if the content of the phenol or the carbonic acid diester is less than the above range, the plasticity at the time of melting the resin may be reduced.

< method for producing polycarbonate resin composition >

In one embodiment of the present invention, the polycarbonate resin can be produced according to the method described in WO 2018/016516. Specifically, the diol compound represented by the above formula (1 '), the diol compound represented by the above formula (2 '), and the diol compound represented by the above general formula (3 ') can be produced by reacting the diol compound with a carbonate precursor such as a carbonic acid diester by a melt polycondensation method under heating and further under normal pressure or reduced pressure in the presence or absence of a basic compound catalyst and/or an ester exchange catalyst. The method for producing the polycarbonate resin composition of the present invention is not limited to the above-described production method.

< Properties of polycarbonate resin composition >

(A) Refractive index (nD)

In one embodiment of the present invention, the polycarbonate resin composition has a refractive index of preferably 1.565 to 1.600, more preferably 1.585 to 1.600, and particularly preferably 1.585 to 1.590 at a wavelength of 587.6nm and 23 ℃. The polycarbonate resin composition of the present invention has a high refractive index and is suitable as an optical lens material. The refractive index can be measured according to JIS-K-7142: 2014 it is measured by Abbe refractometer.

(B) Abbe number (v)

In one embodiment of the present invention, the abbe number of the polycarbonate resin composition at 23 ℃ is preferably 26 to 32, more preferably 27 to 31, and particularly preferably 28 to 30. The abbe number can be measured by an abbe refractometer and calculated by the method described in the following examples.

In one embodiment of the present invention, the refractive index (nD) and abbe number (v) of the polycarbonate resin composition preferably satisfy the following relational expression.

－0.0130v+1.9480＜nD＜－0.0130v+1.9900

More preferably, the refractive index (nD) and the abbe number (v) satisfy the following relational expression.

－0.0130v+1.9480＜nD＜－0.0065v+1.7785

Satisfying such a relational expression is preferable because a well-balanced relationship between the refractive index and the abbe number is obtained.

(C) Glass transition temperature (Tg)

In one embodiment of the present invention, the polycarbonate resin composition preferably has a glass transition temperature (Tg) of 140 to 200 ℃, more preferably 145 to 160 ℃, and particularly preferably 150 to 160 ℃. When the glass transition temperature (Tg) of the polycarbonate resin composition is within the above range, injection molding is facilitated. If Tg is less than 140 ℃, the use temperature range is narrowed, which is not preferable. Further, if it exceeds 200 ℃, the melting temperature of the resin becomes high, and decomposition or coloring of the resin is likely to occur, which is not preferable. If the glass transition temperature of the resin is too high, the difference between the mold temperature and the glass transition temperature of the resin becomes large in a general-purpose mold temperature adjusting machine. Therefore, in applications where strict surface precision is required for products, it is difficult to use a resin having an excessively high glass transition temperature, which is not preferable.

(D) Other characteristics

The polycarbonate resin composition of the present invention has high moist heat resistance. The moist heat resistance can be evaluated by performing a "PCT test" (pressure cooker test) on an optical molded article obtained using the polycarbonate resin composition, and measuring the total light transmittance of the optical molded article after the test. The PCT test can be carried out by holding an injection-molded article having a diameter of 50mm and a thickness of 3mm obtained by the method described in the following examples at 120 ℃ under 0.2MPa at 100% RH for 20 hours. The polycarbonate resin composition of the present invention has a total light transmittance after PCT test of preferably 60% or more, more preferably 70% or more, still more preferably 75% or more, and particularly preferably 80% or more. When the total light transmittance is 60% or more, the resin composition can be said to have a high moist heat resistance as compared with conventional polycarbonate resins. The total light transmittance can be measured by the method described in the following examples.

The polycarbonate resin composition of the present invention preferably has a b value of 5 or less. The smaller the b value, the weaker the yellowish color and the better the hue. The b value can be measured by the method described in the following examples.

