WO2012063652A1 - ポリカーボネート系樹脂組成物、成形品、及び太陽光発電用構造部材 - Google Patents
ポリカーボネート系樹脂組成物、成形品、及び太陽光発電用構造部材 Download PDFInfo
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- WO2012063652A1 WO2012063652A1 PCT/JP2011/074873 JP2011074873W WO2012063652A1 WO 2012063652 A1 WO2012063652 A1 WO 2012063652A1 JP 2011074873 W JP2011074873 W JP 2011074873W WO 2012063652 A1 WO2012063652 A1 WO 2012063652A1
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- 239000000203 mixture Substances 0.000 title claims abstract description 43
- 229920005668 polycarbonate resin Polymers 0.000 title claims abstract description 38
- 239000004431 polycarbonate resin Substances 0.000 title claims abstract description 38
- 238000010248 power generation Methods 0.000 title claims abstract description 23
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims abstract description 71
- -1 polytetrafluoroethylene Polymers 0.000 claims abstract description 67
- 239000004408 titanium dioxide Substances 0.000 claims abstract description 34
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- 238000000465 moulding Methods 0.000 claims abstract description 25
- 239000011342 resin composition Substances 0.000 claims abstract description 25
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- 229920005862 polyol Polymers 0.000 claims abstract description 19
- 150000003077 polyols Chemical class 0.000 claims abstract description 19
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- 125000003118 aryl group Chemical group 0.000 claims abstract description 16
- 125000004433 nitrogen atom Chemical group N* 0.000 claims abstract description 15
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- 229910052757 nitrogen Inorganic materials 0.000 claims abstract description 6
- 125000005375 organosiloxane group Chemical group 0.000 claims abstract description 6
- LSNNMFCWUKXFEE-UHFFFAOYSA-M Bisulfite Chemical compound OS([O-])=O LSNNMFCWUKXFEE-UHFFFAOYSA-M 0.000 claims abstract 3
- 125000004432 carbon atom Chemical group C* 0.000 claims description 23
- 229920000515 polycarbonate Polymers 0.000 claims description 20
- 239000004417 polycarbonate Substances 0.000 claims description 20
- 229910052784 alkaline earth metal Inorganic materials 0.000 claims description 12
- 229910052783 alkali metal Inorganic materials 0.000 claims description 11
- 125000003545 alkoxy group Chemical group 0.000 claims description 10
- 230000002378 acidificating effect Effects 0.000 claims description 9
- 239000002253 acid Substances 0.000 claims description 8
- 125000000217 alkyl group Chemical group 0.000 claims description 8
- 239000006229 carbon black Substances 0.000 claims description 8
- ZJCCRDAZUWHFQH-UHFFFAOYSA-N Trimethylolpropane Chemical compound CCC(CO)(CO)CO ZJCCRDAZUWHFQH-UHFFFAOYSA-N 0.000 claims description 7
- 125000004435 hydrogen atom Chemical group [H]* 0.000 claims description 6
- QXJQHYBHAIHNGG-UHFFFAOYSA-N trimethylolethane Chemical compound OCC(C)(CO)CO QXJQHYBHAIHNGG-UHFFFAOYSA-N 0.000 claims description 5
- 125000001931 aliphatic group Chemical group 0.000 claims description 3
- 125000002947 alkylene group Chemical group 0.000 claims description 3
- 125000005843 halogen group Chemical group 0.000 claims description 3
- WMYINDVYGQKYMI-UHFFFAOYSA-N 2-[2,2-bis(hydroxymethyl)butoxymethyl]-2-ethylpropane-1,3-diol Chemical compound CCC(CO)(CO)COCC(CC)(CO)CO WMYINDVYGQKYMI-UHFFFAOYSA-N 0.000 claims description 2
- RSROEZYGRKHVMN-UHFFFAOYSA-N 2-ethyl-2-(hydroxymethyl)propane-1,3-diol;oxirane Chemical compound C1CO1.CCC(CO)(CO)CO RSROEZYGRKHVMN-UHFFFAOYSA-N 0.000 claims description 2
- 125000001118 alkylidene group Chemical group 0.000 claims description 2
- 125000002993 cycloalkylene group Chemical group 0.000 claims description 2
- WXZMFSXDPGVJKK-UHFFFAOYSA-N pentaerythritol Chemical compound OCC(CO)(CO)CO WXZMFSXDPGVJKK-UHFFFAOYSA-N 0.000 claims description 2
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- 239000002184 metal Substances 0.000 abstract description 18
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- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 30
- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical compound C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 description 28
- 238000000034 method Methods 0.000 description 28
- 239000004205 dimethyl polysiloxane Substances 0.000 description 21
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- 150000001875 compounds Chemical class 0.000 description 12
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- 235000013870 dimethyl polysiloxane Nutrition 0.000 description 10
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- 238000004519 manufacturing process Methods 0.000 description 9
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- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 8
- ATUOYWHBWRKTHZ-UHFFFAOYSA-N Propane Chemical compound CCC ATUOYWHBWRKTHZ-UHFFFAOYSA-N 0.000 description 8
- 239000003513 alkali Substances 0.000 description 8
- 238000004987 plasma desorption mass spectroscopy Methods 0.000 description 8
- 229910052700 potassium Inorganic materials 0.000 description 8
- 239000011591 potassium Substances 0.000 description 8
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 7
- 238000006116 polymerization reaction Methods 0.000 description 7
- 229910052708 sodium Inorganic materials 0.000 description 7
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- 238000005481 NMR spectroscopy Methods 0.000 description 5
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 5
- 239000007864 aqueous solution Substances 0.000 description 5
- TVFDJXOCXUVLDH-UHFFFAOYSA-N caesium atom Chemical compound [Cs] TVFDJXOCXUVLDH-UHFFFAOYSA-N 0.000 description 5
- 229920000172 poly(styrenesulfonic acid) Polymers 0.000 description 5
- 229940005642 polystyrene sulfonic acid Drugs 0.000 description 5
- 238000005406 washing Methods 0.000 description 5
- NPBVQXIMTZKSBA-UHFFFAOYSA-N Chavibetol Natural products COC1=CC=C(CC=C)C=C1O NPBVQXIMTZKSBA-UHFFFAOYSA-N 0.000 description 4
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- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 4
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- 229920006361 Polyflon Polymers 0.000 description 4
- UVMRYBDEERADNV-UHFFFAOYSA-N Pseudoeugenol Natural products COC1=CC(C(C)=C)=CC=C1O UVMRYBDEERADNV-UHFFFAOYSA-N 0.000 description 4
- 239000000654 additive Substances 0.000 description 4
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- 238000010438 heat treatment Methods 0.000 description 4
- 150000002430 hydrocarbons Chemical group 0.000 description 4
- 239000001257 hydrogen Substances 0.000 description 4
- 229910052739 hydrogen Inorganic materials 0.000 description 4
- 125000005027 hydroxyaryl group Chemical group 0.000 description 4
- 238000004898 kneading Methods 0.000 description 4
- 229910052749 magnesium Inorganic materials 0.000 description 4
- 239000011777 magnesium Substances 0.000 description 4
- 150000002989 phenols Chemical class 0.000 description 4
- 239000001294 propane Substances 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- 125000001273 sulfonato group Chemical group [O-]S(*)(=O)=O 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- BATCUENAARTUKW-UHFFFAOYSA-N 4-[(4-hydroxyphenyl)-diphenylmethyl]phenol Chemical compound C1=CC(O)=CC=C1C(C=1C=CC(O)=CC=1)(C=1C=CC=CC=1)C1=CC=CC=C1 BATCUENAARTUKW-UHFFFAOYSA-N 0.000 description 3
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- YXVFYQXJAXKLAK-UHFFFAOYSA-N biphenyl-4-ol Chemical compound C1=CC(O)=CC=C1C1=CC=CC=C1 YXVFYQXJAXKLAK-UHFFFAOYSA-N 0.000 description 3
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- QBDSZLJBMIMQRS-UHFFFAOYSA-N p-Cumylphenol Chemical compound C=1C=C(O)C=CC=1C(C)(C)C1=CC=CC=C1 QBDSZLJBMIMQRS-UHFFFAOYSA-N 0.000 description 3
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- CIOAGBVUUVVLOB-UHFFFAOYSA-N strontium atom Chemical compound [Sr] CIOAGBVUUVVLOB-UHFFFAOYSA-N 0.000 description 3
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- HCNHNBLSNVSJTJ-UHFFFAOYSA-N 1,1-Bis(4-hydroxyphenyl)ethane Chemical compound C=1C=C(O)C=CC=1C(C)C1=CC=C(O)C=C1 HCNHNBLSNVSJTJ-UHFFFAOYSA-N 0.000 description 2
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- HTVITOHKHWFJKO-UHFFFAOYSA-N Bisphenol B Chemical compound C=1C=C(O)C=CC=1C(C)(CC)C1=CC=C(O)C=C1 HTVITOHKHWFJKO-UHFFFAOYSA-N 0.000 description 2
- SDDLEVPIDBLVHC-UHFFFAOYSA-N Bisphenol Z Chemical compound C1=CC(O)=CC=C1C1(C=2C=CC(O)=CC=2)CCCCC1 SDDLEVPIDBLVHC-UHFFFAOYSA-N 0.000 description 2
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 2
- JKIJEFPNVSHHEI-UHFFFAOYSA-N Phenol, 2,4-bis(1,1-dimethylethyl)-, phosphite (3:1) Chemical compound CC(C)(C)C1=CC(C(C)(C)C)=CC=C1OP(OC=1C(=CC(=CC=1)C(C)(C)C)C(C)(C)C)OC1=CC=C(C(C)(C)C)C=C1C(C)(C)C JKIJEFPNVSHHEI-UHFFFAOYSA-N 0.000 description 2
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 2
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- ORILYTVJVMAKLC-UHFFFAOYSA-N adamantane Chemical compound C1C(C2)CC3CC1CC2C3 ORILYTVJVMAKLC-UHFFFAOYSA-N 0.000 description 2
- 150000001335 aliphatic alkanes Chemical class 0.000 description 2
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- PXKLMJQFEQBVLD-UHFFFAOYSA-N bisphenol F Chemical compound C1=CC(O)=CC=C1CC1=CC=C(O)C=C1 PXKLMJQFEQBVLD-UHFFFAOYSA-N 0.000 description 2
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- MIHINWMALJZIBX-UHFFFAOYSA-N cyclohexa-2,4-dien-1-ol Chemical class OC1CC=CC=C1 MIHINWMALJZIBX-UHFFFAOYSA-N 0.000 description 2
- JJRDHFIVAPVZJN-UHFFFAOYSA-N cyclotrisiloxane Chemical compound O1[SiH2]O[SiH2]O[SiH2]1 JJRDHFIVAPVZJN-UHFFFAOYSA-N 0.000 description 2
- 230000006866 deterioration Effects 0.000 description 2
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- 125000001495 ethyl group Chemical group [H]C([H])([H])C([H])([H])* 0.000 description 2
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- CGEXUOTXYSGBLV-UHFFFAOYSA-N phenyl benzenesulfonate Chemical compound C=1C=CC=CC=1S(=O)(=O)OC1=CC=CC=C1 CGEXUOTXYSGBLV-UHFFFAOYSA-N 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
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- 125000001436 propyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])[H] 0.000 description 2
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- ARCGXLSVLAOJQL-UHFFFAOYSA-N trimellitic acid Chemical compound OC(=O)C1=CC=C(C(O)=O)C(C(O)=O)=C1 ARCGXLSVLAOJQL-UHFFFAOYSA-N 0.000 description 2
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- 150000003961 organosilicon compounds Chemical class 0.000 description 1
- 235000010292 orthophenyl phenol Nutrition 0.000 description 1
- 125000005010 perfluoroalkyl group Chemical group 0.000 description 1
- JGTNAGYHADQMCM-UHFFFAOYSA-N perfluorobutanesulfonic acid Chemical compound OS(=O)(=O)C(F)(F)C(F)(F)C(F)(F)C(F)(F)F JGTNAGYHADQMCM-UHFFFAOYSA-N 0.000 description 1
