WO2020166408A1 - ポリカーボネート系樹脂組成物または共重合体、および光学フィルム - Google Patents
ポリカーボネート系樹脂組成物または共重合体、および光学フィルム Download PDFInfo
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- WO2020166408A1 WO2020166408A1 PCT/JP2020/003920 JP2020003920W WO2020166408A1 WO 2020166408 A1 WO2020166408 A1 WO 2020166408A1 JP 2020003920 W JP2020003920 W JP 2020003920W WO 2020166408 A1 WO2020166408 A1 WO 2020166408A1
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- C—CHEMISTRY; METALLURGY
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- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L69/00—Compositions of polycarbonates; Compositions of derivatives of polycarbonates
- C08L69/005—Polyester-carbonates
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- 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
- C08G64/00—Macromolecular compounds obtained by reactions forming a carbonic ester link in the main chain of the macromolecule
- C08G64/02—Aliphatic polycarbonates
- C08G64/0291—Aliphatic polycarbonates unsaturated
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- 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
- C08G64/00—Macromolecular compounds obtained by reactions forming a carbonic ester link in the main chain of the macromolecule
- C08G64/04—Aromatic polycarbonates
- C08G64/06—Aromatic polycarbonates not containing aliphatic unsaturation
- C08G64/08—Aromatic polycarbonates not containing aliphatic unsaturation containing atoms other than carbon, hydrogen or oxygen
- C08G64/085—Aromatic polycarbonates not containing aliphatic unsaturation containing atoms other than carbon, hydrogen or oxygen containing silicon
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- 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
- C08G64/00—Macromolecular compounds obtained by reactions forming a carbonic ester link in the main chain of the macromolecule
- C08G64/16—Aliphatic-aromatic or araliphatic polycarbonates
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- C08G64/00—Macromolecular compounds obtained by reactions forming a carbonic ester link in the main chain of the macromolecule
- C08G64/16—Aliphatic-aromatic or araliphatic polycarbonates
- C08G64/1608—Aliphatic-aromatic or araliphatic polycarbonates saturated
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- C—CHEMISTRY; METALLURGY
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- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G64/00—Macromolecular compounds obtained by reactions forming a carbonic ester link in the main chain of the macromolecule
- C08G64/18—Block or graft polymers
- C08G64/183—Block or graft polymers containing polyether sequences
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- C08G64/00—Macromolecular compounds obtained by reactions forming a carbonic ester link in the main chain of the macromolecule
- C08G64/20—General preparatory processes
- C08G64/30—General preparatory processes using carbonates
- C08G64/307—General preparatory processes using carbonates and phenols
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- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/18—Manufacture of films or sheets
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- 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
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
- G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
- G02B1/14—Protective coatings, e.g. hard coatings
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/133308—Support structures for LCD panels, e.g. frames or bezels
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- C08J2369/00—Characterised by the use of polycarbonates; Derivatives of polycarbonates
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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- C08L2201/00—Properties
- C08L2201/08—Stabilised against heat, light or radiation or oxydation
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- C08L2201/00—Properties
- C08L2201/10—Transparent films; Clear coatings; Transparent materials
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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- C08L2203/00—Applications
- C08L2203/16—Applications used for films
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2203/00—Applications
- C08L2203/20—Applications use in electrical or conductive gadgets
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
- C08L2205/025—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
Definitions
- the present invention relates to a polycarbonate resin composition or copolymer having high heat resistance, excellent transparency and bending resistance, and a low retardation, and an optical film.
- PC-A polycarbonate resin obtained by reacting a carbonate precursor with 2,2-bis(4-hydroxyphenyl)propane (hereinafter, referred to as bisphenol A)
- PC-A polycarbonate resin
- bisphenol A 2,2-bis(4-hydroxyphenyl)propane Due to its excellent characteristics and dimensional stability, it has been widely used in many fields as an engineering plastic. Further, in recent years, its transparency has been utilized to develop its use as an optical material in the fields of optical disks, films, lenses and the like.
- Patent Documents 1 and 2 bisphenol A and 9,9-bis(4-hydroxy-3-methylphenyl)fluorene polycarbonate copolymer have high heat resistance.
- Patent Documents 3 and 4 a film made of the polycarbonate resin made of 9,9-bis(4-hydroxy-3-methylphenyl)fluorene is used for a retardation film and a protective film for a polarizing plate. It has been proposed that a polycarbonate resin composed of 9,9-bis[4-(2-hydroxyethoxy)phenyl]fluorene and spiroglycol having a fluorene structure is formed into a film by a melt film-forming method. (Patent Document 7).
- the above-mentioned polycarbonate resin composed of 9,9-bis[4-(2-hydroxyethoxy)phenyl]fluorene and spiroglycol has a low thermal decomposition temperature, so that melt film formation is difficult and decomposition during film formation is difficult. There is a problem that bubbles and gel are generated. Moreover, the strength of the film was low, and there was a problem in bending properties. Further, as disclosed in Patent Document 8, 9,9-bis(4-hydroxy-3-methylphenyl)fluorene and 3,9-bis(2-hydroxy) are used as low phase difference/high refractive index materials for camera lenses of mobile phones.
- a copolymerized polycarbonate resin of -1,1-dimethylethyl)-2,4,8,10-tetraoxaspiro(5.5)undecane has been proposed, but when it is formed into a film, it is very brittle and difficult to use. there were.
- An object of the present invention is to provide a polycarbonate resin composition or copolymer having excellent heat resistance, transparency, bending resistance, and low retardation, and an optical member formed from the same, particularly an optical film. ..
- a polycarbonate-based resin composition or copolymer containing units in a specific ratio particularly a copolymerized polycarbonate resin containing a diol having a fluorene ring in a side chain and a monomer having a specific spiro ring structure in a specific ratio;
- PC-A resin 2-bis(4-hydroxyphenyl)propane-polycarbonate resin
- the main repeating unit is a carbonate unit (a-1) having a fluorene ring in the side chain, the following formula (a-2)
- W represents an alkylene group having 1 to 20 carbon atoms or a cycloalkylene group having 6 to 20 carbon atoms
- R has a branched or straight chain alkyl group having 1 to 20 carbon atoms, or a substituent.
- the molar ratio of the carbonate unit (a-1) and the carbonate unit (a-2) is 50/50 to 80/20
- Polycarbonate-based resin composition or copolymer having a molar ratio of the total of carbonate units (a-1) and carbonate units (a-2) to carbonate units (a-3) of 1:99 to 70:30 Coalescing.
- the main repeating unit is a carbonate unit (a-1) having a fluorene ring in the side chain and the following formula (a-2)
- W represents an alkylene group having 1 to 20 carbon atoms or a cycloalkylene group having 6 to 20 carbon atoms
- R has a branched or straight chain alkyl group having 1 to 20 carbon atoms, or a substituent.