The amount of residual phenol contained in the polycarbonate resin composition of the present invention is preferably 500ppm or less, more preferably 300ppm or less, still more preferably 150ppm or less, and particularly preferably 50ppm or less. Further, it is considered that the slight content of residual phenol provides an advantage of increasing thermoplasticity and imparting an antibacterial effect.

The amount of residual diphenyl carbonate (DPC) contained in the polycarbonate resin composition of the present invention is preferably 200ppm or less, more preferably 150ppm or less, still more preferably 100ppm or less, and particularly preferably 50ppm or less. Further, it is considered that the slight content of the residual diphenyl carbonate (DPC) has an advantage that hydrolysis at the time of melt molding can be prevented.

< optical lens >

The optical lens of the present invention can be obtained by injection molding the polycarbonate resin composition of the present invention into a lens shape by an injection molding machine or an injection compression molding machine. In one embodiment of the present invention, the optical lens can be manufactured according to the method described in WO 2018/016516. The molding conditions for injection molding are not particularly limited, and the molding temperature is preferably 180 to 300 ℃, more preferably 180 to 290 ℃. In addition, noteThe injection pressure is preferably 50 to 1700kg/cm²。

In order to avoid the inclusion of foreign matter in the optical lens as much as possible, the molding environment must be a low-dust environment, and is preferably class 1000 or less, and more preferably class 100 or less.

The optical lens of the present invention is preferably implemented to be used in the form of an aspherical lens as necessary. Since the spherical aberration can be substantially zero with only 1 lens, the aspherical lens does not need to be combined with a plurality of spherical lenses to eliminate the spherical aberration, and thus, the weight and production cost can be reduced. Therefore, the aspherical lens is useful as an optical lens, particularly a camera lens. The astigmatism (non-point aberration) of the aspherical lens is preferably 0 to 15m λ, and more preferably 0 to 10m λ.

The thickness of the optical lens of the present invention can be set in a wide range depending on the application, and is not particularly limited, but is preferably 0.01 to 30mm, and more preferably 0.1 to 15 mm. The surface of the optical lens of the present invention may be provided with a coating layer such as an antireflection layer or a hard coat layer as required. The antireflection layer may be a single layer or a plurality of layers, and may be either an organic layer or an inorganic layer, and is preferably an inorganic layer. Specific examples thereof include oxides and fluorides such as silicon oxide, aluminum oxide, zirconium oxide, titanium oxide, cerium oxide, magnesium oxide, and magnesium fluoride. More preferred among these are silica and zirconia, and still more preferred is a combination of silica and zirconia. The antireflection layer is not particularly limited in any combination of single layer and multiple layers, and in any combination of components and thicknesses thereof, and preferably has a 2-layer structure or a 3-layer structure, and particularly preferably has a 3-layer structure. The anti-reflection layer may be formed to have a thickness of 0.00017 to 3.3% of the thickness of the optical lens, specifically 0.05 to 3 μm, and particularly preferably 1 to 2 μm.

Examples

The present invention will be described below with reference to examples, but the present invention is not limited to these examples.

< refractive index (nD) >

For a film having a thickness of 0.1mm formed of a polycarbonate resin obtained below, the film was measured using an Abbe refractometer in accordance with JIS-K-7142: 2014 the refractive index (nD) at 23 ℃ and a wavelength of 587.6nm is measured. The 0.1mm film was obtained by compression molding.

Abbe number (v) >

The refractive indices of a polycarbonate resin film having a thickness of 0.1mm obtained below at 23 ℃ at wavelengths of 486nm, 587.6nm and 656nm were measured by an Abbe refractometer, and the Abbe number (. nu.) was calculated by the following equation. The 0.1mm film was obtained by compression molding.

ν＝(nD－1)/(nF－nC)

nD: refractive index at wavelength of 587.6nm

nC: refractive index at wavelength 656nm

nF: refractive index at wavelength of 486nm

< glass transition temperature (Tg) >

The glass transition temperature (Tg) was measured using a Differential Scanning Calorimeter (DSC). Specific conditions are as follows.