- BPHQIXJDBIHMLT-UHFFFAOYSA-N perfluorodecane Chemical compound FC(F)(F)C(F)(F)C(F)(F)C(F)(F)C(F)(F)C(F)(F)C(F)(F)C(F)(F)C(F)(F)C(F)(F)F BPHQIXJDBIHMLT-UHFFFAOYSA-N 0.000 description 1
- QZHDEAJFRJCDMF-UHFFFAOYSA-N perfluorohexanesulfonic acid Chemical compound OS(=O)(=O)C(F)(F)C(F)(F)C(F)(F)C(F)(F)C(F)(F)C(F)(F)F QZHDEAJFRJCDMF-UHFFFAOYSA-N 0.000 description 1
- YFSUTJLHUFNCNZ-UHFFFAOYSA-N perfluorooctane-1-sulfonic acid Chemical compound OS(=O)(=O)C(F)(F)C(F)(F)C(F)(F)C(F)(F)C(F)(F)C(F)(F)C(F)(F)C(F)(F)F YFSUTJLHUFNCNZ-UHFFFAOYSA-N 0.000 description 1
- 239000012071 phase Substances 0.000 description 1
- 125000001997 phenyl group Chemical group [H]C1=C([H])C([H])=C(*)C([H])=C1[H] 0.000 description 1
- ZUOUZKKEUPVFJK-UHFFFAOYSA-N phenylbenzene Natural products C1=CC=CC=C1C1=CC=CC=C1 ZUOUZKKEUPVFJK-UHFFFAOYSA-N 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 229920001707 polybutylene terephthalate Polymers 0.000 description 1
- 239000002685 polymerization catalyst Substances 0.000 description 1
- XAEFZNCEHLXOMS-UHFFFAOYSA-M potassium benzoate Chemical compound [K+].[O-]C(=O)C1=CC=CC=C1 XAEFZNCEHLXOMS-UHFFFAOYSA-M 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 239000011164 primary particle Substances 0.000 description 1
- 150000003242 quaternary ammonium salts Chemical class 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000012779 reinforcing material Substances 0.000 description 1
- 230000000979 retarding effect Effects 0.000 description 1
- 229910052701 rubidium Inorganic materials 0.000 description 1
- IGLNJRXAVVLDKE-UHFFFAOYSA-N rubidium atom Chemical compound [Rb] IGLNJRXAVVLDKE-UHFFFAOYSA-N 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 238000010008 shearing Methods 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 239000004332 silver Substances 0.000 description 1
- CSMWJXBSXGUPGY-UHFFFAOYSA-L sodium dithionate Chemical compound [Na+].[Na+].[O-]S(=O)(=O)S([O-])(=O)=O CSMWJXBSXGUPGY-UHFFFAOYSA-L 0.000 description 1
- 229940075931 sodium dithionate Drugs 0.000 description 1
- JVBXVOWTABLYPX-UHFFFAOYSA-L sodium dithionite Chemical compound [Na+].[Na+].[O-]S(=O)S([O-])=O JVBXVOWTABLYPX-UHFFFAOYSA-L 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 150000003460 sulfonic acids Chemical class 0.000 description 1
- 150000003512 tertiary amines Chemical class 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- TXEYQDLBPFQVAA-UHFFFAOYSA-N tetrafluoromethane Chemical compound FC(F)(F)F TXEYQDLBPFQVAA-UHFFFAOYSA-N 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- ITMCEJHCFYSIIV-UHFFFAOYSA-N triflic acid Chemical compound OS(=O)(=O)C(F)(F)F ITMCEJHCFYSIIV-UHFFFAOYSA-N 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L83/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon only; Compositions of derivatives of such polymers
- C08L83/04—Polysiloxanes
- C08L83/06—Polysiloxanes containing silicon bound to oxygen-containing groups
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L69/00—Compositions of polycarbonates; Compositions of derivatives of polycarbonates
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G77/00—Macromolecular compounds obtained by reactions forming a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon in the main chain of the macromolecule
- C08G77/42—Block-or graft-polymers containing polysiloxane sequences
- C08G77/445—Block-or graft-polymers containing polysiloxane sequences containing polyester sequences
- C08G77/448—Block-or graft-polymers containing polysiloxane sequences containing polyester sequences containing polycarbonate sequences
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/20—Oxides; Hydroxides
- C08K3/22—Oxides; Hydroxides of metals
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/36—Sulfur-, selenium-, or tellurium-containing compounds
- C08K5/41—Compounds containing sulfur bound to oxygen
- C08K5/42—Sulfonic acids; Derivatives thereof
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/49—Phosphorus-containing compounds
- C08K5/51—Phosphorus bound to oxygen
- C08K5/52—Phosphorus bound to oxygen only
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K9/00—Use of pretreated ingredients
- C08K9/04—Ingredients treated with organic substances
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L27/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L27/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers
- C08L27/02—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers not modified by chemical after-treatment
- C08L27/12—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers not modified by chemical after-treatment containing fluorine atoms
- C08L27/18—Homopolymers or copolymers or tetrafluoroethene
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L83/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon only; Compositions of derivatives of such polymers
- C08L83/10—Block- or graft-copolymers containing polysiloxane sequences
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
- H02S40/30—Electrical components
- H02S40/34—Electrical components comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/20—Oxides; Hydroxides
- C08K3/22—Oxides; Hydroxides of metals
- C08K2003/2237—Oxides; Hydroxides of metals of titanium
- C08K2003/2241—Titanium dioxide
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K2201/00—Specific properties of additives
- C08K2201/002—Physical properties
- C08K2201/005—Additives being defined by their particle size in general
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
Definitions
- the present invention relates to a polycarbonate-based resin composition, a molded product formed by molding the resin composition, and a structural member for photovoltaic power generation including the molded product.
- a photovoltaic power generation module that converts solar energy into electrical energy may lose power generation capacity due to poor connection between the modules or a decrease in sunlight due to partial shadowing on the module.
- the junction box for solar power generation (including the connector) plays a role of preventing the power down of the entire system due to such a loss of power generation capacity.
- a photovoltaic power generation structural member such as a photovoltaic power generation junction box is usually installed outdoors, characteristics such as advanced low-temperature impact characteristics, tracking resistance, and flame resistance are required.
- the demand for materials is increasing due to the demands for thinner structural members for solar power generation and design.
- a polycarbonate-polydimethylsiloxane copolymer (hereinafter also referred to as a PC-PDMS copolymer), which is a polycarbonate material, is known as a resin material having high-temperature impact characteristics.
- the PC-PDMS copolymer alone is inferior in tracking resistance and is not suitable as it is.
- resin compositions containing various compounds are known (see Patent Documents 1 to 5).
- Patent Document 1 discloses a resin composition containing aluminum borate whiskers
- Patent Document 2 discloses a resin composition containing an alloy of a polycarbonate resin and a polybutylene terephthalate resin.
- Patent Document 1 uses whiskers, the rigidity increases, but the low-temperature impact characteristics are extremely inferior. Moreover, since an organic bromine compound is used, there is a possibility of generating harmful substances when the resin is burned. Moreover, an alloy like patent document 2 also causes the fall of a low temperature impact characteristic.
- Patent Documents 3 and 4 disclose resin compositions containing a low molecular silicone compound. However, even when a low molecular silicone compound is contained, the tracking resistance cannot be improved, and there is a concern about a problem of electrical contact failure due to a volatile component of the low molecular silicone compound. Furthermore, Patent Document 5 attempts to improve the tracking resistance by blending titanium dioxide into the resin composition, but no investigation has been made on the surface treatment and impact resistance characteristics of titanium dioxide.
- the present invention relates to a polycarbonate resin composition having excellent tracking resistance and flame retardancy without impairing the low-temperature impact characteristics of a polycarbonate-polyorganosiloxane copolymer (PC-POS copolymer), and the resin composition It aims at providing the structural member for photovoltaic power generation which consists of a molded article formed by shape
- PC-POS copolymer polycarbonate-polyorganosiloxane copolymer
- the present inventors have reported that an alkali (earth) metal salt of an organic sulfonic acid and a polytetrafluoroethylene having a fibril type performance with respect to a PC-POS copolymer having an average number of repeating organosiloxane structural units within a specific range. It has been found that the above problems can be solved by blending a specific amount of fluoroethylene and further blending a specific amount of titanium dioxide particles having a coating layer made of a polyol not containing nitrogen atoms on the outermost surface of the particles. completed.
- the present invention provides the following [1] to [3].
- [1] (A) The structural unit represented by the general formula (I) and the structural unit represented by the general formula (II), and the average number of repeating n of the organosiloxane structural unit in the general formula (II) 30 to 100% by mass of a polycarbonate-polyorganosiloxane copolymer (A-1) having an A of 70 to 500, and an aromatic polycarbonate resin (A-) other than the polycarbonate-polyorganosiloxane copolymer (A-1) 2) 100 parts by mass of a resin mixture comprising 70 to 0% by mass, (B) Alkali metal salt and / or alkaline earth metal salt of organic sulfonic acid 0.01 to 0.15 parts by mass, (C) 0.1-1 part by mass of polytetrafluoroethylene having fibril-forming ability, and (D) 2 to 15 parts by mass of titanium dioxide particles having a coating layer made of a polyol not containing nitrogen
- R 1 and R 2 each independently represents an alkyl group having 1 to 6 carbon atoms or an alkoxy group having 1 to 6 carbon atoms
- X represents a single bond or an alkylene having 1 to 8 carbon atoms.
- Group, an alkylidene group having 2 to 8 carbon atoms, a cycloalkylene group having 5 to 15 carbon atoms, a cycloalkylidene group having 5 to 15 carbon atoms, —S—, —SO—, —SO 2 —, —O— or —CO -And a and b each independently represent an integer of 0 to 4.
- R 3 to R 6 are each independently a hydrogen atom, a halogen atom, an alkyl group having 1 to 6 carbon atoms, an alkoxy group having 1 to 6 carbon atoms, or an aryl having 6 to 12 carbon atoms.
- Y represents an organic residue containing an aliphatic group or an aromatic group
- n represents an average number of repetitions.
- [2] A molded product obtained by molding the polycarbonate resin composition according to [1].