- a polycarbonate resin (A) which is a carbonate unit (a-2) represented by and a polycarbonate resin (B) whose main repeating unit is 2,2-bis(4-hydroxyphenyl)propane, 1)
- the molar ratio of the carbonate unit (a-1) to the carbonate unit (a-2) in the polycarbonate resin (A) is 50/50 to 80/20
- a polycarbonate resin composition in which the weight ratio of the polycarbonate resin (A) and the polycarbonate resin (B) is 1:99 to 70:30.
- R 1 and R 2 each independently represent a hydrogen atom, a hydrocarbon group which may contain an aromatic group having 1 to 10 carbon atoms or a halogen atom
- R 3 and R 4 each independently represent Represents a hydrocarbon group having 1 to 10 carbon atoms which may include an aromatic group
- m and n each independently represent an integer of 0 to 4
- p and q each independently represent 0 or more. Indicates an integer.
- the carbonate unit (a-1) is a unit derived from 9,9-bis[4-(2-hydroxyethoxy)phenyl]fluorene or 9,9-bis(4-hydroxy-3-methylphenyl)fluorene.
- the carbonate unit (a-2) is a unit derived from 3,9-bis(2-hydroxy-1,1-dimethylethyl)-2,4,8,10-tetraoxaspiro(5.5)undecane. 5.
- An optical film comprising the polycarbonate resin composition or copolymer described in any one of 1 to 6 above.
- the polycarbonate resin composition or copolymer of the present invention is derived from a monomer raw material containing a diol having a fluorene structure, a diol having a specific spiro ring structure, and 2,2-bis(4-hydroxyphenyl)propane.
- the polycarbonate resin composition or copolymer of the present invention has a main repeating unit having a carbonate unit (a-1) having a fluorene ring as a side chain and a spiro ring structure represented by the above formula (a-2).
- a carbonate unit (a-2) and a carbonate unit (a-3) derived from 2,2-bis(4-hydroxyphenyl)propane 1) The molar ratio of the carbonate unit (a-1) and the carbonate unit (a-2) is 50/50 to 80/20, 2) Polycarbonate-based resin composition or copolymer having a molar ratio of the total of carbonate units (a-1) and carbonate units (a-2) to carbonate units (a-3) of 1:99 to 70:30 It is united.
- the molar ratio of the carbonate unit (a-1) to the carbonate unit (a-2) is 50/50 to 80/20, preferably 50/50 to 75/25. Within the above range, it is possible to obtain a polycarbonate resin composition or copolymer having an excellent balance of heat resistance and retardation.
- the molar ratio of the total amount of the carbonate units (a-1) and the carbonate units (a-2) to the carbonate units (a-3) is 1:99 to 70:30, preferably 10:90 to. It is in the range of 50:50, and more preferably in the range of 20:80 to 40:60. Within the above range, a polycarbonate resin composition or copolymer having low heat resistance, transparency and retardation can be obtained.
- a copolymerized polycarbonate resin whose main repeating unit is a carbonate unit (a-1) having a fluorene ring as a side chain and a carbonate unit (a-2) having a spiro ring structure represented by the above formula (a-2).
- A) and a polycarbonate resin (B) whose main repeating unit is 2,2-bis(4-hydroxyphenyl)propane 1)
- the molar ratio of the carbonate unit (a-1) to the carbonate unit (a-2) in the polycarbonate resin (A) is 50/50 to 80/20
- a polycarbonate resin composition in which the weight ratio of the polycarbonate resin (A) and the polycarbonate resin (B) is 1:99 to 70:30 is preferably used.
- the copolymerized polycarbonate resin (A) in the present invention has a carbonate unit (a-1) whose main repeating unit has a fluorene ring as a side chain and a carbonate unit (a-2) represented by the above formula (a-2). Is a copolycarbonate resin (A).
- the “main” means that the total amount of the carbonate units (a-1) and the carbonate units (a-2) is 70 mol% or more, more preferably 75 mol% or more, based on all the carbonate units. It is preferably 80 mol% or more.
- the carbonate unit (a-1) is a carbonate unit (a-1) which is a polycarbonate resin having a fluorene ring as a side chain.
- Preferred structures of the carbonate unit (a-1) include the following (a-1-1) or (a-1-2).
- the following (a-1-1) is mentioned as a more preferable structure, and the following (a-1-1-a) or (a-1-1-) is further preferable as (a-1-1).
- b) are mentioned, and particularly preferable structures include the following (a-1-1-a1) or (a-1-1-b1).
- the carbonate unit (a-1-1) is represented by the following formula.
- R 1 and R 2 each independently represent a hydrogen atom, a hydrocarbon group which may contain an aromatic group having 1 to 10 carbon atoms, or a halogen atom.
- the hydrocarbon group is preferably an alkyl group having 1 to 10 carbon atoms, a cycloalkyl group having 5 to 10 carbon atoms, an aryl group having 6 to 10 carbon atoms, an aralkyl group having 7 to 10 carbon atoms, or 1 to 10 carbon atoms.
- R 3 and R 4 each independently represent a hydrocarbon group having 1 to 10 carbon atoms which may include an aromatic group.
- the hydrocarbon group is preferably an alkylene group having 1 to 10 carbon atoms, more preferably an alkylene group having 1 to 4 carbon atoms, and further preferably an ethylene group.
- m and n each independently represent an integer of 0 to 4
- p and q each independently represent an integer of 0 or more, preferably an integer of 0 to 20, more preferably an integer of 0 to 12, More preferably, it is an integer of 0 to 8, particularly preferably 0 to 4, and most preferably 0 and 1.
- the carbonate unit (a-1-1) is represented by the following formula (a-1-1-a).
- R 1 and R 2 in the above formulas each independently represent a hydrogen atom, a hydrocarbon group which may contain an aromatic group having 1 to 10 carbon atoms, or a halogen atom.
- the hydrocarbon group is preferably an alkyl group having 1 to 10 carbon atoms, a cycloalkyl group having 5 to 10 carbon atoms, an aryl group having 6 to 10 carbon atoms, an aralkyl group having 7 to 10 carbon atoms, or 1 to 10 carbon atoms.
- R 3 and R 4 each independently represent a hydrocarbon group having 1 to 10 carbon atoms which may include an aromatic group.
- the hydrocarbon group is preferably an alkylene group having 1 to 10 carbon atoms, more preferably an alkylene group having 1 to 4 carbon atoms, and further preferably an ethylene group.
- m and n each independently represent an integer of 0-4.
- Specific compounds of the unit (a-1-1-a) include 9,9-bis(4-hydroxyphenyl)fluorene, 9,9-bis(4-hydroxy-3-methylphenyl)fluorene, 9,9- Bis(4-hydroxy-3-ethylphenyl)fluorene, 9,9-bis(4-hydroxy-3-n-propylphenyl)fluorene, 9,9-bis(4-hydroxy-3-isopropylphenyl)fluorene, 9 ,9-bis(4-hydroxy-3-n-butylphenyl)fluorene, 9,9-bis(4-hydroxy-3-sec-butylphenyl)fluorene, 9,9-bis(4-hydroxy-3-tert) Units derived from -propylphenyl)fluorene, 9,9-bis(4-hydroxy-3-cyclohexylphenyl)fluorene, 9,9-bis(4-hydroxy-3-phenylphenyl)fluorene, etc. are preferred
- 9,9-bis(4-hydroxyphenyl)fluorene and 9,9-bis(4-hydroxy-3-methylphenyl)fluorene are more preferable, and 9,9-bis(4-hydroxy-3-methylphenyl) A unit (a-1-1-a1) represented by the following formula and derived from fluorene is particularly preferable.
