阅读说明：本技术 树脂组合物以及成型体 (Resin composition and molded article ) 是由 大关弘贵 高野大贵 小齐拓人 于 2020-01-09 设计创作，主要内容包括：本发明提供一种可成型性优异且所获得成型体的阻燃性及抗冲击性优异的树脂组合物。本发明涉及的树脂组合物含有芳香族聚碳酸酯树脂、具有如下述式(1)所示结构的砜树脂、无机填料、含磷化合物、以及含硅化合物或含硅粒子。(The invention provides a resin composition which has excellent formability and the obtained formed body has excellent flame retardance and impact resistance. The resin composition according to the present invention contains an aromatic polycarbonate resin, a sulfone resin having a structure represented by the following formula (1), an inorganic filler, a phosphorus-containing compound, and a silicon-containing compound or silicon-containing particles.)

1. A resin composition comprising:

an aromatic polycarbonate resin,

A sulfone resin having a structure represented by the following formula (1),

Inorganic filler,

A phosphorus-containing compound, and

a silicon-containing compound or a silicon-containing particle,

[ chemical formula 1]

2. The resin composition according to claim 1, wherein the sulfone resin is a polyphenylsulfone resin having a structure represented by the following formula (11),

[ chemical formula 2]

3. The resin composition according to claim 1 or 2, wherein the content of the sulfone resin is 5% by weight or more and 35% by weight or less in the total content 100% by weight of the content of the aromatic polycarbonate resin and the content of the sulfone resin.

4. The resin composition according to any one of claims 1 to 3, wherein the weight ratio of the content of the sulfone resin to the content of the phosphorus-containing compound is 0.6 or more and 3.5 or less.

5. The resin composition according to any one of claims 1 to 4, wherein the content of the phosphorus-containing compound is 5 parts by weight or more and 16 parts by weight or less with respect to 100 parts by weight of the total content of the aromatic polycarbonate resin and the content of the sulfone resin.

6. The resin composition according to any one of claims 1 to 5, wherein the content of the inorganic filler is 10 parts by weight or more and 40 parts by weight or less with respect to 100 parts by weight of the total content of the aromatic polycarbonate resin and the content of the sulfone resin.

7. The resin composition according to any one of claims 1 to 6, wherein the inorganic filler is talc.

8. The resin composition according to any one of claims 1 to 7, wherein the total content of the silicon-containing compound and the silicon-containing particles is 2 parts by weight or more and 20 parts by weight or less with respect to 100 parts by weight of the total content of the aromatic polycarbonate resin and the sulfone resin.

9. The resin composition according to any one of claims 1 to 8, which contains the silicon-containing particles, wherein,

the silicon-containing particles are core-shell particles having a core and a shell disposed on the surface of the core.

10. The resin composition according to any one of claims 1 to 9, which comprises a fluorine-based resin,

the content of the fluorine-based resin is 0.5 parts by weight or more and 2 parts by weight or less with respect to 100 parts by weight of the total content of the aromatic polycarbonate resin and the sulfone resin.

11. A molded article obtained by molding the resin composition according to any one of claims 1 to 10.

12. The shaped body according to claim 11, which is in the form of a sheet.

13. Shaped body according to ISO5660-1, according to claim 11 or 12, having a radiant heat at the heater of 50kW/m²And an average maximum heat release rate of 130kW/m measured in the presence of an ignition device²The following.

14. The molded article according to any one of claims 11 to 13, which is an interior material for transport machinery.

15. The molded article according to any one of claims 11 to 14, which is an interior material for a railway vehicle.

Technical Field

The present invention relates to a resin composition containing an aromatic polycarbonate resin. The present invention also relates to a molded article comprising the aromatic polycarbonate resin.

Background

Thermoplastic resins such as polycarbonate resins are excellent in durability, light weight, moldability and the like. Therefore, thermoplastic resins are used in various fields such as the construction field, the household electrical appliance field, and the transportation field.

Specific applications of the thermoplastic resin include interior materials for transportation machines such as railway vehicles, airplanes, ships, and automobiles. Examples of the interior material include ceilings, window frames, armrests, backrests, and table boards.

In the above applications, molded articles using a thermoplastic resin are required to have excellent flame retardancy and impact resistance. However, thermoplastic resins are generally flammable and have weak impact resistance, and therefore, it is currently being widely studied how to optimize the flame retardancy and impact resistance of molded articles using thermoplastic resins.

Patent document 1 discloses a thermoplastic resin composition containing (a) a polyetherimide resin, (b) an aromatic polycarbonate resin, and (c) a functionalized polysiloxane polymer.

Patent document 2 discloses a sulfone polymer composition containing a sulfone polymer (a) having a high glass transition temperature and a specific structure, a miscible polymer (B), and a non-miscible polymer (C).

Documents of the prior art

Patent document

Patent document 1 Japanese patent application laid-open No. 11-256035

Patent document 2 Japanese patent application laid-open No. 2008-516028

Disclosure of Invention

Problems to be solved by the invention

When the resin composition is molded, a molded article having a specific shape can be produced by vacuum molding. In vacuum forming, a molded article is generally produced by the following steps (1), (2) and (3). (1) The resin composition is molded to obtain a sheet-like molded article. (2) The obtained sheet-like shaped body is heated and softened. (3) The softened sheet-like formed body is subjected to vacuum suction in accordance with a desired specific shape to deform the sheet-like formed body, thereby obtaining a formed body having a specific shape.

In the resin compositions described in patent documents 1 and 2, deterioration in moldability may occur. For example, when a molded article is produced by vacuum molding using the resin composition, heating at a high temperature (for example, 220 ℃ or higher) is sometimes required, and the sheet-like molded article may be difficult to deform.

In addition, in a conventional molded article containing a resin, when the flame retardancy of the molded article is intended to be improved, the impact resistance may be lowered, and when the impact resistance is intended to be improved, the flame retardancy may be lowered.

Molded articles obtained from the resin compositions described in patent documents 1 and 2 have high flame retardancy and impact resistance to some extent, but are not sufficient, and further improvement in flame retardancy and impact resistance is required.

The purpose of the present invention is to provide a resin composition which has excellent moldability and gives a molded article having excellent flame retardancy and impact resistance. It is another object of the present invention to provide a molded article using the resin composition.

Means for solving the problems

According to a broad aspect of the present invention, there is provided a resin composition comprising: an aromatic polycarbonate resin, a sulfone resin having a structure represented by the following formula (1), an inorganic filler, a phosphorus-containing compound, and a silicon-containing compound or silicon-containing particles,

[ chemical formula 1]

According to a specific aspect of the resin composition of the present invention, the sulfone resin is a polyphenylsulfone resin having a structure represented by the following formula (11),

[ chemical formula 2]

According to a specific aspect of the resin composition of the present invention, the content of the sulfone resin is 5 wt% or more and 35 wt% or less in 100 wt% of the total content of the aromatic polycarbonate resin and the sulfone resin.

According to a specific aspect of the resin composition of the present invention, the weight ratio of the content of the sulfone resin to the content of the phosphorus-containing compound is 0.6 or more and 3.5 or less.

According to a specific aspect of the resin composition of the present invention, the content of the phosphorus-containing compound is 5 parts by weight or more and 16 parts by weight or less with respect to 100 parts by weight of the total content of the aromatic polycarbonate resin and the content of the sulfone resin.