- [3] A structural member for photovoltaic power generation comprising the molded product according to [2].
- the polycarbonate resin composition of the present invention has excellent tracking resistance and flame retardancy without impairing the excellent low-temperature impact characteristics of the PC-POS copolymer. Therefore, a molded product formed by molding this resin composition is suitable for use as a structural member for photovoltaic power generation.
- the polycarbonate resin composition of the present invention comprises (A) a polycarbonate-polyorganosiloxane copolymer (A-1) having a structural unit represented by general formula (I) and a structural unit represented by general formula (II). ) And an aromatic polycarbonate resin (A-2) other than the polycarbonate-polyorganosiloxane copolymer (A-1), (B) an alkali metal salt and / or an alkaline earth metal salt of an organic sulfonic acid And (C) polytetrafluoroethylene having a fibril-forming ability, and (D) titanium dioxide particles having a coating layer made of a polyol not containing nitrogen atoms on the outermost surface of the particles.
- the polycarbonate-type resin composition of this invention contains (E) polyorganosiloxane, (F) acidic carbon black below pH6, and another additive further.
- E polyorganosiloxane
- F acidic carbon black below pH6, and another additive further.
- the PC-POS copolymer used in the present invention is a copolymer containing structural units represented by the above general formulas (I) and (II).
- the content of the structural unit represented by the general formula (I) is preferably 70 to 98% by mass, more preferably 85 to 97.5% by mass in the (A-1) PC-POS copolymer, Preferably, the content is 90 to 97% by mass.
- the content of the structural unit represented by the general formula (II) is preferably 2 to 30% by mass, more preferably 2.5 to 15% by mass in the (A-1) PC-POS copolymer. More preferably, it is 3 to 10% by mass.
- the content of the structural unit in (A-1) PC-POS is a value calculated by nuclear magnetic resonance (NMR) measurement.
- the average repeating number n of the organosiloxane structural unit in the general formula (II) is 70 to 500, more preferably 80 to 400, still more preferably 85 to 250, and still more preferably 87 to 190. It is.
- n is less than 70, the effect of improving the impact resistance at low temperatures is insufficient, and when it exceeds 500, not only the impact resistance at low temperatures is inferior, but also the flame retardancy is inferior.
- the value of the average number of repetitions n is a value calculated by nuclear magnetic resonance (NMR) measurement.
- the viscosity average molecular weight (Mv) of the PC-POS copolymer of component (A-1) is preferably 12,000 to 50,000, more preferably from the viewpoint of the balance between the strength and productivity of the molded product. Is 14,000 to 30,000, more preferably 16,000 to 25,000.
- the (A-1) component PC-POS copolymer comprises a dihydric phenol represented by the following general formula (1), a polyorganosiloxane represented by the following general formula (2), phosgene, a carbonate ester, Alternatively, it is obtained by copolymerizing with chloroformate.
- R 1 and R 2 , X, a and b are the same as those in the general formula (I).
- R 3 to R 6 , Y, n Is the same as in the general formula (II)
- m is 0 or 1
- Z is halogen, —R 7 OH, —R 7 COOH, —R 7 NH 2 , —COOH or —SH
- 7 represents a linear, branched or cyclic alkylene group, an aryl-substituted alkylene group, an aryl-substituted alkylene group which may have an alkoxy group on the ring, or an arylene group.
- the dihydric phenol represented by the general formula (1) used as a raw material for the PC-POS copolymer of the component (A-1) is not particularly limited. 2-bis (4-hydroxyphenyl) propane (common name: bisphenol A) is preferred.
- dihydric phenols other than bisphenol A include bis (4-hydroxyphenyl) methane, 1,1-bis (4-hydroxyphenyl) ethane, 2,2-bis (4-hydroxyphenyl) butane, 2,2 -Bis (4-hydroxyphenyl) octane, bis (4-hydroxyphenyl) phenylmethane, bis (4-hydroxyphenyl) diphenylmethane, 2,2-bis (4-hydroxy-3-methylphenyl) propane, bis (4- Hydroxyphenyl) naphthylmethane, 1,1-bis (4-hydroxy-t-butylphenyl) propane, 2,2-bis (4-hydroxy-3-bromophenyl) propane, 2,2-bis (4-hydroxy-) 3,5-tetramethylphenyl) propane, 2,2-bis (4-hydroxy-3-chlorofe) Bis (hydroxyaryl) alkanes such as propane, 2,2-bis (4-hydroxy-3,5-dichlorophenyl) propane, 2,2-bis (4-hydroxy-3,5-d
- the polyorganosiloxane represented by the general formula (2) is a phenol having an olefinically unsaturated carbon-carbon bond, preferably vinylphenol, allylphenol, eugenol, isopropenylphenol or the like having a predetermined average number of repetitions n. It can be easily produced by subjecting the end of a polyorganosiloxane chain having a hydrosilation reaction.
- the phenols are more preferably allylphenol or eugenol.
- Y in the general formula (II) of the component (A-1) is an organic residue derived from allylphenol or eugenol.
- Examples of the polyorganosiloxane represented by the general formula (2) include compounds represented by the following general formulas (3) to (11).
- R 3 to R 6 are each independently a hydrogen atom, a halogen atom or an alkyl group having 1 to 6 carbon atoms, 6 represents an alkoxy group having 6 carbon atoms or an aryl group having 6 to 12 carbon atoms, and n represents an average repeating number of the organosiloxane constituent unit and represents a number of 70 to 500.
- R 8 represents an alkyl, alkenyl, aryl or aralkyl group, c represents a positive integer, and is usually an integer of 2 to 6.
- a phenol-modified polyorganosiloxane represented by the general formula (3) is preferable.
- ⁇ , ⁇ -bis [3- (o-hydroxyphenyl) propyl] polydimethylsiloxane which is one of the compounds represented by the general formula (4), is represented by the general formula (5): ⁇ , ⁇ -bis [3- (4-hydroxy-3-methoxyphenyl) propyl] polydimethylsiloxane, which is one of the compounds shown, is preferred.
- the phenol-modified polyorganosiloxane can be produced by a known method. As a manufacturing method, the method shown below is mentioned, for example. First, cyclotrisiloxane and disiloxane are reacted in the presence of an acidic catalyst to synthesize ⁇ , ⁇ -dihydrogenorganopolysiloxane. At this time, ⁇ , ⁇ -dihydrogenorganopolysiloxane having a desired average repeating unit can be synthesized by changing the charging ratio of cyclotrisiloxane and disiloxane.
- this ⁇ , ⁇ -dihydrogenorganopolysiloxane is subjected to an addition reaction with a phenol compound having an unsaturated aliphatic hydrocarbon group such as allylphenol or eugenol, to thereby obtain a desired compound.
- a phenol compound having an unsaturated aliphatic hydrocarbon group such as allylphenol or eugenol
- a phenol-modified polyorganosiloxane having an average repeating unit can be produced.
- the component (A-2), which is an aromatic polycarbonate other than (A-1), contains a dihydric phenol compound and an organic solvent inactive to the reaction, in the presence of an alkaline aqueous solution.
- interfacial polymerization method in which polymerization catalyst such as tertiary amine or quaternary ammonium salt is added to polymerize, or dihydric phenol compound is dissolved in pyridine or mixed solution of pyridine and inert solvent
- polymerization catalyst such as tertiary amine or quaternary ammonium salt
- dihydric phenol compound is dissolved in pyridine or mixed solution of pyridine and inert solvent
- Examples of the dihydric phenol compound used in the production of the component (A-2) aromatic polycarbonate include 2,2-bis (4-hydroxyphenyl) propane [common name: bisphenol A], bis (4-hydroxy). Phenyl) methane, 1,1-bis (4-hydroxyphenyl) ethane, 2,2-bis (4-hydroxyphenyl) butane, 2,2-bis (4-hydroxyphenyl) octane, bis (4-hydroxyphenyl) Phenylmethane, bis (4-hydroxyphenyl) diphenylmethane, 2,2-bis (4-hydroxy-3-methylphenyl) propane, bis (4-hydroxyphenyl) naphthylmethane, 1,1-bis (4-hydroxy-3) -T-butylphenyl) propane, 2,2-bis (4-hydroxy-3-bromophenyl) pro Bread, 2,2-bis (4-hydroxy-3,5-dimethylphenyl) propane, 2,2-bis (4-hydroxy-3-chlorophenyl) propane, 2,2-bis (4-hydroxy-3,
- a molecular weight regulator In the production of the aromatic polycarbonate component (A-2), a molecular weight regulator, a terminal terminator, and the like may be used as necessary. Any of these can be used as long as they are usually used for polymerization of polycarbonate resin.
- Specific molecular weight regulators include monohydric phenols such as phenol, on-butylphenol, mn-butylphenol, pn-butylphenol, o-isobutylphenol, m-isobutylphenol, and p-isobutylphenol.
- terminal terminator monovalent carboxylic acid and derivatives thereof, and monovalent phenol can be used.
- examples of such a terminal terminator include p-tert-butyl-phenol, p-phenylphenol, p-cumylphenol, p-perfluorononylphenol, p- (perfluorononylphenyl) phenol, p- (perfluorocarbon).
- a branched polycarbonate can be obtained by using a branching agent for the above dihydric phenol compound.
- the amount of the branching agent added is preferably 0.01 to 3 mol%, more preferably 0.1 to 1.0 mol%, based on the dihydric phenol compound.
- branching agent examples include 1,1,1-tris (4-hydroxyphenyl) ethane, 4,4 ′-[1- [4- [1- (4-hydroxyphenyl) -1-methylethyl] phenyl ] Ethylidene] bisphenol, ⁇ , ⁇ ′, ⁇ ′′ -tris (4-hydroxyphenyl) -1,3,5-triisopropylbenzene, 1- [ ⁇ -methyl- ⁇ - (4′-hydroxyphenyl) ethyl]- Examples thereof include compounds having three or more functional groups such as 4- [ ⁇ ′, ⁇ ′-bis (4 ′′ -hydroxyphenyl) ethyl] benzene, phloroglysin, trimellitic acid, and isatin bis (o-cresol).
- the content of (A-1) is 30 to 100% by mass, preferably 45 to 100% by mass, more preferably Is 60 to 100% by mass.
- the content of (A-2) is 70 to 0% by mass, preferably 55 to 0% by mass, more preferably 40 to 0% by mass.
- the content of the polyorganosiloxane block portion, which is the structural unit represented by the general formula (II), is preferably 2 to 30% by mass in the (A) resin mixture comprising the components (A-1) and (A-2). More preferably, it is 2.5 to 15% by mass, and further preferably 3 to 10% by mass. If it is 2% by mass or more, the effect of improving impact strength is sufficient, while if it is 30% by mass or less, sufficient heat resistance is obtained.
- component (B) Alkali (earth) metal salt of organic sulfonic acid
- component (B) an alkali metal salt and / or alkaline earth metal salt of an organic sulfonic acid (hereinafter also referred to as an alkali (earth) metal salt of an organic sulfonic acid).
- alkali (earth) metal salt of an organic sulfonic acid hereinafter also referred to as an alkali (earth) metal salt of an organic sulfonic acid.