The device comprises the following steps: hitachi high New technology DSC7000X of Kabushiki Kaisha

Sample amount: 5mg of

Atmosphere: under nitrogen atmosphere

Temperature rising conditions are as follows: 10 ℃/min

< weight average molecular weight (Mw) >)

The polystyrene-equivalent weight average molecular weight (Mw) was determined from a calibration curve of a standard polystyrene prepared in advance. That is, a calibration curve was prepared using a standard polystyrene (manufactured by tokyo corporation, "PStQuick MP-M") having a known molecular weight (molecular weight distribution of 1), and the elution time and the molecular weight of each peak were plotted from the standard polystyrene obtained by measurement, and a three-step approximation was performed to obtain a calibration curve. Mw is calculated by the following equation.

Mw＝Σ(Wi×Mi)÷Σ(Wi)

Where i represents the ith division point at which the molecular weight M is divided, Wi represents the ith weight, and Mi represents the ith molecular weight. In addition, the molecular weight M represents the polystyrene molecular weight value at the same elution time of the calibration curve. As a GPC apparatus, HLC-8320 GPC available from Tosoh corporation was used, 1 TSKguardcolumnSuperMPHZ-M was used as a protective column, and 3 TSKgel SuperMultipolypore HZ-M were used as an analytical column connected in series. Other conditions are as follows.

Solvent: HPLC grade tetrahydrofuran

Injection amount: 10 μ L

Sample concentration: 0.2 w/v% HPLC grade chloroform solution

Flow rate of solvent: 0.35ml/min

Measuring temperature: 40 deg.C

A detector: RI (Ri)

< Heat resistance test >

The polycarbonate resin obtained below was vacuum-dried at 120 ℃ for 4 hours, and then injection-molded by an injection molding machine (FANUC ROBOSHOT. alpha. -S30iA) at a cylinder temperature of 270 ℃ and a mold temperature of Tg-10 ℃ to obtain a plate, and then the plate was heated at Tg-20 ℃ for 4 hours and allowed to stand at 25 ℃ for 24 hours to obtain a disc-shaped plate test piece having a diameter of 50.00mm and a thickness of 3 mm. The disk-shaped plate test piece was left standing at 125 ℃ for 1000 hours in the air, and the diameter of the test piece was measured. The heat resistance was evaluated according to the following criteria.

Heat resistance A: the diameter of the disc-shaped plate is 49.9mm to 50.00mm

Heat resistance B: the diameter of the disc-shaped plate is more than 49.8mm and less than 49.9mm

Heat resistance C: the diameter of the disc-shaped plate is less than 49.8mm

< Molding cyclicity test >

The polycarbonate resin obtained below was vacuum-dried at 120 ℃ for 4 hours, and then injection-molded by an injection molding machine (FANUC ROBOSHOT. alpha. -S30iA) at a cylinder temperature of 270 ℃ and a mold temperature Tg-10 ℃. The molding cycle, and the resulting molded article was visually checked for breakage and adhesion to the mold. The molding cyclability was evaluated according to the following criteria.

Molding cyclicity A: the molding cycle can be performed for 20 seconds. The molded article was not broken and the mold was not stuck.

Molding cyclicity B: the molding cycle occurred 20 seconds after the molding, and the molded article was broken and/or stuck to the mold. The molding cycle can be performed for 30 seconds.

Molding cyclicity C: the molding cycle failed to mold at 20 seconds. The molding cycle for 30 seconds also causes breakage of the molded article or adhesion to the mold during molding.

< measurement of phenol (PhOH) and Diphenyl carbonate (DPC) in polycarbonate resin >

0.5g of the polycarbonate resin obtained below was dissolved in 50mL of Tetrahydrofuran (THF) to prepare a sample solution. As the standard samples of phenol and diphenyl carbonate, commercially available pure products obtained by distilling phenol and diphenyl carbonate were used to prepare standard curves of phenol and diphenyl carbonate, and 2 μ L of the sample solution was quantified by LC-MS under the following measurement conditions. The detection limit value under the measurement conditions was 0.01ppm (mass ratio).