According to a specific aspect of the resin composition of the present invention, the content of the inorganic filler is 10 parts by weight or more and 40 parts by weight or less with respect to 100 parts by weight of the total content of the aromatic polycarbonate resin and the content of the sulfone resin.

According to a certain aspect of the resin composition related to the present invention, the inorganic filler is talc.

According to a certain aspect of the resin composition related to the present invention, the total content of the silicon-containing compound and the silicon-containing particles is 2 parts by weight or more and 20 parts by weight or less with respect to 100 parts by weight of the total content of the aromatic polycarbonate resin and the content of the sulfone resin.

According to a specific aspect of the resin composition of the present invention, the resin composition contains the silicon-containing particles, and the silicon-containing particles are core-shell particles having a core and a shell disposed on a surface of the core.

According to a specific aspect of the resin composition of the present invention, the resin composition contains a fluorine-based resin, and the content of the fluorine-based resin is 0.5 parts by weight or more and 2 parts by weight or less with respect to 100 parts by weight of the total content of the aromatic polycarbonate resin and the sulfone resin.

According to a broad aspect of the present invention, there is provided a molded article obtained by molding the resin composition.

According to a specific aspect of the molded article according to the present invention, the molded article is in the form of a sheet.

According to a particular aspect of the shaped bodies according to the invention, these are in accordance with ISO5660-1 and have a radiant heat at the heater of 50kW/m²And an average maximum heat release rate of 130kW/m measured in the presence of an ignition device²The following.

According to a specific aspect of the molded article according to the present invention, the molded article is an interior material of a transport machine.

According to a specific aspect of the molded article according to the present invention, the molded article is an interior material for a railway vehicle.

ADVANTAGEOUS EFFECTS OF INVENTION

The resin composition according to the present invention comprises: an aromatic polycarbonate resin, a sulfone resin having a structure represented by the above formula (1), an inorganic filler, a phosphorus-containing compound, and a silicon-containing compound or silicon-containing particles. The resin composition according to the present invention has the above-described structure, and therefore, has excellent moldability, and the molded article obtained therefrom has excellent flame retardancy and impact resistance.

Detailed Description

The present invention will be described in detail below.

The resin composition according to the present invention comprises: an aromatic polycarbonate resin, a sulfone resin having a structure represented by the following formula (1), an inorganic filler, a phosphorus-containing compound, and a silicon-containing compound or silicon-containing particles,

[ chemical formula 3]

The resin composition according to the present invention has the above-described structure, and therefore, has excellent moldability, and the molded article obtained therefrom has excellent flame retardancy and impact resistance. The resin composition of the present invention can enhance all of moldability, flame retardancy and impact resistance. The resin composition of the present invention has excellent moldability, and thus can give a molded article having a predetermined shape without heating at a high temperature, for example.

In the present specification, the silicon-containing compound and the silicon-containing particles may be collectively referred to as a silicon-containing substance.

The specific details of the components contained in the resin composition according to the present invention will be described below.

[ aromatic polycarbonate resin ]

The resin composition according to the present invention contains an aromatic polycarbonate resin. The aromatic polycarbonate resin may be used alone or in combination of two or more.

The aromatic polycarbonate resin is preferably an aromatic polycarbonate resin having a structural unit represented by the following formula (2).

[ chemical formula 4]

In the formula (2), R1 and R2 each represent a hydrogen atom, an alkyl group having 1 to 20 carbon atoms, a group having a substituent bonded to the alkyl group having 1 to 20 carbon atoms, or an aryl group. In the above formula (2), R3 and R4 each represents a hydrogen atom or an alkyl group.

When R3 or R4 in the formula (2) is an alkyl group, the number of carbon atoms in the alkyl group is preferably 1 or more, preferably 6 or less, more preferably 3 or less, and still more preferably 2 or less. Preferred examples of the alkyl group include a methyl group, an ethyl group, a propyl group, a butyl group, a tert-butyl group, a pentyl group, and a heptyl group.

The aromatic polycarbonate resin may have only one kind of the structural unit represented by the formula (2), or may have two or more kinds.

In obtaining the aromatic polycarbonate resin, examples of the compound for introducing the structural unit represented by the above formula (2) include 2, 2-bis (4-hydroxyphenyl) propane (bisphenol A), 2-bis (4-hydroxy-3-methylphenyl) propane, 2-bis (4-hydroxyphenyl) butane, 2-bis (4-hydroxyphenyl) pentane, 2-bis (4-hydroxyphenyl) -4-methylpentane, 2-bis (4-hydroxy-3-methylphenyl) propane (bisphenol C), 2-bis (4-hydroxy-3- (1-methylethyl) phenyl) propane, 2-bis (4-hydroxy-3-tert-butylphenyl) propane, and mixtures thereof, 2, 2-bis (4-hydroxy-3- (1-methylpropyl) phenyl) propane, 2-bis (4-hydroxy-3-cyclohexylphenyl) propane, 2-bis (4-hydroxy-3-phenylphenyl) propane, 1-bis (4-hydroxyphenyl) decane, 1-bis (4-hydroxyphenyl) cyclohexyl (bisphenol Z), 1-bis (4-hydroxyphenyl) -1-phenylethane, 1-bis (4-hydroxy-3-methylphenyl) cyclohexane, 1-bis (4-hydroxy-3, 5-dimethylphenyl) cyclohexane, 1-bis (4-hydroxy-3- (1-methylethyl) phenyl) cyclohexane, 1, 1-bis (4-hydroxy-3-t-butylphenyl) cyclohexane, 1-bis (4-hydroxy-3- (1-methylpropyl) phenyl) cyclohexane, 1-bis (4-hydroxy-3-cyclohexylphenyl) cyclohexane, 1-bis (4-hydroxy-3-phenylphenyl) cyclohexane, 1-bis (4-hydroxy-3-methylphenyl) -1-phenylethane, 1-bis (4-hydroxy-3, 5-dimethylphenyl) -1-phenylethane, 1-bis (4-hydroxy-3- (1-methylethyl) phenyl) -1-phenylethane, 1-bis (4-hydroxy-3- (1-methylpropyl) phenyl) cyclohexane- 1-phenylethane, 1-bis (4-hydroxy-3-cyclohexylphenyl) -1-phenylethane, 1-bis (4-hydroxy-3-phenylphenyl) -1-phenylethane, 1-bis (4-hydroxyphenyl) cyclooctane, 4 ' - (1, 3-phenylenediisopropylpropene) bisphenol, 4 ' - (1, 4-phenylenediisopropylpropene) bisphenol, 9-bis (4-hydroxy-3-hydroxyphenyl) fluorene, 9-bis (4-hydroxy-3-methylphenyl) fluorene, 4 ' -dihydroxybenzophenone, 4 ' -dihydroxyphenyl ether, 4 ' -dihydroxybiphenyl, 1-bis (4-hydroxyphenyl) -3, 3-5-trimethylcyclohexane, and 1, 1-bis (4-hydroxy-6-methyl-3-tert-butylphenyl) butane.

