JP-2026075277-A - Polycarbonate resin composition and molded article made thereof

Abstract

[Problem] To provide a polycarbonate resin composition with excellent flow stability, thermal stability, and rigidity. [Solution] A polycarbonate resin composition comprising 100 parts by weight of a resin component consisting of (A) 50.0 to 95.0 parts by weight of polycarbonate resin (component A) and (B) 50.0 to 5.0 parts by weight of polyester resin (component B), with (C) 0.001 to 1.0 parts by weight of phosphonic acid compounds excluding phosphonic acid esters (component C) and (D) 5.0 to 110.0 parts by weight of inorganic filler (component D). [Selection Diagram] None

Inventors

• 武田 豊穂

Assignees

• 帝人株式会社

Dates

Publication Date

20260508

Application Date

20241022

Claims (6)

1. A polycarbonate resin composition comprising 100 parts by weight of a resin component consisting of (A) 50.0 to 95.0 parts by weight of polycarbonate resin (component A) and (B) 50.0 to 5.0 parts by weight of polyester resin (component B), with (C) 0.001 to 1.0 parts by weight of phosphonic acid compounds excluding phosphonic acid esters (component C) and (D) 5.0 to 110.0 parts by weight of inorganic filler (component D).
2. The polycarbonate resin composition according to claim 1, wherein component B is at least one polyester resin selected from the group consisting of polyethylene terephthalate resin and polybutylene terephthalate resin.
3. The polycarbonate resin composition according to claim 1 or 2, wherein component C is a phosphonic acid compound represented by formula (1). [In the above general formula (1), R is a group other than the group containing the ester bond.]
4. The polycarbonate resin composition according to claim 1 or 2, wherein component D is at least one inorganic filler selected from the group consisting of wollastonite, mica, and talc.
5. A molded article comprising the resin composition described in claim 1 or 2.
6. A molded article according to claim 5, which is an automotive exterior part.

Description

This invention relates to a polycarbonate resin composition and a molded article made therefrom that exhibits excellent flow stability, thermal stability, and rigidity. Polycarbonate/polyester alloys, which are alloys of polycarbonate resin and polyester resin, are widely used in the automotive sector due to their excellent mechanical properties and chemical resistance. Furthermore, in recent years, there has been a trend towards integrating parts in automotive exterior components to reduce assembly man-hours, leading to active development of large components. Therefore, there is a growing demand for resins with higher rigidity and thermal stability than conventional resins to obtain good strength and molded appearance even in thin-walled, large components. In addition, stable flow during continuous injection molding is required for stable component production. On the other hand, polymer alloys composed of polycarbonate resin and polyester resin have a problem in that excessive heating during melt-mixing in an extruder or during retention in an injection molding machine can cause excessive transesterification reactions, resulting in unstable fluidity of the resin composition. In the past, methods for improving thermal stability have been disclosed, including the use of phosphate compounds and phosphite compounds or phosphonite compounds as thermal stabilizers (see, for example, Patent Document 1) and the addition of organic phosphate ester compounds (see, for example, Patent Document 2). However, these do not disclose polycarbonate resin compositions with excellent flow stability, thermal stability, and rigidity, and suffer from the problem of poor flow stability during continuous injection molding. Patent No. 5640734Patent No. 4983427 The details of this invention will be further explained below. <Component A: Polycarbonate resin> The polycarbonate resin used in this invention is obtained by reacting a divalent phenol with a carbonate precursor. Examples of reaction methods include interfacial polycondensation, molten transesterification, solid-phase transesterification of carbonate prepolymers, and ring-opening polymerization of cyclic carbonate compounds. Typical examples of divalent phenols used here include hydroquinone, resorcinol, 4,4'-dihydroxydiphenyl, bis(4-hydroxyphenyl)methane, bis{(4-hydroxy-3,5-dimethyl)phenyl}methane, 1,1-bis(4-hydroxyphenyl)ethane, 1,1-bis(4-hydroxyphenyl)-1-phenylethane, 2,2-bis(4-hydroxyphenyl)propane (commonly known as bisphenol A), 2,2-bis{(4-hydroxy-3-methyl)phenyl}propane, and 2,2-bis{(4- 2,2-bis{(3-isopropyl-4-hydroxy)phenyl}propane, 2,2-bis{(4-hydroxy-3-phenyl)phenyl}propane, 2,2-bis(4-hydroxyphenyl)butane, 2,2-bis(4-hydroxyphenyl)-3-methylbutane, 2,2-bis(4-hydroxyphenyl)-3,3-dimethylbutane, 2,4-bis(4-hydroxyphenyl)-2-methylbutane, 2,2-bis(4-hydroxyphenyl)pentane, 2,2-bis(4-hydroxyphenyl) 1,1-bis(4-hydroxyphenyl)cyclohexane, 1,1-bis(4-hydroxyphenyl)-4-isopropylcyclohexane, 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, 9,9-bis(4-hydroxyphenyl)fluorene, 9,9-bis{(4-hydroxy-3-methyl)phenyl}fluorene, α,α'-bis(4-hydroxyphenyl)-o-diisopropylbenzene, α,α'-bis(4-hydroxyphenyl)-m-di Examples include sopropylbenzene, α,α'-bis(4-hydroxyphenyl)-p-diisopropylbenzene, 1,3-bis(4-hydroxyphenyl)-5,7-dimethyladamantane, 4,4'-dihydroxydiphenyl sulfone, 4,4'-dihydroxydiphenyl sulfoxide, 4,4'-dihydroxydiphenyl sulfide, 4,4'-dihydroxydiphenyl ketone, 4,4'-dihydroxydiphenyl ether, and 4,4'-dihydroxydiphenyl ester, which can be used individually or in combination of two or more. Among these, homopolymers or copolymers obtained from at least one bisphenol selected from the group consisting of bisphenol A, 2,2-bis{(4-hydroxy-3-methyl)phenyl}propane, 2,2-bis(4-hydroxyphenyl)butane, 2,2-bis(4-hydroxyphenyl)-3-methylbutane, 2,2-bis(4-hydroxyphenyl)-3,3-dimethylbutane, 2,2-bis(4-hydroxyphenyl)-4-methylpentane, 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, and α,α'-bis(4-hydroxyphenyl)-m-diisopropylbenzene are preferred. In particular, homopolymers of bisphenol A and copolymers of 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane with bisphenol A, 2,2-bis{(4-hydroxy-3-methyl)phenyl}propane, or α,α'-bis(4-hydroxyphenyl)-m-diisopropylbenzene are preferred. Carbonyl halides, carbonate esters, or haloformates are used as carbonate precursors; specifically, examples include phosgene, diphenyl carbonate, or dihaloformates of divalent phenols. When producing polycarbonate resin by reacting the above-mentioned divalent phenol with a carbonate precursor using interfacial polycondensation or melt transesterification, catalysts, end-terminating agents, antioxidants for the divalent phenol, etc., may be used as needed. Furthermore, the polycarbonate resin may be a branched polycarbonate resin copolymerized with a trifunctional or polyfunctional aromatic compound, or a polyester carbonate resin copolymerized with an aromatic or aliphatic bifunctional carboxylic acid, or a mixture of two or more