- Various organic sulfonic acid alkali (earth) metal salts include alkali metal earth salts or alkaline earth metal salts of organic sulfonic acids having at least one carbon atom.
- organic sulfonic acid examples include alkyl sulfonic acid, benzene sulfonic acid, alkyl benzene sulfonic acid, diphenyl sulfonic acid, naphthalene sulfonic acid, 2,5-dichlorobenzene sulfonic acid, 2,4,5-trichlorobenzene sulfonic acid, diphenyl sulfone-3.
- perfluoroalkanesulfonic acid, diphenylsulfonic acid, and polystyrenesulfonic acid are preferable, and perfluoroalkanesulfonic acid and polystyrenesulfonic acid are more preferable.
- the alkali metal salt include metal salts such as sodium, potassium, lithium and cesium
- examples of the alkaline earth metal salt include metal salts such as magnesium, calcium, strontium and barium.
- sodium, potassium or cesium metal salts are preferable, and potassium salts are more preferable.
- an alkali metal salt and / or an alkaline earth metal salt of perfluoroalkanesulfonic acid or polystyrenesulfonic acid is preferable.
- the alkali (earth) metal salt of perfluoroalkanesulfonic acid include those represented by the following general formula (12). (C d F 2d + 1 SO 3 ) e M (12)
- d represents an integer of 1 to 10
- M represents an alkaline metal such as lithium, sodium, potassium and cesium, or an alkaline earth metal such as magnesium, calcium, strontium and barium
- e represents M The valence of is shown.
- these metal salts for example, those described in Japanese Patent Publication No. 47-40445 are applicable.
- Examples of the perfluoroalkanesulfonic acid represented by the general formula (12) include perfluoromethanesulfonic acid, perfluoroethanesulfonic acid, perfluoropropanesulfonic acid, perfluorobutanesulfonic acid, perfluoromethylbutanesulfonic acid, Examples include perfluorohexanesulfonic acid, perfluoroheptanesulfonic acid, and perfluorooctanesulfonic acid.
- Sodium, potassium or cesium salts of these perfluoroalkanesulfonic acids are preferred, and potassium salts are more preferably used.
- alkali (earth) metal salt of polystyrene sulfonic acid examples include an alkali (earth) metal salt of a sulfonate group-containing aromatic vinyl resin represented by the following general formula (13).
- Q represents a sulfonate group
- R 9 represents a hydrogen atom or a hydrocarbon group having 1 to 10 carbon atoms.
- s represents an integer of 1 to 5
- t represents a mole fraction
- the sulfonate group of Q is an alkali metal salt and / or an alkaline earth metal salt of sulfonic acid.
- the metal include alkali metals such as sodium, potassium, lithium, rubidium and cesium, and alkaline earth metals such as beryllium, magnesium, calcium, strontium and barium. Among these, sodium, potassium, or cesium salt is preferable, and potassium salt is more preferable.
- R 9 is a hydrogen atom or a hydrocarbon group having 1 to 10 carbon atoms, preferably a hydrogen atom or a methyl group.
- s is an integer of 1 to 5, and t has a relationship of 0 ⁇ t ⁇ 1. Therefore, the sulfonate group (Q) may include a fully substituted or partially substituted aromatic ring.
- the content of the alkali (earth) metal salt of the organic sulfonic acid is 0.01 to 0.15 parts by mass, preferably 0.02 to 0 with respect to 100 parts by mass of the (A) resin mixture. .13 parts by mass, more preferably 0.03 to 0.12 parts by mass. When the amount is less than 0.01 parts by mass or exceeds 0.15 parts by mass, the flame retardancy cannot be sufficiently improved.
- polytetrafluoroethylene (hereinafter, also referred to as PTFE) having fibril-forming ability is blended as the component (C) in order to give the resin composition a melt dripping preventing effect and improve flame retardancy.
- PTFE polytetrafluoroethylene
- fibril forming ability means that resins tend to be bonded and become fibrous due to an external action such as shearing force.
- PTFE having fibril-forming ability has a very high molecular weight, and the number average molecular weight determined from the standard specific gravity is usually 500,000 or more, preferably 500,000 to 15 million, more preferably 1,000,000 to 10 million.
- Such PTFE is, for example, tetrafluoroethylene in an aqueous solvent in the presence of sodium, potassium or ammonium peroxydisulfide, at a pressure of 6.9 to 690 kPa (1 to 100 psi), at a temperature of 0 to 200 ° C., preferably It can be obtained by polymerization at 20 to 100 ° C.
- fluorinated olefins such as hexafluoropropylene, chlorotrifluoroethylene, fluoroalkylethylene and perfluoroalkyl vinyl ether, and perfluoroalkyl (meth) are used as the copolymerization component.
- Fluorine-containing alkyl (meth) acrylates such as acrylate can be used.
- the content of such a copolymer component is preferably 10% by mass or less with respect to tetrafluoroethylene in polytetrafluoroethylene.
- the PTFE is preferably PTFE particles from the viewpoint of being uniformly dispersed in the polycarbonate.
- the particle diameter of the PTFE particles is usually 10 ⁇ m or less, preferably 0.05 to 1.0 ⁇ m.
- Type 3 As PTFE which has a fibril formation ability, what is classified into type 3 by ASTM standard can be used, for example.
- Commercially available products classified as Type 3 include, for example, Teflon (registered trademark) 6-J (trade name, manufactured by Mitsui DuPont Fluorochemical Co., Ltd.), Polyflon D-1 and Polyflon F-103 (trade name, Daikin). Kogyo Co., Ltd.), CD-076 (trade name, manufactured by Asahi Glass Co., Ltd.) and the like.
- Algoflon F5 (trade name, manufactured by Montefluos), Polyflon MPA, Polyflon FA-100 (trade name, manufactured by Daikin Industries, Ltd.), and the like can be given.
- These PTFE can be used individually or in combination of 2 or more types.
- the amount of PTFE having fibril-forming ability is 0.1 to 1 part by weight, preferably 0.2 to 0.8 part by weight, more preferably 100 parts by weight of the resin mixture (A). Is 0.25 to 0.5 parts by mass. If the amount is less than 0.1 parts by mass, the flame retardancy cannot be sufficiently improved. On the other hand, if the amount exceeds 1 part by mass, the low-temperature impact strength is inferior.
- titanium dioxide particles (hereinafter simply referred to as a component (D)) having a coating layer made of a polyol containing no nitrogen atoms on the outermost surface of the particles. Also referred to as “titanium dioxide particles”.
- the primary particle size of such titanium dioxide is preferably 0.05 to 0.5 ⁇ m, more preferably 0.1 to 0.4 ⁇ m, and still more preferably 0.15 to 0.3 ⁇ m.
- the titanium dioxide particles used in the present invention are coated with a polyol not containing nitrogen atoms on the outermost surface of the particles, and can prevent the impact strength of the resin composition from being lowered.
- a polyol not containing nitrogen atoms on the outermost surface of the particles, and can prevent the impact strength of the resin composition from being lowered.
- For surface treatment of titanium dioxide particles with an organic compound it is known to coat the surface with an organosilicon compound, alkanolamines, higher fatty acids and the like.
- the present inventors have found that titanium dioxide having a coating layer made of a polyol containing no nitrogen atom on the outermost surface of the particles is particularly preferable from the above viewpoint.
- the surface of the titanium dioxide is made of at least one element containing elements such as aluminum, silicon, magnesium, zirconia titanium and tin.
- a hydrous oxide and / or an oxide may be coated.
- Examples of the polyol containing no nitrogen atom that covers the outermost surface of the titanium dioxide particles include trimethylolpropane, trimethylolethane, ditrimethylolpropane, trimethylolpropane ethoxylate, pentaerythritol and the like. Among these, trimethylolpropane or trimethylolethane is preferable from the viewpoint of preventing a decrease in impact strength. In addition, these polyols can be used individually or in combination of 2 or more types. Examples of the method for coating the outermost surface of the titanium dioxide particles with a polyol not containing a nitrogen atom include a wet method and a dry method.
- titanium dioxide is added to a mixture of a polyol not containing nitrogen atoms and a low-boiling solvent, and after stirring, the low-boiling solvent is removed and the polyol is coated on the outermost surface of the titanium dioxide particles.
- a polyol not containing nitrogen atoms and titanium dioxide are mixed in a mixer such as a Henschel mixer or a tumbler, or a polyol not containing nitrogen atoms is dissolved in a solvent, or a dispersed mixed solution is titanium dioxide.
- the polyol is coated on the outermost surface of the titanium dioxide particles.
- a method for producing titanium dioxide one produced by either a chlorine method or a sulfuric acid method can be used.
- the crystal structure of titanium dioxide can be either a rutile type or an anatase type, but the rutile type is preferred from the viewpoint of the thermal stability and light resistance of the polycarbonate resin composition.
- the compounding amount of the titanium dioxide particles is 2 to 15 parts by mass, preferably 3 to 10 parts by mass, more preferably 4 to 7 parts by mass with respect to 100 parts by mass of the (A) resin mixture. When it is less than 2 parts by mass, the tracking resistance is inferior, and when it exceeds 15 parts by mass, the low-temperature impact strength is inferior.
- polyorganosiloxane is further contained as the component (E) in order to prevent deterioration of the resin composition and maintain properties such as mechanical strength, stability and heat resistance.
- Such polyorganosiloxane is not particularly limited, and examples thereof include alkyl hydrogen silicone and alkoxy silicone.
- examples of the alkyl hydrogen silicone include methyl hydrogen silicone and ethyl hydrogen silicone.
- examples of the alkoxysilicone include methoxysilicone and ethoxysilicone. Among these, alkoxy silicone is preferable.
- the alkoxysilicone is a silicone compound containing an alkoxysilyl group in which an alkoxy group is bonded to a silicon atom directly or via a divalent hydrocarbon group.
- a linear, cyclic, network-like, or linearly branched linear group Polyorganosiloxane is mentioned.
- linear polyorganosiloxane is preferable, and polyorganosiloxane having a molecular structure in which an alkoxy group is bonded to the silicone main chain via a methylene chain is more preferable.
- component (E) for example, commercially available SH1107, SR2402, BY16-160, BY16-161, BY16-160E, BY16-161E manufactured by Toray Dow Corning Co., Ltd. is preferably used. it can.
- the content of (E) polyorganosiloxane is preferably 0.05 to 0.30 parts by mass, more preferably 0.05 to 0.20 parts by mass, and still more preferably 100 parts by mass of the resin mixture (A). Is 0.07 to 0.15 parts by mass. If it is 0.05 mass part or more, deterioration of polycarbonate resin will not occur easily and the fall of the molecular weight of resin can be suppressed. Moreover, if it is 0.30 mass part or less, since the balance of economical efficiency is favorable, since silver does not generate
- (F) Acidic carbon black when using for the use of the structural member for solar power generation, it is preferable to mix
- the pH of the acidic carbon black (F) is preferably 6 or less, more preferably 4 or less, from the viewpoint of maintaining tracking resistance.
- acidic carbon black commercially available products can be used, and examples thereof include MA100R (manufactured by Mitsubishi Chemical Corporation, pH 3.5).