From the viewpoint of further improving flame retardancy and impact resistance, in obtaining the above aromatic polycarbonate resin, the compound for introducing the structural unit represented by the above formula (2) is preferably 2, 2-bis (4-hydroxyphenyl) propane (bisphenol a), 2-bis (4-hydroxy-3-methylphenyl) propane (bisphenol C), or 1, 1-bis (4-hydroxyphenyl) cyclohexyl (bisphenol Z), and more preferably 2, 2-bis (4-hydroxyphenyl) propane (bisphenol a). The aromatic polycarbonate resin preferably has a structural unit derived from the above-mentioned preferred compound.

Commercially available products of aromatic polycarbonate resins having a structural unit derived from a bisphenol A compound include "Ipiplon E series" manufactured by Mitsubishi gas chemical corporation.

Commercially available products of aromatic polycarbonate resins having a structural unit derived from a bisphenol Z-type compound include "Panlite series" manufactured by Ditaminizer Kabushiki Kaisha and "Iipilon Z series" manufactured by Mitsubishi gas chemical corporation.

The viscosity average molecular weight (Mv) of the aromatic polycarbonate resin is preferably 10000 or more, more preferably 15000 or more, and preferably 50000 or less, more preferably 40000 or less. If the viscosity average molecular weight is not less than the lower limit and not more than the upper limit, the flame retardancy and impact resistance can be further improved.

The aromatic polycarbonate resin may or may not have a branched structure.

The aromatic polycarbonate resin can be produced by a conventionally known method. Examples of the method for producing the aromatic polycarbonate resin include a melt polymerization method and a phase interface method.

The method for producing an aromatic polycarbonate resin by the above melt polymerization method includes a method in which a diphenol compound and a diphenyl carbonate compound are reacted in a molten state by an ester exchange reaction. In this method, for example, a diphenol compound and a diphenyl carbonate compound are put in a reactor equipped with a stirrer and a distillation and concentration device, and the reactor is heated to a predetermined temperature under a nitrogen atmosphere, whereby the reaction mixture can be brought into a molten state. In the method for producing an aromatic polycarbonate resin by the above melt polymerization method, a branching agent, a chain terminator and the like may be used.

The method for producing an aromatic polycarbonate resin by the phase interface method includes a method of reacting a diphenol compound, a carbonic acid halide or an aromatic dicarboxylic acid dihalide, if necessary, with a branching agent and, if necessary, with a chain terminator. In this method, a carbonic acid halide may be used, an aromatic dicarboxylic acid dihalide may be used, or a carbonic acid halide and an aromatic dicarboxylic acid dihalide may be used together.

The above diphenol compound is not particularly limited. As the diphenol compound, conventionally known diphenol compounds may be used. The diphenol compound may be used alone or in combination of two or more.

The diphenyl carbonate compound is not particularly limited. As the diphenyl carbonate compound, conventionally known diphenyl carbonate compounds can be used. The diphenyl carbonate compound may be used alone or in combination of two or more.

The above-mentioned carbonic acid halide is not particularly limited. As the above-mentioned carbonate halide, conventionally known carbonate halides can be used. The carbonate halide may be used alone or in combination of two or more.

The above-mentioned carbonic acid halide is preferably phosgene.

The aromatic dicarboxylic acid dihalide is not particularly limited. As the aromatic dicarboxylic acid dihalide, conventionally known aromatic dicarboxylic acid dihalides can be used. The aromatic dicarboxylic acid dihalide may be used alone or in combination of two or more.

The aromatic dicarboxylic acid dihalide is preferably benzenedicarboxylic acid dihalide.

The above-mentioned branching agent is not particularly limited. As the branching agent, a conventionally known branching agent can be used. The branching agent may be used alone or in combination of two or more.

The branching agent is preferably a trifunctional phenol compound or a tetrafunctional phenol compound, more preferably a triphenol, a tetraphenol, or a phenol compound having a relatively low reactivity and having at least 3 functional groups, and still more preferably 1,1, 1-tris- (p-hydroxyphenyl) ethane. By using these preferred branching agents, an aromatic polycarbonate resin having a branched structure can be obtained well.

The branching agent may be a phenol compound having an amine functional group. When the branching agent is a phenol compound having an amine functional group, the amine functional group functions as an active functional group to branch the aromatic polycarbonate resin via an amide bond.

The above-mentioned chain terminator is not particularly limited. As the above-mentioned chain terminator, a conventionally known chain terminator can be used. The above-mentioned chain terminator may be used alone or in combination of two or more.

The chain terminator is preferably phenol from the viewpoint of obtaining an aromatic polycarbonate resin favorably; p-chlorophenol; p-tert-butylphenol; 2,4, 6-tribromophenol; 4- (1, 3-tetramethylbutyl) -phenol described in DE-A2842005, and a long-chain alkylphenol such as monoalkylphenol having 8 or more and 20 or less carbon atoms in the alkyl substituent; and alkylphenols such as 3, 5-di-tert-butylphenol, p-tert-octylphenol, p-dodecylphenol, 2- (3, 5-dimethylheptyl) -phenol, and 4- (3, 5-dimethylheptyl) -phenol.

The content of the chain terminator is preferably 0.5mol or more and preferably 10mol or less based on 100mol of the diphenol compound, from the viewpoint of obtaining an aromatic polycarbonate resin satisfactorily.

The content of the aromatic polycarbonate resin is preferably 50% by weight or more, more preferably 55% by weight or more, preferably 85% by weight or less, and more preferably 80% by weight or less, in 100% by weight of the resin composition. When the content of the aromatic polycarbonate resin is not less than the lower limit and not more than the upper limit, the flame retardancy and impact resistance can be further improved.

[ sulfone resin ]

The resin composition according to the present invention contains a sulfone resin having a structure represented by the following formula (1). The above sulfone resin is a thermoplastic resin. By incorporating a sulfone resin having a structure represented by the following formula (1) into the resin composition, even when the molded article is burned, carbide (coke) can be formed satisfactorily on the surface of the molded article, and the amount of oxygen supplied can be suppressed. As a result, the flame retardancy of the molded article can be improved. If the resin composition does not contain the sulfone resin, it is difficult to improve flame retardancy. Further, the resin composition can improve moldability and flame retardancy by containing both the sulfone resin having a structure represented by the following formula (1) and the phosphorus-containing compound. The sulfone resin may be used alone or in combination of two or more.

[ chemical formula 5]

The sulfone resin has the structural unit represented by the above (1).

Examples of the sulfone resin include polysulfone resin (PSU), polyethersulfone resin (PESU), and polyphenylsulfone resin (PPSU).

From the viewpoint of further improving flame retardancy and impact resistance, the sulfone resin is preferably a polyethersulfone resin or a polyphenylsulfone resin, and more preferably a polyphenylsulfone resin.

From the viewpoint of further improving flame retardancy and impact resistance, the sulfone resin is preferably a polyphenylsulfone resin having a structure represented by the following formula (11). The sulfone resin is preferably a polyphenylsulfone resin having a structural unit represented by the following formula (11).

[ chemical formula 6]

The content of the sulfone resin is preferably 5% by weight or more, more preferably 8% by weight or more, further preferably 10% by weight or more, and preferably 40% by weight or less, more preferably 35% by weight or less, further preferably 30% by weight or less, and particularly preferably 25% by weight or less, in the total content 100% by weight of the content of the aromatic polycarbonate resin and the content of the sulfone resin. When the content of the sulfone resin is not less than the lower limit and not more than the upper limit, the moldability and flame retardancy can be further improved.