LC-MS measurement conditions:

measurement apparatus (LC part): agilent Infinity 1260LC System

A chromatographic column: ZORBAX Eclipse XDB-18, and protective column core (Guard cartridge)

Mobile phase:

a: 0.01mol/L ammonium acetate aqueous solution

B: 0.01 mol/L-ammonium acetate in methanol

C：THF

Gradient program of mobile phase:

as shown in table 1 below, the mixture of a to C was used as a mobile phase, and the composition of the mobile phase was switched when the time shown in the column of time (minutes) elapsed, and the mobile phase was allowed to flow through the column for 30 minutes.

[ Table 1]

Flow rate: 0.3 mL/min

Column temperature: 45 deg.C

A detector: UV (225nm)

Measurement apparatus (MS part): agilent 6120single quad LCMS System

An ion source: ESI

Polarity: positive (DPC) & negative (PhOH)

Cleavage voltage: 70V

Dry gas: 10L/min, 350 deg.C

An atomizer: 50psi

Capillary voltage: 3000V (positive), 2500V (negative)

And (3) ion determination:

[ Table 2]

Monomer	Ion species	m/z
			PhOH	[M-H]-	93.1
DPC	[M+NH4]+	232.1

Sample injection amount: 2 μ L

< full light transmittance after PCT test >

The polycarbonate resin obtained below was vacuum-dried at 120 ℃ for 4 hours, and then injection-molded by an injection molding machine (FANUC ROBOSHOT. alpha. -S30iA) at a cylinder temperature of 270 ℃ and a mold temperature Tg-10 ℃ to obtain a disk-shaped test piece having a diameter of 50mm and a thickness of 3 mm. The PCT test was carried out by holding the obtained sheet having a diameter of 50mm and a thickness of 3mm at 120 ℃ under 0.2MPa at 100% RH for 20 hours. The total light transmittance after the PCT test was measured by a turbidimeter (MODEL 1001DP, manufactured by japan electrochrome industries, ltd.) according to old JIS K7105.

Value of < b >

The polycarbonate resin obtained below was vacuum-dried at 120 ℃ for 4 hours, and then injection-molded by an injection molding machine (FANUC ROBOSHOT. alpha. -S30iA) at a cylinder temperature of 270 ℃ and a mold temperature Tg-10 ℃ to obtain a disk-shaped test piece having a diameter of 50mm and a thickness of 3 mm. The obtained sheet was used to measure the b value by a SE2000 type spectroscopic color difference meter manufactured by Nippon Denshoku industries Co., Ltd in accordance with old JIS K7105. A smaller b value indicates a weaker yellowish color and a better hue.

(example 1)

As a raw material, SPG (spiroglycol: 3, 9-bis (1, 1-dimethyl-2-hydroxyethyl) -2, 4,8, 10-tetraoxaspiro [5.5] represented by the following structural formula]Undecane) 0.30mol, Bis-TMC (1, 1-Bis (4-hydroxyphenyl) -3, 3, 5-trimethylcyclohexane) 0.41mol, BPEF (9, 9-Bis [ 4- (2-hydroxyethoxy) phenyl) represented by the following structural formula]Fluorene) 0.29mol, DPC (diphenyl carbonate) 1.15mol and sodium bicarbonate 1X 10 mol^－5mol was charged into a 2L reactor equipped with a stirrer and a distillation apparatus, and heated to 180 ℃ under a nitrogen atmosphere of 760 mmHg. Complete dissolution of the starting material was confirmed 10 minutes after the start of heating, and stirring was performed under the same conditions for 110 minutes. Then, the temperature was raised at a rate of 60 ℃/hr to 200 ℃ while the reduced pressure was adjusted to 200 mmHg. At this time, the start of distillation of the by-produced phenol was confirmed. Then, the reaction was carried out at 200 ℃ for 20 minutes. Then, the temperature was increased to 230 ℃ at a rate of 75 ℃/hr, and after the temperature increase was completed for 10 minutes, the reduced pressure was maintained at this temperature for 1 hour to 1mmHg or less. Then, the temperature was raised to 245 ℃ at a rate of 60 ℃/hr, followed by stirring for 30 minutes. After the reaction, nitrogen was introduced into the reactor to return to normal pressure, and the produced polycarbonate resin was taken out. The obtained polycarbonate resin had a phenol (PhOH) content of 100ppm (by mass) and a DPC content of 100ppm (by mass). The physical properties of the obtained resin are summarized in table 3 below.