- the blending amount of (F) acidic carbon black is preferably 0.5 to 3 parts by mass, more preferably 0.7 to 2.5 parts by mass, and still more preferably 0 with respect to 100 parts by mass of (A) resin mixture. .8 to 1.5 parts by mass. If it is 0.5 mass part or more, even when it uses for the use of the structural member for solar power generation, it can become a molded article of the black body which can be used without a problem. Moreover, if it is 3 mass parts or less, tracking resistance will not fall.
- the polycarbonate-based resin composition of the present invention is conventionally added to the polycarbonate-based resin composition as necessary as long as the effects of the present invention are not impaired.
- Various known additives can be blended. These include reinforcing materials, fillers, stabilizers, antioxidants, ultraviolet absorbers, antistatic agents, lubricants, mold release agents, dyes, pigments, other flame retardants, and elastomers for improving impact resistance. .
- the content of these other additives is usually 0 to 1 part by mass, preferably 0 to 0.5 part by mass with respect to 100 parts by mass of the (A) resin mixture.
- a molded article made of the polycarbonate resin composition of the present invention can be obtained by molding and kneading the above components.
- the kneading method is not particularly limited, and examples thereof include a method using a ribbon blender, a Henschel mixer, a Banbury mixer, a drum tumbler, a single screw extruder, a twin screw extruder, a kneader, a multi screw extruder, and the like. .
- the heating temperature at the time of kneading is usually selected in the range of 240 to 330 ° C., preferably 250 to 320 ° C.
- the molding method conventionally known various molding methods can be used, for example, injection molding method, injection compression molding method, extrusion molding method, blow molding method, press molding method, vacuum molding method and foam molding method. It is done.
- the components other than the polycarbonate resin can be added in advance as a masterbatch by melt-kneading with the polycarbonate resin or other thermoplastic resin. Further, it is preferably pelletized and injection molded, and special molding methods such as general injection molding method or injection compression molding method and gas assist molding method can be used, and various molded products can be produced. .
- molding technique which improves external appearance such as a heat cycle shaping
- molding techniques such as lamination molding with the resin material which has a flame retardance, and two-color molding.
- the polycarbonate resin composition of the present invention has tracking resistance and excellent flame retardancy without impairing low-temperature impact characteristics. Therefore, a molded product formed by molding the resin composition is suitable as a structural member for photovoltaic power generation such as a junction box for photovoltaic power generation installed outdoors.
- CTI rank 0 600V ⁇ CTI value
- CTI rank 1 400V ⁇ CTI value ⁇ 600V
- CTI rank 2 250V ⁇ CTI value ⁇ 400V
- CTI rank 3 170V ⁇ CTI value ⁇ 250V
- CTI rank 4 100V ⁇ CTI value ⁇ 170V
- CTI rank 5 0V ⁇ CTI value ⁇ 100V
- Flammability Using a test piece (length 12.7 mm, width 12.7 mm, thickness 3.2 mm) prepared in accordance with UL standard 94, a vertical combustion test was conducted, and V-0, It was classified into V-1 and V-2 and evaluated.
- the UL standard 94 is a method for evaluating the flame retardancy from the afterflame time after the burner flame is indirectly fired for 10 seconds on a test piece of a predetermined size held vertically.
- Production Example 1 (1) Synthesis of polycarbonate oligomer To a 5.6 mass% aqueous sodium hydroxide solution, 2000 mass ppm of sodium dithionite is added to bisphenol A which is dissolved later, and the bisphenol A concentration is 13.5 mass%. Then, bisphenol A was dissolved so that an aqueous sodium hydroxide solution of bisphenol A was prepared. At a flow rate of 40 L / hr of this sodium hydroxide aqueous solution of bisphenol A and 15 L / hr of methylene chloride, phosgene was continuously passed through a tubular reactor having an inner diameter of 6 mm and a tube length of 30 m at a flow rate of 4.0 kg / hr.
- the tubular reactor had a jacket portion, and the temperature of the reaction solution was kept at 40 ° C. or lower by passing cooling water through the jacket.
- the reaction solution exiting the tubular reactor was continuously introduced into a 40-liter baffled tank reactor equipped with a receding blade, and further bisphenol A aqueous sodium hydroxide solution 2.8 L / hr, 25 mass.
- the reaction was carried out by adding 0.64 L / hr of a 0.07 L / hr aqueous sodium hydroxide solution, 17 L / hr water, and 1 wt% triethylamine aqueous solution.
- the reaction liquid overflowing from the tank reactor was continuously extracted and allowed to stand to separate and remove the aqueous phase, and the methylene chloride phase was collected.
- the concentration of the polycarbonate oligomer thus obtained was 329 g / L, and the chloroformate group concentration was 0.74 mol / L.
- a methylene chloride solution of pt-butylphenol (132 g of pt-butylphenol dissolved in 2.0 L of methylene chloride), an aqueous sodium hydroxide solution of bisphenol A (577 g of sodium hydroxide and A solution obtained by dissolving 1012 g of bisphenol A in an aqueous solution in which 2.0 g of sodium dithionate was dissolved in 8.4 L of water was added, and the polymerization reaction was carried out for 50 minutes.
- PTBP pt-butylphenol
- PC-PDMS copolymer A-1-1 The polycarbonate-polyorganosiloxane copolymer (polycarbonate-polydimethylsiloxane copolymer: PC-PDMS copolymer) obtained as described above is referred to as PC-PDMS copolymer A-1-1.
- PC-PDMS copolymer A-1-1 has an amount of polydimethylsiloxane residue (content of PDMS block portion) determined by NMR measurement of 6.0% by mass, a viscosity number of 49.5, and a viscosity average molecular weight. (Mv) was 18,500.
- Examples 1 to 13 and Comparative Examples 1 to 11 Components (A) to (F) were mixed at the blending ratios shown in Tables 2 and 3, to obtain polycarbonate resin compositions.
- the components (A) to (F) used are as follows.
- (A-1) PC-PDMS copolymer obtained in Production Examples 1 to 5 shown in Table 1.
- (A-2) Product name “Taflon FN1900A” (manufactured by Idemitsu Kosan Co., Ltd., bisphenol A polycarbonate having pt-butylphenol as a terminal machine, viscosity number 49.5, viscosity average molecular weight (Mv) 18500).
- D-1 Titanium dioxide (product name “CR60-2”, Ishihara Sangyo Co., Ltd.) having an average particle size of 0.21 ⁇ m, in which polyol (trimethylolpropane) is used as the organic surface treatment and the outermost surface is coated with trimethylolpropane (Made by Co., Ltd.)
- D-2) 1 part by mass of trimethylolpropane is added to titanium dioxide (product name “CR-60”, manufactured by Ishihara Sangyo Co., Ltd.) having an average particle size of 0.21 ⁇ m and coated with alumina on the surface.
- (D-6) 1 part by mass of triethanolamine is added to titanium dioxide (product name “CR-60”, manufactured by Ishihara Sangyo Co., Ltd.) with an average particle diameter of 0.21 ⁇ m whose surface is coated with alumina. Then, after mixing for 30 minutes with a Henschel mixer, the outermost surface was coated with triethanolamine by heat treatment at 150 ° C. for 3 hours.
- titanium dioxide product name “CR-60”, manufactured by Ishihara Sangyo Co., Ltd.
- each resin composition tris (2,4-di-tert-butylphenyl) phosphite (manufactured by BASF, trade name “Irgafos168”) as an antioxidant was added to 100 parts by mass of component (A). 10 parts by mass were mixed and melt-kneaded at a resin temperature of 290 ° C. with a vented twin screw extruder (manufactured by Toshiba Machine Co., Ltd., model name “TEM-35B”) to obtain pellets of each polycarbonate resin composition .
- the polycarbonate resin composition pellets were injection molded using a molding machine under the molding conditions of a cylinder temperature of 280 ° C. and a mold temperature of 80 ° C. to obtain test pieces. Using the obtained test piece, the impact strength, tracking resistance and flame retardancy at 23 ° C. and ⁇ 30 ° C. were measured by the above-described methods. The results are shown in Tables 2 and 3.
- the polycarbonate resin compositions of Examples 1 to 13 exhibit superior properties than the polycarbonate resin compositions of Comparative Examples 1 to 11. That is, the polycarbonate-based resin compositions of Examples 1 to 13 have excellent impact resistance at normal temperature (23 ° C.) and low temperature ( ⁇ 30 ° C.), have good tracking resistance, and are highly flame retardant. Have sex. On the other hand, the polycarbonate resin compositions of Comparative Examples 1 to 11 were inferior in any of low temperature impact strength at ⁇ 30 ° C., tracking resistance and flame retardancy, and a resin composition satisfying all of them could not be obtained.
- the polycarbonate-based resin composition of the present invention does not impair the low-temperature impact characteristics, and has tracking resistance and excellent flame retardancy.
- a solar power generation junction box or the like installed outdoors It is suitable as a material for a structural member for photovoltaic power generation.