The weight ratio of the content of the sulfone resin to the content of the phosphorus-containing compound (the content of the sulfone resin/the content of the phosphorus-containing compound) is preferably 0.6 or more, more preferably 0.7 or more, and preferably 6.0 or less, more preferably 4.0 or less, further preferably 3.5 or less, and particularly preferably 3.0 or less. When the weight ratio (the content of the sulfone resin/the content of the phosphorus-containing compound) is not less than the lower limit and not more than the upper limit, the moldability, flame retardancy and impact resistance can be further improved. When the weight ratio (the content of the sulfone resin/the content of the phosphorus-containing compound) is not less than the lower limit but not more than the upper limit, the moldability and the flame retardancy can be further improved.

[ inorganic Filler ]

The resin composition of the present invention contains an inorganic filler. The flame retardancy can be improved by adding the inorganic filler to the resin composition. If the resin composition does not contain the inorganic filler, it is difficult to improve flame retardancy. The inorganic filler may be used alone or in combination of two or more.

Examples of the inorganic filler include talc, mica, montmorillonite, diatomaceous earth, alumina, titanium oxide, calcium oxide, magnesium oxide, iron oxide, tin oxide, antimony oxide, ferrites, calcium hydroxide, magnesium hydroxide, basic magnesium carbonate, calcium carbonate, magnesium carbonate, zinc carbonate, barium carbonate, dawsonite, hydrotalcite, calcium sulfate, barium sulfate, gypsum fiber, potassium salt, clay mineral, glass fiber, glass bead, aluminum nitride, boron nitride, carbon black, graphite, carbon fiber, carbon sphere, charcoal powder, metal powder, potassium titanate, magnesium sulfate, lead titanate zirconate, aluminum borate, molybdenum sulfide, stainless steel fiber, zinc borate, magnetic powder, slag fiber, coal powder, silica-alumina fiber, silica fiber, and zirconia fiber.

From the viewpoint of further improving flame retardancy and impact resistance, the inorganic filler is preferably talc, mica, or montmorillonite, and more preferably talc.

The talc may be a compressed talc. If the talc is a compressed talc, the resin composition can be easily processed.

The inorganic filler may be subjected to surface treatment such as silylation treatment, plasma treatment, and ashing treatment. When the inorganic filler is an inorganic filler subjected to a surface treatment such as a silanization treatment, the compatibility with the aromatic polycarbonate resin is further improved. The inorganic filler subjected to the silanization treatment is not contained in the silicon-containing particles.

From the viewpoint of further improving flame retardancy and impact resistance, the volume average particle diameter (D50) of the inorganic filler is preferably 1 μm or more, more preferably 1.5 μm or more, and preferably 6 μm or less, more preferably 5 μm or less. When the volume average particle diameter (D50) of the inorganic filler is not more than the upper limit, a molded article having a small center-of-gravity distance between adjacent inorganic fillers and a large number of particles of the inorganic filler can be obtained. The molded article having a small center-of-gravity distance between adjacent inorganic fillers and a large number of particles of the inorganic filler has more excellent flame retardancy and gas barrier properties. When the center of gravity distance between adjacent inorganic fillers is small and the number of particles of the inorganic filler is large, even if the molded body is burned, the amount of oxygen flowing from the gap between the inorganic fillers can be suppressed, and the release of combustible gas generated during combustion can be suppressed. In addition, a molded article in which the center of gravity distance between adjacent inorganic fillers is small and the number of particles of the inorganic filler is large tends to have excellent impact resistance.

The volume average particle diameter of the above inorganic filler is an average particle diameter measured on a volume basis, and is a value of 50% of the median diameter (D50). The volume average particle diameter (D50) can be measured by a laser diffraction/scattering method, an image analysis method, a coulter method, a centrifugal sedimentation method, or the like. The volume average particle diameter (D50) is preferably measured by a laser diffraction/scattering method.

The content of the inorganic filler is preferably 8% by weight or more, more preferably 12% by weight or more, and preferably 25% by weight or less, more preferably 20% by weight or less, in 100% by weight of the resin composition. If the content of the inorganic filler is not less than the lower limit, the flame retardancy can be further optimized. If the content of the inorganic filler is not more than the upper limit, the impact resistance can be further optimized.

The content of the inorganic filler is preferably 10 parts by weight or more, more preferably 15 parts by weight or more, and preferably 40 parts by weight or less, more preferably 30 parts by weight or less, relative to 100 parts by weight of the aromatic polycarbonate resin. If the content of the inorganic filler is not less than the lower limit, the flame retardancy can be further improved. When the content of the inorganic filler is not more than the upper limit, the impact resistance can be further improved.

The content of the inorganic filler is preferably 10 parts by weight or more, more preferably 13 parts by weight or more, and preferably 40 parts by weight or less, more preferably 30 parts by weight or less, relative to 100 parts by weight of the total content of the aromatic polycarbonate resin and the content of the sulfone resin. If the content of the inorganic filler is not less than the lower limit, the flame retardancy can be further improved. When the content of the inorganic filler is not more than the upper limit, the impact resistance can be further improved.

[ phosphorus-containing Compound ]

The resin composition of the present invention contains a phosphorus-containing compound. The above-mentioned phosphorus-containing compound is a compound having a phosphorus atom. The resin composition containing the phosphorus-containing compound can improve moldability and flame retardancy. If the resin composition does not contain the phosphorus-containing compound, the moldability may be lowered and the flame retardancy may be lowered. The phosphorus-containing compound may be used alone or in combination of two or more.

The phosphorus-containing compound is preferably a phosphorus-based flame retardant from the viewpoint of further improving flame retardancy.

The phosphorus-containing compound may be a phosphorus-containing compound having a halogen atom, a phosphorus-containing compound having no halogen atom, or a mixture of a phosphorus-containing compound having no halogen atom and a phosphorus-containing compound having a halogen atom.

The phosphorus-containing compound may be any compound containing a phosphorus atom, and may be a compound derived from resorcinol, hydroquinone, bisphenol a, diphenol, or the like.

Examples of the phosphorus-containing compound include phosphoric acid monomers, phosphoric acid oligomers, phosphonic acid esters, organic phosphorous acid esters, phosphonic acid salts, phosphonic acid ester amines, phosphoric acid salts, phosphazenes, and phosphoric acid esters.

The phosphorus-containing compound is preferably a phosphate ester from the viewpoint of further improving flame retardancy. The phosphate ester is a compound having a phosphate ester structure.

The phosphate may be a phosphoric monoester, a phosphoric diester, or a phosphoric triester.

Examples of the phosphate ester include tributyl phosphate, triphenyl phosphate, tricresyl phosphate, diphenylcresyl phosphate, diphenyl-2-ethylcresyl phosphate, tris- (ethylphenylphenyl) phosphate, resorcinol crosslinked diphosphate, and bisphenol A crosslinked diphosphate. The above-mentioned phosphoric acid esters are preferably oligomeric phosphoric acid esters derived from bisphenol A.

The content of the phosphorus-containing compound is preferably 2% by weight or more, more preferably 4% by weight or more, and preferably 18% by weight or less, more preferably 15% by weight or less, in 100% by weight of the resin composition. When the content of the phosphorus-containing compound is not less than the lower limit, moldability and flame retardancy can be further optimized. If the content of the phosphorus-containing compound is not more than the upper limit, the impact resistance can be further optimized.