(examples 2 to 7, comparative examples 1 to 4)

Polycarbonate resins were obtained in the same manner as in example 1, except that the dihydroxy compounds (mol) in the raw materials were replaced with the dihydroxy compounds shown in table 3 below. The physical properties of the obtained resin are summarized in table 3 below.

(example 8)

As a raw material, SPG (spiroglycol: 3, 9-bis (1, 1-dimethyl-2-hydroxyethyl) -2, 4,8, 10-tetraoxaspiro [5.5] shown by the above structural formula]Undecane) 2.00mol, Bis-TMC (1, 1-Bis (4-hydroxyphenyl) -3, 3, 5-trimethylcyclohexane) 3.70mol shown in the above structural formula, BPEF (9, 9-Bis [ 4- (2-hydroxyethoxy) phenyl) shown in the above structural formula]Fluorene) 4.30mol, DPC (diphenyl carbonate) 11.52mol and sodium bicarbonate 1X 10 mol^－4mol was charged into a 25L reactor equipped with a stirrer and a distillation apparatus and heated to 180 ℃ under a nitrogen atmosphere of 760 mmHg. Complete dissolution of the starting material was confirmed 20 minutes after the start of heating, followed by stirring under the same conditions for 110 minutes. Then, while the reduced pressure was adjusted to 200mmHg, the temperature was raised at a rate of 60 ℃/hr to 200 ℃. At this time, the start of distillation of the by-produced phenol was confirmed. Then, the reaction was carried out at 200 ℃ for 20 minutes. Further, the temperature was raised to 230 ℃ at a rate of 75 ℃/hr, and after the temperature rise was completed for 10 minutes, the reduced pressure was set to 1mmHg for 1 hour while keeping the temperature. Then, the temperature was raised to 245 ℃ at a rate of 60 ℃/hr, followed by stirring for 30 minutes. After the reaction, nitrogen was introduced into the reactor to return to normal pressure, and the produced polycarbonate resin was taken out while being pelletized. The obtained polycarbonate resin had a phenol (PhOH) content of 300ppm (mass ratio), a DPC content of 150ppm (mass ratio), and a total light transmittance after PCT test of 78%.

Next, the obtained polycarbonate resin pellets were dried at 100 ℃ for 4 hours by a dryer. The dried pellets were mixed with 1000ppm of pentaerythritol-tetrakis [ 3- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionate ] (AO-60: antioxidant, manufactured by ADEKA Co., Ltd.), 1500ppm of glycerol monostearate (S-100A: mold release agent, manufactured by Rikian vitamin Co., Ltd.) and 300ppm of 3, 9-bis (2, 6-di-tert-butyl-4-methylphenoxy) -2, 4,8, 10-tetraoxa-3, 9-diphosphaspiro [5.5] undecane (PEP-36: antioxidant, manufactured by ADEKA Co., Ltd.) as additives, and the additives were added to the dried pellets. Then, the mixture was melt-kneaded under reduced pressure of 40mmHg by a twin-screw extruder to form pellets. The obtained polycarbonate resin composition had a refractive index of 1.583, an Abbe number of 29, a Tg of 154 ℃, an Mw of 30,000, a b value of 1.0, and both heat resistance and molding cycle properties A. The phenol (PhOH) content in the composition was 120ppm (by mass) and the DPC content was 100ppm (by mass). Then, the total light transmittance of the composition after the PCT test was 89%, and the total light transmittance was improved by adding the additive.

[ Table 3]