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Abstract
Description
ここで、太陽光発電用ジャンクションボックス等の太陽光発電用構造部材は、通常屋外に設置されるため、高度な低温衝撃特性、耐トラッキング性、難燃性等の特性が要求される。加えて、太陽光発電用構造部材の薄肉化や意匠性の要求から、ますます材料への要求は高まっている。
このようなポリカーボネート系材料の様々な特性を改良するために、種々の化合物が配合された樹脂組成物が知られている(特許文献1~5参照)。
特許文献1では、ホウ酸アルミニウムウィスカーを含む樹脂組成物が開示されており、特許文献2では、ポリカーボネート樹脂とポリブチレンテレフタレート樹脂とのアロイを含む樹脂組成物が開示されている。しかしながら、特許文献1の樹脂組成物では、ウィスカーを使用しているため、剛性は増すが、低温衝撃特性は著しく劣る。また、有機臭素化合物を使用しているため、樹脂の燃焼時に有害物質を発生する可能性がある。また、特許文献2のようなアロイも、低温衝撃特性の低下を招く。
更に、特許文献5では、樹脂組成物中に二酸化チタンを配合することで、耐トラッキング性の改良を試みているが、二酸化チタンの表面処理と耐衝撃特性に関する検討はなされていない。
本発明は、ポリカーボネート-ポリオルガノシロキサン共重合体(PC-POS共重合体)が有する低温衝撃特性を損なわず、優れた耐トラッキング性と難燃性を有するポリカーボネート系樹脂組成物、及びその樹脂組成物を成形してなる成形品、並びにその成形品からなる太陽光発電用構造部材を提供することを目的とする。
〔1〕(A)一般式(I)で表される構成単位及び一般式(II)で表される構成単位を有し、かつ、一般式(II)におけるオルガノシロキサン構成単位の平均繰り返し数nが70~500であるポリカーボネート-ポリオルガノシロキサン共重合体(A-1)30~100質量%、及び、該ポリカーボネート-ポリオルガノシロキサン共重合体(A-1)以外の芳香族ポリカーボネート樹脂(A-2)70~0質量%からなる樹脂混合物100質量部、
(B)有機スルホン酸のアルカリ金属塩及び/又はアルカリ土類金属塩0.01~0.15質量部、
(C)フィブリル形成能を有するポリテトラフルオロエチレン0.1~1質量部、及び、
(D)粒子最表面に窒素原子を含まないポリオールからなる被覆層を有する二酸化チタン粒子2~15質量部、
を含有する、ポリカーボネート系樹脂組成物。
〔3〕上記〔2〕に記載の成形品からなる、太陽光発電用構造部材。
本発明のポリカーボネート系樹脂組成物は、(A)一般式(I)で表される構成単位及び一般式(II)で表される構成単位を有するポリカーボネート-ポリオルガノシロキサン共重合体(A-1)及び該ポリカーボネート-ポリオルガノシロキサン共重合体(A-1)以外の芳香族ポリカーボネート樹脂(A-2)からなる樹脂混合物、(B)有機スルホン酸のアルカリ金属塩及び/又はアルカリ土類金属塩、(C)フィブリル形成能を有するポリテトラフルオロエチレン、及び、(D)粒子最表面に窒素原子を含まないポリオールからなる被覆層を有する二酸化チタン粒子を含有する。
また、本発明のポリカーボネート系樹脂組成物は、更に、(E)ポリオルガノシロキサン、(F)pH6以下の酸性カーボンブラック、その他の添加剤を含有することが好ましい。
以下、本発明のポリカーボネート系樹脂組成物中の各成分について説明する。
本発明で用いられるPC-POS共重合体は、上記一般式(I)及び(II)で表される構成単位を含む共重合体である。
上記一般式(I)で表される構成単位の含有量は、(A-1)PC-POS共重合体中、好ましくは70~98質量%、より好ましくは85~97.5質量%、更に好ましくは90~97質量%である。
また、上記一般式(II)で表される構成単位の含有量は、(A-1)PC-POS共重合体中、好ましくは2~30質量%、より好ましくは2.5~15質量%、更に好ましくは3~10質量%である。2質量%以上であれば耐衝撃強さ向上の効果が十分であり、一方、30質量%以下であれば十分な耐熱性を有する。
なお、(A-1)PC-POS中の構成単位の含有量は、核磁気共鳴(NMR)測定により算出された値である。
ビスフェノールA以外の二価フェノールとしては、例えば、ビス(4-ヒドロキシフェニル)メタン、1,1-ビス(4-ヒドロキシフェニル)エタン、2,2-ビス(4-ヒドロキシフェニル)ブタン、2,2-ビス(4-ヒドロキシフェニル)オクタン、ビス(4-ヒドロキシフェニル)フェニルメタン、ビス(4-ヒドロキシフェニル)ジフェニルメタン、2,2-ビス(4-ヒドロキシ-3-メチルフェニル)プロパン、ビス(4-ヒドロキシフェニル)ナフチルメタン、1,1-ビス(4-ヒドロキシ-t-ブチルフェニル)プロパン、2,2-ビス(4-ヒドロキシ-3-ブロモフェニル)プロパン、2,2-ビス(4-ヒドロキシ-3,5-テトラメチルフェニル)プロパン、2,2-ビス(4-ヒドロキシ-3-クロロフェニル)プロパン、2,2-ビス(4-ヒドロキシ-3,5-ジクロロフェニル)プロパン、2,2-ビス(4-ヒドロキシ-3,5-ジブロモフェニル)プロパン等のビス(ヒドロキシアリール)アルカン類、1,1-ビス(4-ヒドロキシフェニル)シクロペンタン、1,1-ビス(4-ヒドロキシフェニル)シクロヘキサン、1,1-ビス(4-ヒドロキシフェニル)-3,5,5-トリメチルシクロヘキサン、2,2-ビス(4-ヒドロキシフェニル)ノルボルナン、1,1-ビス(4-ヒドロキシフェニル)シクロドデカン等のビス(ヒドロキシアリール)シクロアルカン類、4,4’-ジヒドロキシフェニルエーテル、4,4’-ジヒドロキシ-3,3’-ジメチルフェニルエーテル等のジヒドロキシアリールエーテル類、4,4’-ジヒドロキシジフェニルスルフィド、4,4’-ジヒドロキシ-3,3’-ジメチルジフェニルスルフィド等のジヒドロキシジアリールスルフィド類、4,4’-ジヒドロキシジフェニルスルホキシド、4,4’-ジヒドロキシ-3,3’-ジメチルジフェニルスルホキシド等のジヒドロキシジアリールスルホキシド類、4,4’-ジヒドロキシジフェニルスルホン、4,4’-ジヒドロキシ-3,3’-ジメチルジフェニルスルホン等のジヒドロキシジアリールスルホン類、4,4’-ジヒロキシジフェニル等のジヒドロキシジフェニル類、9,9-ビス(4-ヒドロキシフェニル)フルオレン、9,9-ビス(4-ヒドロキシ-3-メチルフェニル)フルオレン等のジヒドロキシジアリールフルオレン類、ビス(4-ヒドロキシフェニル)ジフェニルメタン、1,3-ビス(4-ヒドロキシフェニル)アダマンタン、2,2-ビス(4-ヒドロキシフェニル)アダマンタン、1,3-ビス(4-ヒドロキシフェニル)-5,7-ジメチルアダマンタン等のジヒドロキシジアリールアダマンタン類、4,4’-[1,3-フェニレンビス(1-メチルエチリデン)]ビスフェノール、10,10-ビス(4-ヒドロキシフェニル)-9-アントロン、1,5-ビス(4-ヒドロキシフェニルチオ)-2,3-ジオキサペンタエン等が挙げられる。
これらの二価フェノールは、単独で又は二種以上を混合して用いてもよい。
これらの中でも、重合の容易さの観点においては、一般式(3)に示すフェノール変性ポリオルガノシロキサンが好ましい。また、入手の容易さの観点においては、一般式(4)に示す化合物中の一種であるα,ω-ビス[3-(o-ヒドロキシフェニル)プロピル]ポリジメチルシロキサン、一般式(5)に示す化合物中の一種であるα,ω-ビス[3-(4-ヒドロキシ-3-メトキシフェニル)プロピル]ポリジメチルシロキサンが好ましい。
まず、シクロトリシロキサンとジシロキサンとを酸性触媒存在下で反応させ、α,ω-ジハイドロジェンオルガノポリシロキサンを合成する。このとき、シクロトリシロキサンとジシロキサンとの仕込み比を変えることで所望の平均繰り返し単位を持つα,ω-ジハイドロジェンオルガノポリシロキサンを合成することができる。次いで、ヒドロシリル化反応用触媒の存在下に、このα,ω-ジハイドロジェンオルガノポリシロキサンにアリルフェノールやオイゲノール等の不飽和脂肪族炭化水素基を有するフェノール化合物を付加反応させることで、所望の平均繰り返し単位を有するフェノール変性ポリオルガノシロキサンを製造することができる。
また、この段階では、低分子量の環状ポリオルガノシロキサンや過剰量の上記フェノール化合物が不純物として残存するために、減圧下で加熱し、これらの低分子化合物を留去することが好ましい。
本発明のポリカーボネート系樹脂組成物において、(A-1)以外の芳香族ポリカーボネートである(A-2)成分は、反応に不活性な有機溶媒、アルカリ水溶液の存在下、二価フェノール系化合物及びホスゲンと反応させた後、第三級アミンもしくは第四級アンモニウム塩等の重合触媒を添加して重合させる界面重合法や、二価フェノール系化合物をピリジン又はピリジンと不活性溶媒の混合溶液に溶解し、ホスゲンを導入し直接製造するピリジン法等従来の芳香族ポリカーボネートの製造法により得られるものが使用できる。
具体的な分子量調節剤としては、一価フェノールとして、例えば、フェノール、o-n-ブチルフェノール、m-n-ブチルフェノール、p-n-ブチルフェノール、o-イソブチルフェノール、m-イソブチルフェノール、p-イソブチルフェノール、o-t-ブチルフェノール、m-t-ブチルフェノール、p-t-ブチルフェノール、o-n-ペンチルフェノール、m-n-ペンチルフェノール、p-n-ペンチルフェノール、o-n-ヘキシルフェノール、m-n-ヘキシルフェノール、p-n-ヘキシルフェノール、p-t-オクチルフェノール、o-シクロヘキシルフェノール、m-シクロヘキシルフェノール、p-シクロヘキシルフェノール、o-フェニルフェノール、m-フェニルフェノール、p-フェニルフェノール、o-n-ノニルフェノール、m-ノニルフェノール、p-n-ノニルフェノール、o-クミルフェノール、m-クミルフェノール、p-クミルフェノール、o-ナフチルフェノール、m-ナフチルフェノール、p-ナフチルフェノール、2,5-ジ-t-ブチルフェノール、2,4-ジ-t-ブチルフェノール、3,5-ジ-t-ブチルフェノール、2,5-ジクミルフェノール、3,5-ジクミルフェノール、p-クレゾール、ブロモフェノール、トリブロモフェノール、平均炭素数12~35の直鎖状又は分岐状のアルキル基をオルト位、メタ位又はパラ位に有するモノアルキルフェノール、9-(4-ヒドロキシフェニル)-9-(4-メトキシフェニル)フルオレン、9-(4-ヒドロキシ-3-メチルフェニル)-9-(4-メトキシ-3-メチルフェニル)フルオレン、4-(1-アダマンチル)フェノール等が挙げられる。
これらの一価フェノールの中では、p-t-ブチルフェノール、p-クミルフェノール、p-フェニルフェノール等が好ましい。また、これらの化合物は、単独で又は二種以上の化合物を併用して用いることができる。
分岐化剤としては、例えば、1,1,1-トリス(4-ヒドロキシフェニル)エタン、4,4’-[1-[4-[1-(4-ヒドロキシフェニル)-1-メチルエチル]フェニル]エチリデン]ビスフェノール、α,α’,α”-トリス(4-ヒドロキシフェニル)-1,3,5-トリイソプロピルベンゼン、1-[α-メチル-α-(4’-ヒドロキシフェニル)エチル]-4-[α’,α’-ビス(4”-ヒドロキシフェニル)エチル]ベンゼン、フロログリシン、トリメリト酸、イサチンビス(o-クレゾール)等の官能基を3つ以上有する化合物が挙げられる。