The content of the phosphorus-containing compound is preferably 3 parts by weight or more, more preferably 5 parts by weight or more, further preferably 7 parts by weight or more, and preferably 25 parts by weight or less, more preferably 20 parts by weight or less, relative to 100 parts by weight of the aromatic polycarbonate resin. When the content of the phosphorus-containing compound is not less than the lower limit, moldability and flame retardancy can be further improved. When the content of the phosphorus-containing compound is not more than the upper limit, the impact resistance can be further improved.

The content of the phosphorus-containing compound is preferably 5 parts by weight or more, more preferably 7 parts by weight or more, and preferably 16 parts by weight or less, more preferably 15 parts by weight or less, relative to 100 parts by weight of the total content of the aromatic polycarbonate resin and the content of the sulfone resin. When the content of the phosphorus-containing compound is not less than the lower limit, moldability and flame retardancy can be further improved. When the content of the phosphorus-containing compound is not more than the upper limit, the impact resistance can be further improved.

[ silicon-containing substance ]

The resin composition of the present invention contains a silicon-containing compound or silicon-containing particles. The resin composition according to the present invention contains a silicon-containing substance. The silicon-containing substance is a silicon-containing compound or a silicon-containing particle. The flame retardancy can be improved by adding the silicon-containing substance to the resin composition. If the resin composition does not contain the silicon-containing substance, flame retardancy may be deteriorated. The silicon-containing compound may be used alone or in combination of two or more.

The above silicon-containing compound is a compound having a silicon atom. The silicon-containing particles are particles having silicon atoms. The resin composition according to the present invention may contain the silicon-containing compound, the silicon-containing particles, or both the silicon-containing compound and the silicon-containing particles. Examples of the silicon-containing substance include silica, calcium silicate, silica-based spheres, silicon nitride, silicon carbide, silicone-based flame retardants, and core-shell particles containing silicon atoms.

Silicon-containing compound:

from the viewpoint of further improving flame retardancy, the silicon-containing compound is preferably a silicone-based flame retardant, preferably a polyorganosiloxane.

From the viewpoint of further improving flame retardancy, the polyorganosiloxane preferably has an aromatic skeleton. Examples of the polyorganosiloxane having an aromatic skeleton include polydiphenylsiloxane, polymethylphenylsiloxane, polydimethyldiphenylsiloxane, and cyclic siloxane having a phenyl group.

The polyorganosiloxane may have a functional group such as a silanol group, an epoxy group, an alkoxy group, a hydrosilyl group, and a vinyl group. When the polyorganosiloxane has these functional groups, the compatibility of the polyorganosiloxane with the aromatic polycarbonate resin can be improved, and the reactivity during combustion can be improved, and as a result, the flame retardancy can be improved.

When the polyorganosiloxane contains the silanol group, the content of the silanol group is preferably 1% by weight or more, more preferably 2% by weight or more, still more preferably 3% by weight or more, and particularly preferably 5% by weight or more, based on 100% by weight of the polyorganosiloxane. When the polyorganosiloxane contains the silanol group, the content of the silanol group is preferably 10% by weight or less, more preferably 9% by weight or less, still more preferably 8% by weight or less, and particularly preferably 7.5% by weight or less, based on 100% by weight of the polyorganosiloxane. If the content of the silanol group is not less than the lower limit and not more than the upper limit, the flame retardancy can be further improved. When the content of the silanol group exceeds 10% by weight, the thermal stability and the moist heat stability of the resin composition may be lower than those in the case where the content is 10% by weight or less.

When the polyorganosiloxane contains the alkoxy group, the content of the alkoxy group is preferably 10% by weight or less based on 100% by weight of the polyorganosiloxane. If the content of the alkoxy group is not more than the upper limit, the flame retardancy can be further improved. When the content of the alkoxy group exceeds 10% by weight, the resin composition may be more likely to be gelled than when the content is 10% by weight or less.

The molecular weight of the silicon-containing compound and the polyorganosiloxane is preferably 450 or more, more preferably 1000 or more, further preferably 1500 or more, particularly preferably 1700 or more, and preferably 300000 or less, more preferably 100000 or less, further preferably 20000 or less, and particularly preferably 15000 or less. When the molecular weights of the silicon-containing compound and the polyorganosiloxane are not less than the lower limit, the heat resistance of the silicon-containing compound and the polyorganosiloxane can be improved. When the molecular weights of the silicon-containing compound and the polyorganosiloxane are not more than the upper limit, the stability of the resin composition can be improved, and the dispersibility of the silicon-containing compound and the polyorganosiloxane in the resin composition can be improved, thereby improving the flame retardancy.

When the silicon-containing compound and the polyorganosiloxane are not polymers and the structural formulae of the silicon-containing compound and the polyorganosiloxane can be determined, the molecular weights of the silicon-containing compound and the polyorganosiloxane refer to the molecular weights calculated from the structural formulae. When the silicon-containing compound and the polyorganosiloxane are polymers, the molecular weight of the silicon-containing compound and the polyorganosiloxane refers to a weight average molecular weight in terms of polystyrene measured by Gel Permeation Chromatography (GPC).

The content of the silicon-containing compound is preferably 1% by weight or more, more preferably 2% by weight or more, and preferably 15% by weight or less, more preferably 12% by weight or less, in 100% by weight of the resin composition. If the content of the silicon-containing compound is not less than the lower limit, the flame retardancy can be further optimized. When the content of the silicon-containing compound is not more than the upper limit, the impact resistance can be further optimized.

The content of the silicon-containing compound is preferably 2 parts by weight or more, more preferably 4 parts by weight or more, and preferably 20 parts by weight or less, more preferably 15 parts by weight or less, relative to 100 parts by weight of the aromatic polycarbonate resin. If the content of the silicon-containing compound is not less than the lower limit, the flame retardancy can be further improved. When the content of the silicon-containing compound is not more than the upper limit, the impact resistance can be further improved.

The content of the silicon-containing compound is preferably 2 parts by weight or more, more preferably 3 parts by weight or more, and preferably 20 parts by weight or less, more preferably 16 parts by weight or less, relative to 100 parts by weight of the total content of the aromatic polycarbonate resin and the content of the sulfone resin. If the content of the silicon-containing compound is not less than the lower limit, the flame retardancy can be further improved. When the content of the silicon-containing compound is not more than the upper limit, the impact resistance can be further improved.

Silicon-containing particles:

the silicon-containing particles are preferably core-shell particles having a core and a shell disposed on the surface of the core. That is, the resin composition preferably contains core-shell particles having a core and a shell disposed on the surface of the core. Preferably, in the resin composition, the silicon-containing compound is contained as core-shell particles. The core-shell particles may have a silicon atom in the core, or may have a silicon atom in the shell. When the resin composition contains silicon-containing particles as core-shell particles, not only flame retardancy but also impact resistance can be improved.

In the core-shell particle, it is preferable that the organic compound constituting the core and the organic compound constituting the shell are chemically bonded from the viewpoint of further improving flame retardancy. The chemical bonding is preferably graft bonding.

Examples of the core-shell particles include silicone-based core-shell rubber polymers such as silicone-acrylate-methyl methacrylate copolymers and silicone-acrylate-acrylonitrile-styrene copolymers. The core-shell particles preferably have a core-shell rubber structure.