- the carbonate unit (a-1-1) is represented by the following formula (a-1-1-b).
- R 1 and R 2 each independently represent a hydrogen atom, a hydrocarbon group which may contain an aromatic group having 1 to 10 carbon atoms, or a halogen atom.
- the hydrocarbon group is preferably an alkyl group having 1 to 10 carbon atoms, a cycloalkyl group having 5 to 10 carbon atoms, an aryl group having 6 to 10 carbon atoms, an aralkyl group having 7 to 10 carbon atoms, or 1 to 10 carbon atoms.
- R 3 and R 4 each independently represent a hydrocarbon group having 1 to 10 carbon atoms which may include an aromatic group.
- the hydrocarbon group is preferably an alkylene group having 1 to 10 carbon atoms, more preferably an alkylene group having 1 to 4 carbon atoms, and further preferably an ethylene group.
- m and n each independently represent an integer of 0-4.
- carbonate unit (a-1-1-b) examples include 9,9-bis[4-(2-hydroxyethoxy)phenyl]fluorene and 9,9-bis[4-(3-hydroxypropoxy)phenyl. ] Fluorene, 9,9-bis[4-(4-hydroxybutoxy)phenyl]fluorene, 9,9-bis[4-(2-hydroxyethoxy)-3-methylphenyl]fluorene, 9,9-bis[2 -(2-hydroxyethoxy)-5-methylphenyl]fluorene, 9,9-bis[4-(2-hydroxyethoxy)-3-ethylphenyl]fluorene, 9,9-bis[4-(2-hydroxyethoxy) )-3-Propylphenyl]fluorene, 9,9-bis[4-(2-hydroxyethoxy)-3-isopropylphenyl]fluorene, 9,9-bis[4-(2-hydroxyethoxy)-3-n- Butylphenyl]fluoren
- the preferred carbonate unit (a-1-2) is represented by the following formula.
- R 5 and R 6 are each independently a direct bond, an optionally substituted alkylene group having 1 to 10 carbon atoms, an optionally substituted arylene group having 4 to 10 carbon atoms, or a substituted group.
- R 7 is a direct bond, an optionally substituted alkylene group having 1 to 10 carbon atoms, an optionally substituted arylene group having 4 to 10 carbon atoms, or an optionally substituted carbon atom 6
- R 8 to R 9 are each independently a hydrogen atom, an optionally substituted alkyl group having 1 to 10 carbon atoms, or an optionally substituted aryl group having 4 to 10 carbon atoms.
- acyl group having 1 to 10 carbon atoms, optionally substituted alkoxy group having 1 to 10 carbon atoms, optionally substituted aryloxy group having 1 to 10 carbon atoms, substituted And an optionally substituted amino group, a sulfur atom having a substituent, a halogen atom, a nitro group, or a cyano group.
- r and s each independently represent an integer of 0 to 4, and t represents an integer value of 1 to 5.
- Specific examples of the compound for deriving the general formula (a-1-2) include 9,9′-di(hydroxymethyl)-9,9′-bifluorenyl and bis(9-hydroxymethylfluoren-9-yl).
- Methane 1,2-bis(9-hydroxymethylfluoren-9-yl)ethane, bis[9-(3-hydroxypropyl)-fluoren-9-yl]methane, bis ⁇ 9-[2-(2-hydroxy Ethoxy)carbonylethyl]fluoren-9-yl ⁇ methane, 9,9-bis[(9-hydroxymethylfluoren-9-yl)-methyl]fluorene, 1,2-bis[9-(3-hydroxypropyl)- Fluoren-9-yl]ethane, ⁇ , ⁇ '-bis-(9-hydroxymethylfluoren-9-yl)-1,4-xylene, 1,2-bis(9-hydroxymethylfluoren-9-yl)butane , 1-bis(9-hydroxymethylfluoren-9-yl)ethane, 1,2-bis(9-hydroxyfluoren-9-yl)ethane, bis- ⁇ [4-(2-hydroxyethoxy)phenyl]fluorene- 9-yl ⁇ ethane is preferred.
- the carbonate unit (a-2) in the present invention is derived from a diol having a spiro ring structure as shown in the above formula (a-2).
- a diol compound having a spiro ring structure 3,9-bis(2-hydroxyethyl)-2,4,8,10-tetraoxaspiro(5.5)undecane and 3,9-bis(2-hydroxy-1) ,1-Dimethylethyl)-2,4,8,10-tetraoxaspiro(5.5)undecane, 3,9-bis(2-hydroxy-1,1-diethylethyl)-2,4,8,10 Fats such as tetraoxaspiro(5.5)undecane and 3,9-bis(2-hydroxy-1,1-dipropylethyl)-2,4,8,10-tetraoxaspiro(5.5)undecane Examples thereof include cyclic diol compounds.
- the copolymerized polycarbonate resin (A) in the present invention contains a carbonate unit (a-1) and a carbonate unit (a-2) as main repeating units, and has a molar ratio of (a-1) and (a-2). Is 50/50 to 80/20, preferably 50/50 to 75/25. Within the above range, the compatibility with the above-described polycarbonate resin (B), heat resistance, phase balance, and the like are excellent.
- Carbonate units include bisphenol A, 2,2-bis(4-hydroxy-3-methylphenyl)propane (hereinafter Bis-C), 1,1-bis(4-hydroxyphenyl)-3,3,5.
- Bis-C 2,2-bis(4-hydroxy-3-methylphenyl)propane
- BisTMC 1,1-bis(4-hydroxyphenyl)-3,3,5.
- a ternary composition including trimethylcyclohexane (hereinafter BisTMC) may be used.
- the copolymerized polycarbonate resin (A) in the present invention is produced by a reaction means known per se for producing a usual polycarbonate resin, for example, a method of reacting a diol component with a carbonate precursor such as a carbonic acid diester. Next, the basic means of these manufacturing methods will be briefly described.
- the transesterification reaction using a carbonic acid diester as a carbonate precursor is carried out by a method of distilling the generated alcohol or phenol by agitating a predetermined ratio of the diol component with the carbonic acid diester in an inert gas atmosphere.
- the reaction temperature varies depending on the boiling point of the alcohol or phenol to be produced, but is usually in the range of 120 to 300°C.
- the reaction is completed by depressurizing the alcohol from the initial stage while distilling off the produced alcohol or phenols. Moreover, you may add a terminal terminator, antioxidant, etc. as needed.
- Examples of the carbonic acid diester used in the above transesterification reaction include an optionally substituted ester such as an aryl group having 6 to 12 carbon atoms and an aralkyl group.
- Specific examples include diphenyl carbonate, ditolyl carbonate, bis(chlorophenyl)carbonate and m-cresyl carbonate. Of these, diphenyl carbonate is particularly preferable.