(A-1)の含有量が30質量%未満、もしくは(A-2)の含有量が70質量%を超えた場合、(A)樹脂混合物中のポリオルガノシロキサンブロック部分の含有量を多くし、低温衝撃強度を向上させるために、(A-1)成分の製造時に、一般式(II)で表される構成単位であるポリオルガノシロキサンブロック部分の含有量を多くする必要がある。しかし、(A-1)成分の製造時に当該含有量を多くすると、重合工程で反応の均一性が低下することがあり、また重合物の洗浄工程で重合物と洗浄水との分離性が悪化することがあるため、(A-1)成分の生産性が大きく低下する。
一般式(II)の構成単位であるポリオルガノシロキサンブロック部分の含有量は、(A-1)成分及び(A-2)成分からなる(A)樹脂混合物中、好ましくは2~30質量%、より好ましくは2.5~15質量%、更に好ましくは3~10質量%である。2質量%以上であれば耐衝撃強さ向上の効果が十分であり、一方、30質量%以下であれば十分な耐熱性を有する。
本発明では、難燃性を向上させるために、(B)成分として、有機スルホン酸のアルカリ金属塩及び/又はアルカリ土類金属塩(以下、有機スルホン酸アルカリ(土類)金属塩、ともいう)を配合する。
有機スルホン酸アルカリ(土類)金属塩としては、種々のものが挙げられるが、少なくとも一つの炭素原子を有する有機スルホン酸のアルカリ金属塩又はアルカリ土類金属塩である。
これらの中でも、パーフルオロアルカンスルホン酸、ジフェニルスルホン酸、ポリスチレンスルホン酸が好ましく、パーフルオロアルカンスルホン酸、ポリスチレンスルホン酸がより好ましい。
アルカリ金属塩としては、ナトリウム、カリウム、リチウム及びセシウム等の金属塩が挙げられ、アルカリ土類金属塩としては、マグネシウム、カルシウム、ストロンチウム及びバリウム等の金属塩が挙げられる。これらの中でも、ナトリウム、カリウム、又はセシウムの金属塩が好ましく、カリウム塩がより好ましい。
パーフルオロアルカンスルホン酸のアルカリ(土類)金属塩としては、下記一般式(12)で表されるものが挙げられる。
(CdF2d+1SO3)eM ・・・(12)
式(12)中、dは1~10の整数を示し、Mはリチウム、ナトリウム、カリウム及びセシウム等のアリカリ金属、又はマグネシウム、カルシウム、ストロンチウム及びバリウム等のアルカリ土類金属を示し、eはMの原子価を示す。
これらの金属塩としては、例えば、特公昭47-40445号公報に記載されているものが該当する。
ここで、Qのスルホン酸塩基は、スルホン酸のアルカリ金属塩及び/又はアルカリ土類金属塩である。当該金属としては、ナトリウム、カリウム、リチウム、ルビジウム、セシウム等のアルカリ金属、ベリリウム、マグネシウム、カルシウム、ストロンチウム及びバリウム等のアルカリ土類金属が挙げられる。これらの中でも、ナトリウム、カリウム、又はセシウム塩が好ましく、カリウム塩がより好ましい。
また、R9は、水素原子又は炭素数1~10の炭化水素基であるが、好ましくは水素原子又はメチル基である。
sは1~5の整数であり、tは、0<t≦1の関係である。そのため、スルホン酸塩基(Q)は、芳香環に対して、全置換したもの、部分置換したものを含んでもよい。
本発明では、樹脂組成物に溶融滴下防止効果を付与し、難燃性を向上させるために、(C)成分として、フィブリル形成能を有するポリテトラフルオロエチレン(以下、PTFEともいう)を配合する。
ここで、「フィブリル形成能」とは、せん断力等の外的作用により、樹脂同士が結合して繊維状になる傾向を示すことをいう。
フィブリル形成能を有するPTFEは、極めて高い分子量を有し、標準比重から求められる数平均分子量で、通常50万以上、好ましくは50万~1500万、より好ましく100万~1000万である。
かかるPTFEは、例えば、テトラフルオロエチレンを水性溶媒中で、ナトリウム、カリウムあるいはアンモニウムパーオキシジスルフィドの存在下で、6.9~690kPa(1~100psi)の圧力下、温度0~200℃、好ましくは20~100℃で重合することによって得ることができる。
当該重合の際、ポリテトラフルオロエチレンの特性を損なわない範囲で、共重合成分としてヘキサフルオロプロピレン、クロロトリフルオロエチレン、フルオロアルキルエチレン及びパーフルオロアルキルビニルエーテル等の含フッ素オレフィン、パーフルオロアルキル(メタ)アクリレート等の含フッ素アルキル(メタ)アクリレートを用いることができる。このような共重合成分の含有量は、ポリテトラフルオロエチレン中のテトラフルオロエチレンに対して、好ましくは10質量%以下である。
これらのPTFEは、単独で又は2種以上を組合せて使用することができる。
本発明では、低温衝撃強度と耐トラッキング性との優れたバランスを得るために、(D)成分として、粒子最表面に窒素原子を含まないポリオールからなる被覆層を有する二酸化チタン粒子(以下、単に「二酸化チタン粒子」ともいう)を配合する。
このような二酸化チタンの1次粒径は、好ましくは0.05~0.5μm、より好ましくは0.1~0.4μm、更に好ましくは0.15~0.3μmである。
二酸化チタン粒子の有機化合物による表面処理には、有機珪素化合物、アルカノールアミン類、高級脂肪酸類等により表面を被覆することが知られている。しかし、本発明者らは、粒子最表面に窒素原子を含まないポリオールからなる被覆層を有する二酸化チタンが上記観点から特に好ましいことを見出した。
本発明で使用される二酸化チタン粒子は、窒素原子を含まないポリオールで表面を被覆する前に、その二酸化チタン表面をアルミニウム、珪素、マグネシウム、ジルコニアチタン、錫等の元素を含む少なくとも一種の元素の含水酸化物及び/又は酸化物が被覆されていてもよい。
窒素原子を含まないポリオールで二酸化チタン粒子の最表面を被覆する方法としては、湿式法と乾式法が挙げられる。湿式法では、窒素原子を含まないポリオールと低沸点溶媒の混合液に二酸化チタンを加え、攪拌後、低沸点溶媒を除去して、該ポリオールを二酸化チタン粒子の最表面に被覆する。乾式法では、窒素原子を含まないポリオールと二酸化チタンをヘンシェルミキサー、タンブラー等の混合機中で混合するか、窒素原子を含まないポリオールを溶媒に溶解させるか、あるいは分散させた混合溶液を二酸化チタンに噴霧して、該ポリオールを二酸化チタン粒子の最表面に被覆する。
二酸化チタンの製造方法は、塩素法、硫酸法のどちらで製造されたものも使用可能である。また、二酸化チタンの結晶構造は、ルチル型、アナターゼ型のどちらでも使用可能であるが、ポリカーボネート系樹脂組成物の熱安定性、耐光性等の観点からルチル型が好ましい。
本発明では、樹脂組成物の劣化を防止し、機械的強度や安定性、耐熱性等の特性を維持するために、更に(E)成分として、ポリオルガノシロキサンを含有することが好ましい。
このようなポリオルガノシロキサンとしては、特に限定はされないが、例えば、アルキル水素シリコーン、アルコキシシリコーン等が挙げられる。
アルキル水素シリコーンとしては、例えば、メチル水素シリコーン、エチル水素シリコーン等が挙げられる。一方、アルコキシシリコーンとしては、例えば、メトキシシリコーン、エトキシシリコーン等が挙げられる。
これらの中でも、アルコキシシリコーンが好ましい。アルコキシシリコーンは、アルコキシ基が直接又は二価炭化水素基を介してケイ素原子に結合したアルコキシシリル基を含むシリコーン化合物であり、例えば、直鎖状、環状、網状及び一部分岐を有する直鎖状のポリオルガノシロキサンが挙げられる。これらの中でも、直鎖状ポリオルガノシロキサンが好ましく、シリコーン主鎖に対してメチレン鎖を介してアルコキシ基と結合する分子構造を有するポリオルガノシロキサンがより好ましい。
このような(E)成分としては、例えば、市販の東レ・ダウコーニング(株)製のSH1107、SR2402、BY16-160、BY16-161、BY16-160E、BY16-161E等を好適に使用することができる。
本発明では、太陽光発電用構造部材の用途に用いる場合は、更に(F)成分として、pH6以下の酸性カーボンブラックを配合することが好ましい。
(F)成分の酸性カーボンブラックのpHは、耐トラッキング性維持の観点から、好ましくは6以下、より好ましくは4以下である。このような酸性カーボンブラックとしては、市販されているものを用いることができ、例えば、MA100R(三菱化学(株)製、pH3.5)等が挙げられる。
本発明のポリカーボネート系樹脂組成物には、上述の(A)~(F)成分の他、本発明の効果を損なわない範囲で、必要に応じて、従来、ポリカーボネート系樹脂組成物に添加される公知の種々の添加剤類が配合可能である。これらとしては補強材、充填剤、安定剤、酸化防止剤、紫外線吸収剤、帯電防止剤、滑剤、離型剤、染料、顔料、その他の難燃剤や耐衝撃性改良用のエラストマー等が挙げられる。
これらその他の添加剤の含有量は、(A)樹脂混合物100質量部に対して、通常0~1質量部、好ましくは0~0.5質量部である。
本発明のポリカーボネート系樹脂組成物からなる成形品は、上述の各成分を配合し、混練したものを成形することで得られる。
混練方法としては、特に制限されず、例えば、リボンブレンダー、ヘンシェルミキサー、バンバリーミキサー、ドラムタンブラー、単軸スクリュー押出機、二軸スクリュー押出機、コニーダ、多軸スクリュー押出機等を用いる方法が挙げられる。また、混練の際の加熱温度は、通常240~330℃、好ましくは250~320℃の範囲で選択される。
成形方法としては、従来公知の各種成形方法を用いることができ、例えば、射出成形法、射出圧縮成形法、押出成形法、ブロー成形法、プレス成形法、真空成形法及び発泡成形法等が挙げられる。
また、ペレット化させ、射出成形することが好ましく、一般的な射出成形法又は射出圧縮成形法、そしてガスアシスト成形法等の特殊成形法を用いることができ、各種成形品を製造することができる。
また、部品に難燃化が求められる場合は、難燃性を有する樹脂材料との積層成形、二色成形等の成形技術を用いることが好ましい。
金属部品のインサート成形、アウトサート成形を行うことにより発熱源からの熱伝達効率を高めることができるので、高発熱源を有する場合には有効な方法となる。
大型薄肉の射出成形品を得るためには、射出圧縮成形や高圧又は超高圧の射出成形を用いることが好ましく、部分的な薄肉部を有する成形品の成形には、部分圧縮成形等を用いることもできる。
本発明のポリカーボネート系樹脂組成物は、低温衝撃特性を損なわず、耐トラッキング性、及び優れた難燃性を有している。そのため、当該樹脂組成物を成形してなる成形品は、例えば、屋外に設置される太陽光発電用ジャンクションボックス等の太陽光発電用構造部材として好適である。
〔粘度数〕
ISO1628-4(1999)に準拠して測定した
〔粘度平均分子量(Mv)〕
製造したポリカーボネート-ポリオルガノシロキサン共重合体を塩化メチレンに溶解し、ウベローデ型粘度管にて、20℃における塩化メチレン溶液の極限粘度〔η〕を測定し、次の関係式(Schnellの式)より計算した。
〔η〕=1.23×10-5×Mv0.83
(1)衝撃試験(衝撃強度)
ASTM D256に準じ、23℃及び-30℃にてノッチ付アイゾッド衝撃試験を行った。
(2)耐トラッキング性
IEC Publication112規格に示されている試験方法に従い、相対トラッキング指数(CTI値)を求めた。CTI値は、試験時の印加電圧が大きい程優れ、0V~600Vの範囲の印加電圧で測定され、当該印加電圧はUL746Aで下記のランクに格付けされている。
CTIランク0:600V≦CTI値
CTIランク1:400V≦CTI値<600V
CTIランク2:250V≦CTI値<400V
CTIランク3:170V≦CTI値<250V
CTIランク4:100V≦CTI値<170V
CTIランク5:0V≦CTI値<100V
(3)燃焼性