From the viewpoint of optimizing the appearance of the molded article and further improving the impact resistance, the volume average particle diameter (D50) of the silicon-containing particles or the core-shell particles is preferably 100nm or more, more preferably 250nm or more, and preferably 800nm or less. The core-shell particles having a volume average particle diameter (D50) of the lower limit or more and the upper limit or less can be produced by emulsion polymerization.

The volume average particle diameter of the silicon-containing particles or the core-shell particles is an average particle diameter measured on a volume basis, and is a value of 50% of the median diameter (D50). The volume average particle diameter (D50) can be measured by a laser diffraction/scattering method, an image analysis method, a coulter method, a centrifugal sedimentation method, or the like. The volume average particle diameter (D50) of the silicon-containing particles or the core-shell particles is preferably measured by a laser diffraction/scattering method.

Commercially available core-shell particles can be used. Commercially available products of the core-shell particles include Metabrene S-2001, S-2006, S-2501, S-2030, S-2100, S-2200, SRK200A, SX005, and SX006 (all of which are manufactured by Mitsubishi RAYON corporation).

The content of the silicon-containing particles is preferably 1 wt% or more, more preferably 2 wt% or more, and preferably 15 wt% or less, more preferably 12 wt% or less, in 100 wt% of the resin composition. If the content of the silicon-containing particles is not less than the lower limit, the flame retardancy can be further improved. When the content of the silicon-containing particles is not more than the upper limit, the impact resistance can be further improved.

The content of the silicon-containing particles is preferably 2 parts by weight or more, more preferably 4 parts by weight or more, and preferably 20 parts by weight or less, more preferably 15 parts by weight or less, relative to 100 parts by weight of the aromatic polycarbonate resin. If the content of the silicon-containing particles is not less than the lower limit, the flame retardancy can be further improved. When the content of the silicon-containing particles is not more than the upper limit, the impact resistance can be further improved.

The content of the silicon-containing particles is preferably 2 parts by weight or more, more preferably 3 parts by weight or more, and preferably 20 parts by weight or less, more preferably 16 parts by weight or less, relative to 100 parts by weight of the total content of the aromatic polycarbonate resin and the content of the sulfone resin. If the content of the silicon-containing particles is not less than the lower limit, the flame retardancy can be further improved. When the content of the silicon-containing particles is not more than the upper limit, the impact resistance can be further improved.

The total content of the silicon-containing compound and the silicon-containing particles (content of the silicon-containing substance) is preferably 1 wt% or more, more preferably 2 wt% or more, and preferably 15 wt% or less, more preferably 12 wt% or less, in 100 wt% of the resin composition. If the total content is not less than the lower limit, the flame retardancy can be further improved. If the total content is not more than the upper limit, the impact resistance can be further improved.

The total content of the silicon-containing compound and the silicon-containing particles (content of the silicon-containing substance) is preferably 2 parts by weight or more, more preferably 4 parts by weight or more, and preferably 20 parts by weight or less, more preferably 15 parts by weight or less, relative to 100 parts by weight of the aromatic polycarbonate resin. If the total content is not less than the lower limit, the flame retardancy can be further improved. If the total content is not more than the upper limit, the impact resistance can be further improved.

The total content of the silicon-containing compound and the silicon-containing particles (content of the silicon-containing substance) is preferably 2 parts by weight or more, more preferably 3 parts by weight or more, and preferably 20 parts by weight or less, more preferably 16 parts by weight or less, relative to 100 parts by weight of the total content of the aromatic polycarbonate resin and the content of the sulfone resin. If the total content is not less than the lower limit, the flame retardancy can be further improved. If the total content is not more than the upper limit, the impact resistance can be further improved.

[ fluorine-containing resin ]

The resin composition according to the present invention preferably contains a fluorine-based resin. The resin composition containing the fluorine-based resin can further improve flame retardancy. The fluorine-based resin may be used alone or in combination of two or more.

Examples of the fluorine-based resin include homopolymers having a fluorinated α -olefin monomer as a structural unit, and copolymers containing a fluorinated α -olefin monomer as a structural unit.

The fluorinated alpha-olefin monomer described above refers to an alpha-olefin monomer comprising a substituent having at least one fluorine atom.

Examples of the fluorinated α -olefin monomer include tetrafluoroethylene (CF) ₂＝CF₂)、CHF＝CF₂Vinylidene fluoride (CH)₂＝CF₂)、CH₂CHF, chlorotrifluoroethylene (CClF ═ CF)₂)、Cl₂＝CF₂、CClF＝CClF、CHF＝CCl₂、CH₂＝CClF、CCl₂CClF, hexachloropropene (CF)₂＝CFCF₃)、CF₃CF＝CHF、CF₃CH＝CF₂、CF₃CH＝CH₂、CF₃CH＝CH₂、CF₃CF＝CHF、CHF₂CH＝CHF、CF₃CH＝CH₂And the like.

Examples of the fluorine-based resin include poly (tetrachloroethylene) homopolymer (PTFE), poly (hexafluoroethylene), poly (tetrafluoroethylene-hexafluoroethylene), and poly (tetrafluoroethylene-ethylene-propylene). The poly (tetrachloroethylene) homopolymer (PTFE) may be fiber-forming or non-fiber-forming.

The content of the fluorine-based resin is preferably 0.01 wt% or more, more preferably 0.1 wt% or more, and preferably 1.5 wt% or less, more preferably 1 wt% or less, in 100 wt% of the resin composition. If the content of the fluorine-based resin is not less than the lower limit, the flame retardancy can be further improved. When the content of the fluorine-based resin is not more than the upper limit, the impact resistance can be further improved.

The content of the fluorine-based resin is preferably 0.3 parts by weight or more, more preferably 0.5 parts by weight or more, and preferably 2 parts by weight or less, more preferably 1.5 parts by weight or less, based on 100 parts by weight of the aromatic polycarbonate resin. If the content of the fluorine-based resin is not less than the lower limit, the flame retardancy can be further improved. When the content of the fluorine-based resin is not more than the upper limit, the impact resistance can be further improved.

The content of the fluorine-based resin is preferably 0.5 parts by weight or more, more preferably 0.6 parts by weight or more, and preferably 2 parts by weight or less, more preferably 1.5 parts by weight or less, relative to 100 parts by weight of the total content of the aromatic polycarbonate resin and the sulfone resin. If the content of the fluorine-based resin is not less than the lower limit, the flame retardancy can be further improved. When the content of the fluorine-based resin is not more than the upper limit, the impact resistance can be further improved.

[ other ingredients ]

The resin composition may contain other components within a range not to impair the object of the present invention.

Examples of the other components include an anti-dripping agent, an antioxidant, a heat stabilizer, a light stabilizer, an ultraviolet absorber, a colorant, a plasticizer, a lubricant, a release agent, and a reinforcing agent. The other components may be used alone or in combination of two or more.

The content of the other component is not particularly limited if the resin composition contains the other component, and for example, the content of the other component is preferably 0.01 part by weight or more, more preferably 0.1 part by weight or more, further preferably 0.5 part by weight or more, and preferably 10 parts by weight or less, and more preferably 5 parts by weight or less, based on 100 parts by weight of the aromatic polycarbonate resin.