- the amount of diphenyl carbonate used is preferably 0.97 to 1.10 mol, and more preferably 1.00 to 1.06 mol, based on 1 mol of the total amount of dihydroxy compounds.
- a polymerization catalyst can be used to accelerate the polymerization rate, and examples of such a polymerization catalyst include an alkali metal compound, an alkaline earth metal compound, a nitrogen-containing compound and a metal compound.
- organic acid salts, inorganic salts, oxides, hydroxides, hydrides, alkoxides, quaternary ammonium hydroxides and the like of alkali metals and alkaline earth metals are preferably used. They can be used alone or in combination.
- Examples include dilithium oxyhydrogen, disodium phenylphosphate, bisphenol A disodium salt, 2 potassium salt, 2 cesium salt, 2 lithium salt, phenol sodium salt, potassium salt, cesium salt, lithium salt and the like.
- examples include barium and barium stearate.
- nitrogen-containing compound examples include quaternary ammonium hydroxides having an alkyl or aryl group such as tetramethylammonium hydroxide, tetraethylammonium hydroxide, tetrapropylammonium hydroxide, tetrabutylammonium hydroxide and trimethylbenzylammonium hydroxide. Can be mentioned. Further, tertiary amines such as triethylamine, dimethylbenzylamine and triphenylamine, and imidazoles such as 2-methylimidazole, 2-phenylimidazole and benzimidazole can be mentioned.
- quaternary ammonium hydroxides having an alkyl or aryl group such as tetramethylammonium hydroxide, tetraethylammonium hydroxide, tetrapropylammonium hydroxide, tetrabutylammonium hydroxide and trimethylbenzylammonium hydroxide
- bases or basic salts of ammonia tetramethylammonium borohydride, tetrabutylammonium borohydride, tetrabutylammonium tetraphenylborate, tetraphenylammonium tetraphenylborate, etc. are exemplified.
- metal compounds include zinc aluminum compounds, germanium compounds, organic tin compounds, antimony compounds, manganese compounds, titanium compounds and zirconium compounds. These compounds may be used alone or in combination of two or more.
- the amount of these polymerization catalysts used is preferably 1 ⁇ 10 ⁇ 9 to 1 ⁇ 10 ⁇ 2 equivalent, preferably 1 ⁇ 10 ⁇ 8 to 1 ⁇ 10 ⁇ 5 equivalent, and more preferably 1 ⁇ , relative to 1 mol of the diol component. It is selected within the range of 10 ⁇ 7 to 1 ⁇ 10 ⁇ 3 equivalent.
- a catalyst deactivator can be added in the latter stage of the reaction.
- known catalyst deactivators are effectively used, and among these, ammonium salts and phosphonium salts of sulfonic acid are preferable.
- salts of dodecylbenzenesulfonic acid such as tetrabutylphosphonium dodecylbenzenesulfonic acid salt and salts of paratoluenesulfonic acid such as paratoluenesulfonic acid tetrabutylammonium salt are preferable.
- methyl benzene sulfonate, ethyl benzene sulfonate, butyl benzene sulfonate, octyl benzene sulfonate, phenyl benzene sulfonate, methyl paratoluene sulfonate, ethyl paratoluene sulfonate, butyl paratoluene sulfonate, Octyl paratoluenesulfonate, phenyl paratoluenesulfonate and the like are preferably used.
- dodecylbenzenesulfonic acid tetrabutylphosphonium salt is most preferably used.
- the polycarbonate resin (B) in the present invention is a polycarbonate whose main repeating unit is 2,2-bis(4-hydroxyphenyl)propane (bisphenol A).
- the specific viscosity ( ⁇ SP ) of the copolymerized polycarbonate resin (A) and the polycarbonate resin (B) is preferably in the range of 0.2 to 1.5. When the specific viscosity is in the range of 0.2 to 1.5, the strength and molding processability of molded products such as films become good. It is more preferably 0.20 to 1.2, further preferably 0.20 to 1.0, and particularly preferably 0.20 to 0.5.
- the specific viscosity referred to in the present invention is determined from a solution of 0.7 g of polycarbonate resin dissolved in 100 ml of methylene chloride at 20° C. using an Ostwald viscometer.
- Specific viscosity ( ⁇ SP ) (t ⁇ t 0 )/t 0 [T 0 is the number of seconds of methylene chloride drop, t is the number of seconds of drop of the sample solution]
- the specific viscosity can be measured in the following manner, for example. First, the polycarbonate resin is dissolved in 20 to 30 times its weight of methylene chloride, and the soluble matter is collected by filtration through Celite, and then the solution is removed and sufficiently dried to obtain a solid matter of the methylene chloride-soluble matter.
- the specific viscosity at 20° C. of a solution prepared by dissolving 0.7 g of this solid in 100 ml of methylene chloride is determined using an Ostwald viscometer.
- the resin composition of the present invention is preferably prepared by blending the copolymerized polycarbonate resin (A) and the polycarbonate resin (B) in a molten state.
- An extruder is generally used as a method of blending in a molten state, and kneading and pelletizing at a molten resin temperature of 200 to 320° C., preferably 220 to 300° C., more preferably 230 to 290° C. Thereby, pellets of the resin composition in which both resins are uniformly blended are obtained.
- the configuration of the extruder and the configuration of the screw are not particularly limited. If the temperature of the molten resin in the extruder exceeds 320° C., the resin may be colored or thermally decomposed. On the other hand, if the resin temperature is below the lower limit, the resin viscosity may be too high and the extruder may be overloaded.
- composition ratio of copolymerized polycarbonate resin (A) and polycarbonate resin (B) The weight ratio of the copolymerized polycarbonate resin (A) and the PC-A resin (B) is in the range of 1:99 to 70:30. The range is preferably 10:90 to 50:50 (weight ratio), and more preferably 20:80 to 40:60 (weight ratio). Within the above range, a polycarbonate resin composition having low heat resistance, transparency and low phase difference can be obtained. If the content of the copolycarbonate resin component is more than the upper limit, cracking tends to occur, which is a problem.
- the glass transition temperature (Tg) of the polycarbonate resin composition of the present invention is preferably single, and its glass transition temperature (Tg) is 130 to 150°C, more preferably 135 to 145°C. When Tg is within the above range, heat resistance and moldability are good, which is preferable.
- the glass transition temperature (Tg) is measured at a temperature rising rate of 20°C/min using a TA Instruments Japan Co., Ltd. model 2910 DSC.
- the single glass transition temperature (Tg) means that when the glass transition temperature is measured using a differential scanning calorimeter (DSC) at a heating rate of 20° C./min in accordance with JIS K7121, Only one inflection point showing the glass transition temperature appears.
- a single glass transition temperature of a polymer blend composition means that the resins to be mixed are in a compatible state on the order of nanometers (molecular level), and are compatible with compatible systems. Can be admitted.
- the polycarbonate resin composition of the present invention comprises a heat stabilizer, a plasticizer, a light stabilizer, a polymeric metal deactivator, a flame retardant, a lubricant, an antistatic agent, a surfactant, an antibacterial agent, and an ultraviolet ray, depending on the use and need.