UL規格94に準じて作製した、試験片(長さ12.7mm、幅12.7mm、厚さ3.2mm)の試験片を用いて垂直燃焼試験を行い、V-0、V-1、V-2に分類して評価した。なお、UL規格94とは、鉛直に保持した所定の大きさの試験片にバーナーの炎を10秒間接炎した後の残炎時間から難燃性を評価する方法である。
(1)ポリカーボネートオリゴマーの合成
5.6質量%水酸化ナトリウム水溶液に、後から溶解するビスフェノールAに対して2000質量ppmの亜二チオン酸ナトリウムを加え、これにビスフェノールA濃度が13.5質量%になるようにビスフェノールAを溶解し、ビスフェノールAの水酸化ナトリウム水溶液を調製した。
このビスフェノールAの水酸化ナトリウム水溶液40L/hr、塩化メチレン15L/hrの流量で、ホスゲンを4.0kg/hrの流量で内径6mm、管長30mの管型反応器に連続的に通した。管型反応器はジャケット部分を有しており、ジャケットに冷却水を通して反応液の温度を40℃以下に保った。
管型反応器を出た反応液は後退翼を備えた内容積40Lのバッフル付き槽型反応器へ連続的に導入され、ここに更にビスフェノールAの水酸化ナトリウム水溶液2.8L/hr、25質量%水酸化ナトリウム水溶液0.07L/hr、水17L/hr、1質量%トリエチルアミン水溶液を0.64L/hr添加して反応を行った。槽型反応器から溢れ出る反応液を連続的に抜き出し、静置することで水相を分離除去し、塩化メチレン相を採取した。
このようにして得られたポリカーボネートオリゴマーの濃度は329g/L、クロロホーメート基濃度は0.74mol/Lであった。
邪魔板、パドル型攪拌翼及び冷却用ジャケットを備えた50L槽型反応器に上記(1)で製造したポリカーボネートオリゴマー溶液15L、塩化メチレン8.9L、ジメチルシロキシ単位の平均繰り返し数が90である2-アリルフェノール末端変性ポリジメチルシロキサン(PDMS-1)411g及びトリエチルアミン8.8mLを仕込み、攪拌下でここに6.4質量%水酸化ナトリウム水溶液1389gを加え、10分間ポリカーボネートオリゴマーと2-アリルフェノール末端変性ポリジメチルシロキサンの反応を行った。
この重合液に、p-t-ブチルフェノール(PTBP)の塩化メチレン溶液(p-t-ブチルフェノール132gを塩化メチレン2.0Lに溶解したもの)、ビスフェノールAの水酸化ナトリウム水溶液(水酸化ナトリウム577gと亜二チオン酸ナトリウム2.0gを水8.4Lに溶解した水溶液にビスフェノールA1012gを溶解させたもの)を添加し、50分間重合反応を実施した。希釈のため塩化メチレン10Lを加えて10分間攪拌した後、ポリカーボネートを含む有機相と、過剰のビスフェノールA及び水酸化ナトリウムを含む水相に分離し、有機相を単離した。
こうして得られたポリカーボネート-ポリジメチルシロキサン共重合体の塩化メチレン溶液を、その溶液に対して順次、15容積%の0.03mol/L水酸化ナトリウム水溶液、0.2mol/L塩酸で洗浄し、次いで洗浄後の水相中の電気伝導度が0.01μS/m以下になるまで純水で洗浄を繰り返した。洗浄により得られたポリカーボネート-ポリジメチルシロキサン共重合体の塩化メチレン溶液を濃縮・粉砕し、得られたフレークを減圧下120℃で乾燥した。
上記のようにして得られたポリカーボネート-ポリオルガノシロキサン共重合体(ポリカーボネート-ポリジメチルシロキサン共重合体:PC-PDMS共重合体)を、PC-PDMS共重合体A-1-1とする。PC-PDMS共重合体A-1-1は、NMR測定により求めたポリジメチルシロキサン残基の量(PDMSブロック部分の含有量)が6.0質量%、粘度数は49.5、粘度平均分子量(Mv)は18500であった。
ポリジメチルシロキサンの種類、ポリジメチルシロキサンの使用量、p-t-ブチルフェノールの使用量を表1に記載のとおりに変更し、PC-PDMS共重合体A-1-2~5を合成した。当該共重合体の物性値を表1に示す。
表2及び表3に示す配合比で、(A)~(F)成分を混合しポリカーボネート系樹脂組成物を得た。用いた(A)~(F)成分は以下のとおりである。
(A-1):表1に示された製造例1~5により得られたPC-PDMS共重合体。
(A-2):製品名「タフロンFN1900A」(出光興産(株)製、p-t-ブチルフェノールを末端機に有するビスフェノールAポリカーボネート、粘度数49.5、粘度平均分子量(Mv)18500)。
(B):製品名「メガファックF114」(大日本インキ化学工業(株)製、パーフルオロアルカンスルホン酸カリウム)。
(C):製品名「CD076」(旭硝子(株)製、フィブリル形成能を有するポリテトラフルオロエチレン粉体)。
(D-2):表面がアルミナで被覆された平均粒径0.21μmの二酸化チタン(製品名「CR-60」、石原産業(株)製)に対して、トリメチロールプロパンを1質量部添加し、ヘンシェルミキサーにて30分間混合した後、150℃で3時間熱処理することにより最表面がトリメチロールプロパンで被覆された二酸化チタン。
(D-3):表面がアルミナで被覆された平均粒径0.21μmの二酸化チタン(製品名「CR-60」、石原産業(株)製)に対して、トリメチロールエタンを1質量部添加し、ヘンシェルミキサーにて30分間混合した後、150℃で3時間熱処理することにより最表面がトリメチロールエタンで被覆された二酸化チタン。
(d-4):最表面がアルミナで被覆された平均粒径0.21μmの二酸化チタン(製品名「CR-60」、石原産業(株)製)。
(d-5):表面がアルミナで被覆された平均粒径0.21μmの二酸化チタン(製品名「CR-60」、石原産業(株)製)に対して、ジメチルポリシロキサンを1質量部添加し、ヘンシェルミキサーにて30分間混合した後、150℃で3時間熱処理することにより最表面がジメチルポリシロキサンで被覆された二酸化チタン。
(d-6):表面がアルミナで被覆された平均粒径0.21μmの二酸化チタン(製品名「CR-60」、石原産業(株)製)に対して、トリエタノールアミンを1質量部添加し、ヘンシェルミキサーにて30分間混合した後、150℃で3時間熱処理することにより最表面がトリエタノールアミンで被覆された二酸化チタン。
(F):製品名「MA100R」(三菱化学(株)製、pH3.5の酸性カーボンブラック)。
このポリカーボネート系樹脂組成物ペレットを、射出成形機を用い、シリンダー温度280℃、金型温度80℃の成形条件で射出成形し、試験片を得た。得られた試験片を用いて、上述の方法で、23℃及び-30℃における耐衝撃強度、耐トラッキング性、難燃性の測定を行った。その結果を表2及び3に示す。
Claims (8)
- (A)一般式(I)で表される構成単位及び一般式(II)で表される構成単位を有し、かつ、一般式(II)におけるオルガノシロキサン構成単位の平均繰り返し数nが70~500であるポリカーボネート-ポリオルガノシロキサン共重合体(A-1)30~100質量%、及び、該ポリカーボネート-ポリオルガノシロキサン共重合体(A-1)以外の芳香族ポリカーボネート樹脂(A-2)70~0質量%からなる樹脂混合物100質量部に対して、
(B)有機スルホン酸のアルカリ金属塩及び/又はアルカリ土類金属塩0.01~0.15質量部、
(C)フィブリル形成能を有するポリテトラフルオロエチレン0.1~1質量部、及び、
(D)粒子最表面に窒素原子を含まないポリオールからなる被覆層を有する二酸化チタン粒子2~15質量部、
を含有する、ポリカーボネート系樹脂組成物。
- 一般式(II)で表される構成単位であるポリオルガノシロキサンブロック部分の含有量が、(A)樹脂混合物中、2~30質量%である、請求項1に記載のポリカーボネート系樹脂組成物。
- 窒素原子を含まないポリオールが、トリメチロールプロパン、トリメチロールエタン、ジトリメチロールプロパン、トリメチロールプロパンエトキシレート、ペンタエリスリトールから選ばれる少なくとも1種である、請求項1又は2に記載のポリカーボネート系樹脂組成物。
- (B)有機スルホン酸のアルカリ金属塩及び/又はアルカリ土類金属塩が、パーフルオロアルカンスルホン酸のアルカリ金属塩及び/又はアルカリ土類金属塩である、請求項1~3のいずれかに記載のポリカーボネート系樹脂組成物。
- 更に、(E)ポリオルガノシロキサンを、(A)成分100質量部に対して、0.05~0.30質量部含有する、請求項1~4のいずれかに記載のポリカーボネート系樹脂組成物。
- 更に、(F)pH6以下の酸性カーボンブラックを、(A)成分100質量部に対して、0.5~3質量部含有する、請求項1~5のいずれかに記載のポリカーボネート系樹脂組成物。
- 請求項1~6のいずれかに記載のポリカーボネート系樹脂組成物を成形してなる、成形品。
- 請求項7に記載の成形品からなる、太陽光発電用構造部材。
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WO2014207651A1 (en) * | 2013-06-26 | 2014-12-31 | Sabic Innovative Plastics Ip B.V. | Dark polycarbonate composition |
CN105492531A (zh) * | 2013-06-26 | 2016-04-13 | 沙特基础全球技术有限公司 | 深色聚碳酸酯组合物 |
US10214644B2 (en) | 2013-06-26 | 2019-02-26 | Sabic Global Technologies B.V. | Dark polycarbonate composition |
US9991622B2 (en) | 2013-07-05 | 2018-06-05 | Asahi Kasei Chemicals Corporation | Electrical component comprising insulating resin molded article, and method for stabilizing flame retardance |
DE112014003158B4 (de) | 2013-07-05 | 2022-12-15 | Asahi Kasei Chemicals Corporation | Elektrisches Bauteil, umfassend ein Isolierharz-Formteil, sowie Verfahren zur Stabilisierung der Flammhemmung |
Also Published As
Publication number | Publication date |
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KR101532490B1 (ko) | 2015-06-29 |
TWI502022B (zh) | 2015-10-01 |
EP2639271B1 (en) | 2016-04-20 |
CN103189450A (zh) | 2013-07-03 |
JP5706667B2 (ja) | 2015-04-22 |
CN103189450B (zh) | 2015-03-11 |
EP2639271A1 (en) | 2013-09-18 |
JP2012102179A (ja) | 2012-05-31 |
US8871836B2 (en) | 2014-10-28 |
EP2639271A4 (en) | 2015-04-22 |
US20130303672A1 (en) | 2013-11-14 |
KR20130132425A (ko) | 2013-12-04 |
TW201219490A (en) | 2012-05-16 |
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