As the above antioxidant, there may be mentioned alkylated monophenols; alkylated polyphenols; alkylation reaction products of polyphenols such as tetrakis [ methylene (3, 5-di-tert-butyl-4-hydroxyhydrogen succinate) ] methane and dienes; butylated reaction products of p-cresol or dicyclopentadiene; alkylated hydroquinones; a hydroxylated thiodiether; alkylene-bisphenols; a benzyl compound; esters of beta- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionic acid with mono-or polyhydric alcohols; esters of beta- (5-tert-butyl-4-hydroxy-3-methylphenyl) propionic acid with mono-or polyhydric alcohols; esters of thioalkyl compounds or thioaryl compounds such as distearylthiopropionate, didodecylthiopropionate, ditridecylthiodipropionate, octadecyl-3- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionate and pentaerythritol-4- [3- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionate; and an amine compound of β - (3, 5-di-tert-butyl-4-hydroxyphenyl) propionic acid, and the like.

When the resin composition contains the antioxidant, the content of the antioxidant is preferably 0.01 part by weight or more and preferably 0.1 part by weight or less based on 100 parts by weight of the aromatic polycarbonate resin.

Examples of the light stabilizer include benzotriazoles such as 2- (2-hydroxy-5-methylphenyl) benzotriazole and 2- (2-hydroxy-5-tert-octylphenyl) -benzotriazole; and 2-hydroxy-4-n-octoxybenzophenone and the like.

When the resin composition contains the light stabilizer, the content of the light stabilizer is preferably 0.01 parts by weight or more and preferably 5 parts by weight or less based on 100 parts by weight of the aromatic polycarbonate resin.

Examples of the ultraviolet absorber include hydroxybenzophenones; hydroxybenzotriazole; a hydroxybenzotriazine; a cyanoacrylate; oxalanilide; benzoxazinone; 2- (2H-benzotriazol-2-yl) -4- (1,1,3, 3-tetramethylbutyl) -phenol; 2-hydroxy-4-n-octyloxybenzophenone; 2- [4, 6-bis (2, 4-dimethylphenyl) -1,3, 5-triazin-2-yl ] -5- (octyloxy) -phenol; 2, 2' - (1, 4-phenylene) bis (4H-3, 1-benzoxazin-4-one); 1, 3-bis [ (2-cyano-3, 3-diphenylacryloyl) oxy ] -2, 2-bis [ [ (2-cyano-3, 3-diphenylacryloyl) oxy ] methyl ] propane; 2, 2' - (1, 4-phenylene) bis (4H-3, 1-benzoxazin-4-one); 1, 3-bis [ (2-cyano-3, 3-diphenylacryloyl) oxy ] -2, 2-bis [ [ (2-cyano-3, 3-diphenylacryloyl) oxy ] methyl ] propane; and inorganic substances having an average particle diameter of 100nm or less, such as cerium oxide and zinc oxide.

When the resin composition contains the ultraviolet absorber, the content of the ultraviolet absorber is preferably 0.01 parts by weight or more and preferably 5 parts by weight or less based on 100 parts by weight of the aromatic polycarbonate resin.

Examples of the colorant include titanium dioxide, carbon black, and organic dyes.

The plasticizer, the lubricant, or the release agent may be used alone or in combination of two or more. Many compounds that can be used as plasticizers are compounds that also have lubricant and release agent properties, many compounds that can be used as lubricants are compounds that also have release agent and plasticizer properties, and many compounds that can be used as release agents are compounds that also have plasticizer and lubricant properties.

Examples of the plasticizer, the lubricant, or the release agent include phthalic acid esters such as dioctyl-4, 5-epoxy-hexahydrophthalate; tris- (octyloxycarbonylethyl) isocyanurate; tristearic acid; poly-alpha-olefins; epoxidized soybean oil; an ester; fatty acid esters such as alkyl stearate; stearic acid esters such as methyl stearate, stearyl stearate, and pentaerythritol tetrastearate; a mixture of a hydrophilic and hydrophobic nonionic surfactant such as a polyethylene glycol polymer, a polypropylene glycol polymer, or a poly (ethylene glycol-co-propylene glycol) copolymer with methyl stearate; a mixture of methyl stearate and polyethylene-polypropylene glycol copolymer; and waxes such as beeswax, montan wax, and paraffin wax.

When the resin composition contains the plasticizer, the lubricant, or the release agent, the content of each of the plasticizer, the lubricant, or the release agent is preferably 0.1 part by weight or more and preferably 1 part by weight or less based on 100 parts by weight of the aromatic polycarbonate resin.

Examples of the reinforcing agent include fibrous reinforcing agents such as glass fibers.

When the reinforcing agent is contained in the resin composition, the content of the reinforcing agent is preferably 1 part by weight or more, more preferably 10 parts by weight or more, and preferably 25 parts by weight or less, more preferably 20 parts by weight or less, based on 100 parts by weight of the aromatic polycarbonate resin.

The relative amounts of the other components have an important influence on the mechanical properties such as low smoke density, low smoke toxicity, and ductility of the molded article. Even if a large amount of a certain component is blended in order to improve a certain characteristic of a molded article, other characteristics may be deteriorated.

(details of the resin composition and the molded article)

The molded article according to the present invention is a molded article obtained by molding the resin composition. The resin composition according to the present invention is molded to obtain a molded article. The molded article is excellent in flame retardancy and impact resistance. Further, since the resin composition according to the present invention has excellent moldability, cracks or cracks are less likely to occur in the obtained molded article. As a result, the molded article obtained had a good appearance.

The molded article according to the present invention can be molded by a known method using the resin composition. For example, the resin composition is heated at 230 to 300 ℃ to mold and cure the resin composition, thereby obtaining a molded article. Further, by vacuum-molding the obtained molded article, a molded article having a specific shape can be obtained.

Since the resin composition of the present invention has excellent moldability, molded articles having various shapes can be obtained. For example, the molded article according to the present invention may have a rectangular shape, a curved shape, an irregular shape, or a sheet shape.

The resin composition of the present invention is preferably used for vacuum forming. The resin composition according to the present invention may not be used for vacuum forming.

The molded article is preferably in the form of a sheet. The sheet-like molded article is a resin sheet. The resin sheet can be produced, for example, by extrusion molding a resin composition into a sheet shape.

The resin sheet may be further deformed by vacuum forming or the like. The resin sheet obtained by extrusion molding is vacuum-molded, whereby a resin sheet having a desired shape can be obtained. The resin composition of the present invention has excellent moldability, and therefore can favorably produce a molded article having a desired shape. For example, the resin sheet may have a curved surface or may have a concave-convex surface.

The molded article according to the present invention may be a vacuum-molded article, may be a molded article before vacuum molding, or may be a molded article without vacuum molding.

The above molded article had a radiant heat of 50kW/m in a heater according to ISO5660-1²And the average maximum heat release rate measured in the presence of an ignition device is preferably 130kW/m²Hereinafter, more preferably 125kW/m²Hereinafter, it is more preferably 120kW/m²The following. If the average maximum heat release rate is not more than the upper limit, the flame retardancy can be further improved. In order to further improve flame retardancy, the lower the average maximum heat release rate, the better.

Specifically, the average maximum heat release rate was measured by the following procedure.

A sample for measuring the heat release rate was obtained by cutting the molded article to a length of 100mm, a width of 100mm and a thickness of 3 mm. According to ISO5660-1, a conical calorimeter test set is used, and the radiant heat at the heater is 50kW/m²And measuring the heat release rate of the obtained heat release rate measuring sample in the presence of an ignition device. When the thickness of the molded article is less than 3mm, a sample for measuring a heat release rate having a thickness of 3mm can be prepared using the material (resin composition) of the molded article.