- Additives known per se such as an absorbent, a release agent, a colorant, and an impact modifier can be contained.
- the polycarbonate resin composition of the present invention is molded and processed by an arbitrary method such as an injection molding method, a compression molding method, an injection compression molding method, a melt film forming method, a casting method, and an optical lens, an optical disk, an optical film, a plastic substrate.
- an injection molding method such as an injection molding method, a compression molding method, an injection compression molding method, a melt film forming method, a casting method, and an optical lens, an optical disk, an optical film, a plastic substrate.
- Optical card liquid crystal panel, headlamp lens, light guide plate, diffusion plate, protective film, OPC binder, front plate, housing, tray, water tank, lighting cover, signboard, resin window, etc. ..
- the film formed from the resin composition of the present invention can be used as a retardation film or a protective film for liquid crystal display devices, organic EL displays and the like.
- the polycarbonate resin composition of the present invention is suitably used as a film.
- the method for producing such a film include known methods such as a solution casting method, a melt extrusion method, a hot pressing method, and a calender method.
- the melt extrusion method is preferable from the viewpoint of productivity.
- a method in which a resin is extruded using a T die and sent to a cooling roll is preferably used.
- the temperature at this time is determined depending on the molecular weight, Tg, melt flow characteristics and the like of the resin composition, but is preferably in the range of 180 to 350°C, more preferably 200 to 320°C. If it is lower than the lower limit, the viscosity becomes high, and the polymer orientation and stress strain tend to remain. On the other hand, if it is higher than the upper limit, problems such as heat deterioration, coloring, and die lines (streaks) from the T die are likely to occur.
- the polycarbonate resin composition used in the present invention has good solubility in an organic solvent
- a solution casting method can also be applied.
- the solution casting method methylene chloride, 1,2-dichloroethane, 1,1,2,2-tetrachloroethane, dioxolane, dioxane and the like are preferably used as the solvent.
- the amount of residual solvent in the film used in the solution casting method is preferably 2% by weight or less, more preferably 1% by weight or less. If it exceeds 2% by weight, if the amount of residual solvent is large, the glass transition temperature of the film is significantly lowered, which is not preferable in terms of heat resistance.
- the in-plane retardation value R(550) at a wavelength of 550 nm of an optical film using the polycarbonate resin composition used in the present invention is preferably R(550) ⁇ 100 nm, and R(550) ⁇ More preferably, it is 30 nm.
- the retardation value R is defined by the following formula, and is a characteristic that expresses a phase delay between the X direction of light transmitted in the direction perpendicular to the film and the Y direction perpendicular thereto.
- R (nx-ny) ⁇ d ⁇ 10 3
- nx is the refractive index in the main stretching direction in the film plane
- ny is the refractive index in the direction perpendicular to the main stretching direction in the film plane
- d is the film thickness (unit: ⁇ m).
- the retardation and wavelength dispersibility of the optical film are measured using KOBRA-WFD manufactured by Oji Scientific Instruments.
- the in-plane birefringence ( ⁇ n) at a wavelength of 550 nm of the optical film using the polycarbonate resin composition used in the present invention is preferably ⁇ n ⁇ 10 3 ⁇ 0.2, and ⁇ n ⁇ 10 3 It is more preferable that ⁇ 0.1.
- the thickness of the optical film obtained from the polycarbonate resin composition of the present invention is preferably 20 to 500 ⁇ m, more preferably 60 to 300 ⁇ m, and further preferably 100 to 300 ⁇ m.
- the haze value of the stretched film in the present invention is preferably 5% or less, more preferably 2% or less, still more preferably 1% or less at a thickness of 300 ⁇ m. When the haze is within the above range, the visibility is excellent and it is preferable.
- surface treatment Various surface treatments can be applied to the film formed from the polycarbonate resin composition of the present invention.
- Surface treatment here means a new layer on the surface of resin molded products such as vapor deposition (physical vapor deposition, chemical vapor deposition, etc.), plating (electroplating, electroless plating, hot dip plating, etc.), painting, coating, printing, etc. It is formed, and a commonly used method can be applied.
- Specific examples of the surface treatment include various types of surface treatment such as a hard coat, a water/oil repellent coat, an ultraviolet absorption coat, an infrared absorption coat, and metalizing (vapor deposition). Hardcoats are a particularly preferred and required surface treatment.
- part in an Example means a "weight part.”
- the resins used and the evaluation methods used in the examples are as follows.
- composition ratio of copolymerized polycarbonate resin Each repeating unit was measured by proton NMR of JNM-ECZ400S/L1 manufactured by JEOL Ltd., and the composition ratio (molar ratio) of the copolymerized polycarbonate resin was calculated.
- Tg Glass transition temperature of copolymerized polycarbonate resin (A) and polycarbonate resin (B) blend Using 8 mg of the blended polycarbonate resin (A) and polycarbonate resin (B) resin, using a thermal analysis system DSC-2910 manufactured by TA Instruments Co., Ltd., nitrogen according to JIS K7121 The measurement was performed under an atmosphere (nitrogen flow rate: 40 ml/min) and a temperature rising rate: 20° C./min.
- Specific viscosity ( ⁇ SP ) of copolymerized polycarbonate resin (A) and polycarbonate resin (B) The specific viscosity ( ⁇ SP ) of the copolymerized polycarbonate resin (A) and the polycarbonate resin (B) was determined from a solution of 0.7 g of the polycarbonate resin dissolved in 100 ml of methylene chloride at 20° C. using an Ostwald viscometer.
- Phase difference (Re) A test piece having a length of 50 mm and a width of 40 mm was cut out from the unstretched film obtained in the example, and the in-plane retardation (Re) (unit: nm) was measured using KOBRA-WFD manufactured by Oji Scientific Co., Ltd. ..
- SPG ⁇ 2,4,8,10-tetraoxaspiro(5,5)undecane
- SPG ⁇ 2,4,8,10-tetraoxaspiro(5,5)undecane
- SPG ⁇ 2,4,8,10-tetraoxaspiro(5,5)undecane
- Copolymer PC2 structural unit derived from BPEF/structural unit derived from SPG/1, structural unit derived from 1,1-bis(4-hydroxy
- the pressure was reduced to 20 kPa over 20 minutes, and at the same time, the jacket was heated to 260° C. at a rate of 60° C./hr to carry out a transesterification reaction. While maintaining the jacket at 260° C., the pressure was reduced to 0.13 kPa over 80 minutes, and a polymerization reaction was performed for 30 minutes under the conditions of 260° C. and 0.13 kPa or less. After completion of the reaction, the produced polycarbonate resin was pelletized and withdrawn to obtain polycarbonate resin pellets. The composition ratio was measured by specific viscosity NMR.
- Copolymer PC1 and PC-A resin 1 were used, each resin was dried at 80° C. for 12 hours or more, and then mixed in a weight ratio of 10:90, and then a vent-type twin-screw extruder [ ) KZW15-25MG manufactured by Technovel] was melt-kneaded at 260° C. for both the cylinder and the die to obtain a blended pellet of copolymer PC1 and PC-A resin 1.
- the Tg of the obtained pellet was measured by DSC. ⁇ Manufacture of optical film> Next, the obtained pellets were dried at 90° C. for 12 hours with a hot air circulation dryer.
- a T-die having a width of 150 mm and a lip width of 500 ⁇ m and a film take-up device were attached to a 15 mm ⁇ twin-screw extruder manufactured by Technovel Co., Ltd., and the obtained pellets were film-formed at 260° C. to obtain a transparent unstretched film.
- the thickness, retardation (Re, Rth), total light transmittance, haze and flexibility of this unstretched film were measured. The results are shown in Table 1.
- Example 4 ⁇ Production of Copolymer PC2> BPEF 91.21 parts, SPG 29.22 parts, BisTMC 29.80 parts, DPC 89.11 parts, and sodium hydrogencarbonate 1.68 ⁇ 10 ⁇ 4 parts as a catalyst were heated to 180° C. under a nitrogen atmosphere and melted. Then, the pressure was reduced to 20 kPa over 20 minutes, and at the same time, the jacket was heated to 260° C.
- Table 1 BCF 51.41 parts, SPG 80.26 parts, DPC 89.29 parts, and tetramethylammonium hydroxide 1.8 ⁇ 10 ⁇ 2 parts and sodium hydroxide 1.6 ⁇ 10 ⁇ 4 parts as a catalyst were heated to 180° C. under a nitrogen atmosphere. It was heated and melted. Then, the degree of pressure reduction was adjusted to 13.4 kPa over 30 minutes. Then, the temperature was raised to 260° C. at a rate of 20° C./hr, the temperature was maintained for 10 minutes, and then the degree of pressure reduction was set to 133 Pa or less over 1 hour. The reaction was carried out under stirring for a total of 6 hours.
- Example 3 The same operation as in Example 1 was performed and the same evaluation was performed, except that only the copolymerized PC2 was changed without blending. The results are shown in Table 2. Although the phase difference was low, it was very brittle and easily cracked when bent by hand.
- Comparative Example 4 Except for changing only PC-A resin 1 without blending, the same operation as in Example 1 was performed and the same evaluation was performed. The results are shown in Table 2. The retardation Re and the birefringence ( ⁇ n) were higher than those in the examples.
- the film formed from the resin composition or the copolymer of the present invention is excellent in heat resistance, transparency, bending resistance, and has a low retardation, so that a liquid crystal display device, an organic EL display device, a head-up display device, etc. Is extremely useful as an optical film.
Abstract
Description
で表されるカーボネート単位(a-2)および2,2-ビス(4-ヒドロキシフェニル)プロパンから誘導されるカーボネート単位(a-3)を含み、
1)カーボネート単位(a-1)とカーボネート単位(a-2)とのモル比が50/50~80/20であり、
2)カーボネート単位(a-1)とカーボネート単位(a-2)との合計とカーボネート単位(a-3)とのモル比が1:99~70:30であるポリカーボネート系樹脂組成物または共重合体。
で表されるカーボネート単位(a-2)である共重合ポリカーボネート樹脂(A)および主たる繰り返し単位が2,2-ビス(4-ヒドロキシフェニル)プロパンであるポリカーボネート樹脂(B)を含有し、
1)ポリカーボネート樹脂(A)におけるカーボネート単位(a-1)とカーボネート単位(a-2)とのモル比が50/50~80/20であり、
2)ポリカーボネート樹脂(A)とポリカーボネート樹脂(B)との重量比が1:99~70:30であるポリカーボネート樹脂組成物。
4.カーボネート単位(a-1)が9,9-ビス[4-(2-ヒドロキシエトキシ)フェニル]フルオレンもしくは9,9-ビス(4-ヒドロキシ-3-メチルフェニル)フルオレンから誘導される単位である前記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または共重合体。
<ポリカーボネート系樹脂組成物または共重合体>
本発明のポリカーボネート系樹脂組成物または共重合体は、主たる繰り返し単位が、フルオレン環を側鎖に有するカーボネート単位(a-1)、上記式(a-2)で表されるスピロ環構造を有するカーボネート単位(a-2)および2,2-ビス(4-ヒドロキシフェニル)プロパンから誘導されるカーボネート単位(a-3)を含み、
1)カーボネート単位(a-1)とカーボネート単位(a-2)とのモル比が50/50~80/20であり、
2)カーボネート単位(a-1)とカーボネート単位(a-2)との合計とカーボネート単位(a-3)とのモル比が1:99~70:30であるポリカーボネート系樹脂組成物または共重合体である。