The average maximum heat release rate is a value calculated according to EN45545-2 using the heat release rate measured according to ISO 5660-1.

From the heat release rate (q) measured according to ISO5660-1 and the measurement time (T) at which the heat release rate was measured, the average heat release rate was calculated according to the following equation.

[ equation 1]

n refers to the number of measurement points per 2 seconds. n is preferably an integer of 3 or more.

The average heat release rates of the plurality of samples for measuring heat release rates are calculated, and the maximum value of the obtained average heat release rates is defined as an average maximum heat release rate. The average maximum heat release rate is preferably a value calculated using 3 or more samples for heat release rate measurement.

The molded article is preferably used as an interior material for a transport machine because of its excellent flame retardancy and impact resistance. Examples of the transport machine include a railway vehicle, an airplane, a ship, and an automobile. Examples of the interior material include ceilings, window frames, armrests, backrests, and desk boards. The molded body is preferably an interior material for a railway vehicle, preferably an interior material for an aircraft, preferably an interior material for a ship, preferably an interior material for an automobile. The resin composition of the present invention has excellent moldability, and thus can be easily molded into a shape required for an interior material of a transportation machine.

The present invention will be described in detail below with reference to examples and comparative examples. The present invention is not limited to the following examples.

The following materials were prepared.

(aromatic polycarbonate resin)

Aromatic polycarbonate resin (aromatic polycarbonate resin having a structural unit derived from bisphenol A compound, "Ipiplon E series" manufactured by Mitsubishi gas chemical corporation, viscosity average molecular weight 20000)

(sulfone resin)

Polyphenylene sulfone resin (Solvay corporation, "Radel 5000")

(phosphorus-containing Compound)

Phosphoric acid ester (ICL JAPAN company, "Fyrol Flex Sol DP")

(silicon-containing substance)

Silicone-acrylic core-shell rubber (Metabrene SX-005, Mitsubishi RAYON Co., Ltd.)

(inorganic Filler)

Talc (Jet Fine 3CA manufactured by Imerys Specialties, volume average particle diameter of 4.8 μm)

The volume average particle diameter (D50) of talc was measured and determined by using a laser diffraction particle diameter distribution measuring apparatus ("SALD-3100" manufactured by Shimadzu corporation). Specifically, in the obtained particle size distribution, the particle size at which the cumulative volume calculated from the small particle size side is 50% is taken as the volume average particle size of talc (D50).

(fluorine-based resin)

Polytetrafluoroethylene (Teflon CFP6000 manufactured by Duppon Co., Ltd.)

(example 1)

Preparation of the resin composition:

the mixture was melt-kneaded at the compounding ratio (parts by weight) shown in table 1 using a twin-screw extruder ("TEX 30 a" manufactured by japan steel-making corporation) under conditions of a cylinder temperature of 280 ℃, a die temperature of 260 ℃, a pressure of 0.7bar (vacuum), a screw diameter of 30mm, a rotation speed of 400rpm, and an extrusion amount of 15 kg/hr, and then melt-extruded. The resin composition obtained by melt extrusion was cooled with a water-cooled type, cut into pellets with a pelletizer, and then dried at about 120 ℃ for about 5 hours to obtain a pelletized resin composition.

Preparation of the shaped bodies:

the resin composition in the form of pellets was melted using a single-screw extruder ("GT 50" manufactured by plastic engineering research) under conditions of a cylinder temperature of 270 ℃, a die temperature of 290 ℃ and an extrusion amount of 20 kg/hour, and then molded into a sheet shape. Subsequently, the ratio of the pulling speed to the roller speed (pulling speed/roller speed) in the pulling machine was set to 1.05, and a resin sheet (molded body) having a thickness of 3mm was obtained.

(examples 2 to 15 and comparative examples 1 to 4)

Resin compositions and molded articles were obtained in the same manner as in example 1, except that the amounts of the respective components (parts by weight) were changed as shown in tables 1 to 4 below.

(evaluation)

(1) Formability of

The obtained resin sheet was cut into a size of 300mm in length, 300mm in width and 3mm in thickness to obtain a test piece. The obtained test piece was subjected to a tensile test in accordance with JIS K7161-2:2014 in a state of being heated to 190 ℃ to thereby evaluate the elongation at break of the test piece.

[ criterion for determining moldability ]

O: an elongation at break of 200% or more,

And (delta): an elongation at break of 100% or more and less than 200%,

And delta: elongation at break of 80% or more and less than 100%,

X: the elongation at break is less than 80%.

(2) Flame retardancy (average maximum heat release rate)

The obtained resin sheet was cut into a size of 100mm in length, 100mm in width and 3mm in thickness to obtain a sample for measuring an exothermic speed. According to ISO5660-1, a conical calorimeter test set is used, and the radiant heat at the heater is 50kW/m²The heat release rate of the obtained sample for measuring the heat release rate was measured for a measurement time of 20 minutes in the presence of an ignition device.

According to EN45545-2, the average maximum heat release rate is calculated from the measured heat release rate. In this evaluation, n in the above equation for the average heat release rate is 600.

[ criterion for determining average maximum Heat Release Rate ]

O: less than 120kW/m²、

△：120kW/m²Above and below 130kW/m²、

X: more than 130kW/m²。

(3) Impact resistance (Dart impact strength)

The obtained resin sheet was cut into a size of 45mm in length, 45mm in width and 3mm in thickness to obtain a sample for impact strength measurement. The impact energy was measured on the obtained impact strength measuring sample according to ASTM D5420 (GE method). Specifically, the impact energy at which no crack was generated in the sample for impact strength measurement was measured by using a Gardner impact tester (BYK corporation) and using a material having a weight of 16lb and a needle point shape of GE type to give an impact to the sample for impact strength measurement.

[ criterion for determining Dart impact Strength ]

O: the impact energy is more than 300in-lb,

And (delta): the impact energy is 190in-lb or more and less than 300in-lb,

X: the impact energy is less than 190 in-lb.

(comprehensive judgment)

The obtained molded article was evaluated based on (1) the evaluation result of moldability, (2) the evaluation result of flame retardancy (average maximum heat release rate), and (3) the evaluation result of impact resistance (dart impact strength).

[ evaluation criteria for comprehensive judgment ]

O: the results of the evaluations (1), (2) and (3) were all O,

And (delta): the results of the evaluations (1), (2) and (3) above showed that Δ and × were absent and Δ,

And delta: the results of the evaluations (1), (2) and (3) above showed that X was absent and Δ,

X: the results of the evaluations (1), (2) and (3) were X.

The compositions and results are shown in tables 1 to 4 below.

[ Table 1]

[ Table 2]

[ Table 3]

[ Table 4]

It was found that the resin sheet (molded article) obtained in the examples had good elongation and excellent moldability even at a relatively low temperature. Therefore, for example, the resin sheet (molded body) obtained in the examples can be favorably molded into various shapes. Further, it was also found that the molded articles obtained in the examples had excellent flame retardancy and impact resistance.

In contrast, it is difficult to improve the moldability, flame retardancy, and impact resistance of the resin sheet (molded article) obtained in the comparative example at the same time.