1)ポリカーボネート樹脂(A)におけるカーボネート単位(a-1)とカーボネート単位(a-2)とのモル比が50/50~80/20であり、
2)ポリカーボネート樹脂(A)とポリカーボネート樹脂(B)との重量比が1:99~70:30であるポリカーボネート樹脂組成物が好ましく使用される。
<共重合ポリカーボネート樹脂(A)>
本発明における共重合ポリカーボネート樹脂(A)は、主たる繰り返し単位が、フルオレン環を側鎖に有するカーボネート単位(a-1)と上記式(a-2)で表されるカーボネート単位(a-2)である共重合ポリカーボネート樹脂(A)である。
(カーボネート単位(a-1))
カーボネート単位(a-1)は、フルオレン環を側鎖に有するポリカーボネート樹脂であるカーボネート単位(a-1)である。
上記一般式(a-1-2)を誘導する化合物の具体的例として、9,9’-ジ(ヒドロキシメチル)-9,9’-ビフルオレニル、ビス(9-ヒドロキシメチルフルオレン-9-イル)メタン、1,2-ビス(9-ヒドロキシメチルフルオレン-9-イル)エタン、ビス[9-(3-ヒドロキシプロピル)-フルオレン-9-イル]メタン、ビス{9-[2-(2-ヒドロキシエトキシ)カルボニルエチル]フルオレン-9-イル}メタン、9,9-ビス[(9-ヒドロキシメチルフルオレン-9-イル)-メチル]フルオレン、1,2-ビス[9-(3-ヒドロキシプロピル)-フルオレン-9-イル]エタン、α,α’-ビス-(9-ヒドロキシメチルフルオレン-9-イル)-1,4-キシレン、1,2-ビス(9-ヒドロキシメチルフルオレン-9-イル)ブタン、1-ビス(9-ヒドロキシメチルフルオレン-9-イル)エタン、1,2-ビス(9-ヒドロキシフルオレン-9-イル)エタン、ビス-{[4-(2-ヒドロキシエトキシ)フェニル]フルオレン-9-イル}エタンが好ましい。
(カーボネート単位(a-2))
本発明におけるカーボネート単位(a-2)は前記式(a-2)に示したように、スピロ環構造を有するジオールから誘導されるものである。スピロ環構造を有するジオール化合物として、3,9-ビス(2-ヒドロキシエチル)-2,4,8,10-テトラオキサスピロ(5.5)ウンデカン、3,9-ビス(2-ヒドロキシ-1,1-ジメチルエチル)-2,4,8,10-テトラオキサスピロ(5.5)ウンデカン、3,9-ビス(2-ヒドロキシ-1,1-ジエチルエチル)-2,4,8,10-テトラオキサスピロ(5.5)ウンデカン、3,9-ビス(2-ヒドロキシ-1,1-ジプロピルエチル)-2,4,8,10-テトラオキサスピロ(5.5)ウンデカンなどの脂環式ジオール化合物があげられる。
本発明における共重合ポリカーボネート樹脂(A)は、主たる繰り返し単位がカーボネート単位(a-1)とカーボネート単位(a-2)とを含み、(a-1)と(a-2)とのモル比は、50/50~80/20であり、好ましくは、50/50~75/25である。上記範囲であると、前述のポリカーボネート樹脂(B)との相溶性、耐熱性、位相差等のバランスに優れる。
(共重合ポリカーボネート樹脂(A)の製造方法)
本発明における共重合ポリカーボネート樹脂(A)は、通常のポリカーボネート樹脂を製造するそれ自体公知の反応手段、例えばジオール成分に炭酸ジエステルなどのカーボネート前駆物質を反応させる方法により製造される。次にこれらの製造方法について基本的な手段を簡単に説明する。
<ポリカーボネート樹脂(B)>
本発明におけるポリカーボネート樹脂(B)は、主たる繰り返し単位が、2,2-ビス(4-ヒドロキシフェニル)プロパン(ビスフェノールA)からなるポリカーボネートである。
(比粘度:ηSP)
共重合ポリカーボネート樹脂(A)およびポリカーボネート樹脂(B)の比粘度(ηSP)は、0.2~1.5の範囲が好ましい。比粘度が0.2~1.5の範囲ではフィルム等の成形品の強度及び成形加工性が良好となる。より好ましくは0.20~1.2であり、さらに好ましくは0.20~1.0であり、特に好ましくは0.20~0.5である。
比粘度(ηSP)=(t-t0)/t0
[t0は塩化メチレンの落下秒数、tは試料溶液の落下秒数]
なお、具体的な比粘度の測定としては、例えば次の要領で行うことができる。まず、ポリカーボネート樹脂をその20~30倍重量の塩化メチレンに溶解し、可溶分をセライト濾過により採取した後、溶液を除去して十分に乾燥し、塩化メチレン可溶分の固体を得る。かかる固体0.7gを塩化メチレン100mlに溶解した溶液から20℃における比粘度を、オストワルド粘度計を用いて求める。
(共重合ポリカーボネート樹脂(A)とポリカーボネート樹脂(B)とを含有するポリカーボネート樹脂組成物の製造方法)
本発明の樹脂組成物は共重合ポリカーボネート樹脂(A)とポリカーボネート樹脂(B)とを溶融状態でブレンドすることが好ましい。溶融状態でブレンドする方法として、押出機が一般的に用いられ、溶融樹脂温度200~320℃、好ましくは220~300℃、より好ましくは、230~290℃で混練し、ペレタイズする。これにより、両樹脂が均一にブレンドされた樹脂組成物のペレットが得られる。押出機の構成、スクリューの構成等は特に限定されない。押出機中の溶融樹脂温度が320℃を超えると樹脂が着色したり、熱分解することがある。一方、樹脂温度が下限を下回ると、樹脂粘度が高過ぎて押出機に過負荷がかかることがある。
(共重合ポリカーボネート樹脂(A)とポリカーボネート樹脂(B)との組成比)
上記共重合ポリカーボネート樹脂(A)とPC-A樹脂(B)との重量比は1:99~70:30の範囲である。好ましくは10:90~50:50(重量比)の範囲であり、より好ましくは20:80~40:60(重量比)の範囲である。上記範囲とすることにより、耐熱性、透明性、位相差が低いポリカーボネート系樹脂組成物を得ることができる。共重合ポリカーボネート樹脂成分が上限より多くなると割れやすくなり問題となる。
(ガラス転移温度:Tg)
本発明のポリカーボネート樹脂組成物のガラス転移温度(Tg)は好ましくは単一であり、そのガラス転移温度(Tg)は130~150℃であり、より好ましくは135~145℃である。Tgが上記範囲内であると、耐熱性及び成形性が良好であり好ましい。
(添加剤)
本発明のポリカーボネート樹脂組成物は、用途や必要に応じて熱安定剤、可塑剤、光安定剤、重合金属不活性化剤、難燃剤、滑剤、帯電防止剤、界面活性剤、抗菌剤、紫外線吸収剤、離型剤、着色剤、衝撃改質剤等のそれ自体公知の添加剤を含有できる。
(成形品)
本発明のポリカーボネート樹脂組成物は、例えば射出成形法、圧縮成形法、射出圧縮成形法、溶融製膜法、キャスティング法など任意の方法により成形、加工され、光学レンズ、光ディスク、光学フィルム、プラセル基板、光カード、液晶パネル、ヘッドランプレンズ、導光板、拡散板、保護フィルム、OPCバインダー、前面板、筐体、トレー、水槽、照明カバー、看板、樹脂窓等の成形品として使用することができる。特に本発明の樹脂組成物から形成されるフィルムは、液晶表示装置、有機ELディスプレイ等の位相差フィルムや保護フィルムとして使用することができる。
(フィルムの製造方法)
本発明のポリカーボネート樹脂組成物はフィルム用途として好適に使用される。かかるフィルムの製造方法としては、例えば、溶液キャスト法、溶融押し出し法、熱プレス法、カレンダー法等公知の方法を挙げることが出来る。本発明のフィルムの製造方法としては、溶融押し出し法が生産性の点から好ましい。
(位相差)
本発明で使用されるポリカーボネート樹脂組成物を用いてなる光学フィルムの波長550nmにおけるフィルム面内の位相差値R(550)は、R(550)≦100nmであることが好ましく、R(550)≦30nmであることがより好ましい。
R=(nx-ny)×d×103
但し、nxはフィルム面内の主延伸方向の屈折率であり、nyはフィルム面内の主延伸方向と垂直方向の屈折率であり、dはフィルムの厚み(単位:μm)である。
(複屈折)
本発明で使用されるポリカーボネート樹脂組成物を用いてなる光学フィルムの波長550nmにおけるフィルム面内の複屈折率(Δn)は、Δn×103≦0.2であることが好ましく、Δn×103≦0.1であることがより好ましい。
(厚み)
本発明のポリカーボネート樹脂組成物から得られる光学フィルムの厚みは20~500μmが好ましく、60~300μmがより好ましく、100~300μmがさらに好ましい。厚みが上限以上になると、ディスプレイ用途において薄膜化の要望が強い偏光板の厚みが分厚くなってしまう問題点や、熱を加えた時の歪みつまり位相差変化が起きることで、色ムラとして光抜けが起こり易くなる。また厚みが下限未満になると、必要な位相差を満たすことができない。
(ヘイズ)
本発明における延伸後のフィルムのヘイズ値は、厚み300μmにおいて、好ましくは5%以下、より好ましくは2%以下、さらに好ましくは1%以下である。ヘイズが上記範囲内であると、視認性が優れ好ましい。
(表面処理)
本発明のポリカーボネート樹脂組成物から形成されるフィルムには、各種の表面処理を行うことが可能である。ここでいう表面処理とは、蒸着(物理蒸着、化学蒸着など)、メッキ(電気メッキ、無電解メッキ、溶融メッキなど)、塗装、コーティング、印刷などの樹脂成形品の表層上に新たな層を形成させるものであり、通常用いられる方法が適用できる。表面処理としては、具体的には、ハードコート、撥水・撥油コート、紫外線吸収コート、赤外線吸収コート、並びにメタライジング(蒸着など)などの各種の表面処理が例示される。ハードコートは特に好ましくかつ必要とされる表面処理である。
日本電子社製JNM-ECZ400S/L1のプロトンNMRにて各繰り返し単位を測定し、共重合ポリカーボネート樹脂の組成比(モル比)を算出した。
共重合ポリカーボネート樹脂(A)とポリカーボネート樹脂(B)ブレンドの樹脂8mgを用いてティー・エイ・インスツルメント(株)製の熱分析システム DSC-2910を使用して、JIS K7121に準拠して窒素雰囲気下(窒素流量:40ml/min)、昇温速度:20℃/minの条件下で測定した。
共重合ポリカーボネート樹脂(A)およびポリカーボネート樹脂(B)の比粘度(ηSP)は、20℃で塩化メチレン100mlにポリカーボネート樹脂0.7gを溶解した溶液からオストワルド粘度計を用いて求めた。
[t0は塩化メチレンの落下秒数、tは試料溶液の落下秒数]
4.未延伸フィルム厚み(d)
実施例で得られた未延伸フィルムの中央部分の厚み(d)(単位:μm)を、アンリツ社製の電子マイクロ膜厚計で測定した。
実施例で得られた未延伸フィルムから長さ50mm、幅40mmの試験片を切り出し、面内位相差(Re)(単位:nm)を王子計測(株)製KOBRA-WFDを使用して測定した。
日本電色工業(株)製分光ヘイズメータSH-7000を用いて、JIS K7136に準拠した共重合ポリカーボネート樹脂(A)とポリカーボネート樹脂(B)ブレンドの全光線透過率・ヘイズを測定した。
実施例で得られた未延伸フィルムを手で1回折り曲げた時に、割れないものは「○」、割れるものは「×」とした。
延伸後のフィルムから長さ50mm、幅40mmの試験片を切り出し、王子計測(株)製KOBRA-WFDを使用して位相差R(550)を測定し、複屈折△n=R(550)/(d×103)を算出した。同サンプルで3回測定したときの平均値を算出した。
[共重合ポリカーボネート樹脂(A)]
共重合PC1:9,9-ビス[4-(2-ヒドロキシエトキシ)フェニル]フルオレン(以下BPEFと略す)に由来する構造単位/3,9-ビス(2-ヒドロキシ-1,1-ジメチルエチル)-2,4,8,10-テトラオキサスピロ(5,5)ウンデカン(以下SPGと略す)に由来する構造単位=60/40(モル%) 比粘度(ηSP)0.23
共重合PC2:BPEFに由来する構造単位/SPGに由来する構造単位/1,1-ビス(4-ヒドロキシフェニル)-3,3,5-トリメチルシクロヘキサン(以下BisTMCと略す)に由来する構造単位=52/24/24(モル%)比粘度(ηSP)0.23
共重合PC3:9,9-ビス(4-ヒドロキシ-3-メチルフェニル)フルオレン(以下BCFと略す)に由来する構造単位/SPGに由来する構造単位=35/65(モル%)比粘度(ηSP)0.31
[ポリカーボネート樹脂(B)]
PC-A樹脂1:ビスフェノールAポリカーボネート樹脂 比粘度(ηSP)0.34
PC-A樹脂2:ビスフェノールAポリカーボネート樹脂 比粘度(ηSP)0.28
[実施例1]
<共重合PC1の製造>
BPEF105.24部、SPG48.7部、ジフェニルカーボネート(以下DPCと略す)89.11部、および触媒として炭酸水素ナトリウム1.68×10-4部を窒素雰囲気下180℃に加熱し溶融させた。その後、20分かけて20kPaまで減圧すると同時に、60℃/hrの速度でジャケットを260℃まで昇温し、エステル交換反応を行った。ジャケットを260℃に保持したまま、80分間かけて0.13kPaまで減圧し、260℃、0.13kPa以下の条件下で30分間重合反応を行った。反応終了後、生成したポリカーボネート樹脂をペレタイズしながら抜き出し、ポリカーボネート樹脂ペレットを得た。比粘度NMRより組成比を測定した。(共重合PC1)
<樹脂組成物の製造>
共重合PC1とPC-A樹脂1を使用し、各々の樹脂を80℃で12時間以上乾燥した後、重量比が10:90となるように混合した後、ベント式二軸押出機[(株)テクノベル製KZW15-25MG]により、シリンダおよびダイス共に260℃にて溶融混練し、共重合PC1とPC-A樹脂1のブレンドペレットを得た。得られたペレットのTgをDSCにて測定した。
<光学フィルムの製造>
次に、得られたペレットを90℃で12時間、熱風循環式乾燥機により乾燥した。(株)テクノベル製15mmφ二軸押出機に幅150mm、リップ幅500μmのTダイとフィルム引取り装置を取り付け、得られたペレットを260℃でフィルム成形することで透明な未延伸フィルムを得た。この未延伸フィルムの厚み、位相差(Re,Rth)、全光線透過率、ヘイズ、屈曲性を測定した。その結果を表1に記載した。
[実施例2]
ブレンド重量比を共重合PC1/PC-A樹脂1=20/80に変更した以外は、実施例1と全く同様の操作を行い、同様の評価を行った。その結果を表1に記載した。
[実施例3]
ブレンド重量比を共重合PC1/PC-A樹脂1=30/70に変更した以外は、実施例1と全く同様の操作を行い、同様の評価を行った。その結果を表1に記載した。
[実施例4]
<共重合PC2の製造>
BPEF91.21部、SPG29.22部、BisTMC29.80部、DPC89.11部、および触媒として炭酸水素ナトリウム1.68×10-4部を窒素雰囲気下180℃に加熱し溶融させた。その後、20分かけて20kPaまで減圧すると同時に、60℃/hrの速度でジャケットを260℃まで昇温し、エステル交換反応を行った。ジャケットを260℃に保持したまま、80分間かけて0.13kPaまで減圧し、260℃、0.13kPa以下の条件下で30分間重合反応を行った。反応終了後、生成したポリカーボネート樹脂をペレタイズしながら抜き出し、ポリカーボネート樹脂ペレットを得た。NMRより組成比を測定した。(共重合PC2)
ブレンド重量比を共重合PC2/PC-A樹脂1=50/50に変更した以外は、実施例1と全く同様の操作を行い、同様の評価を行った。その結果を表1に記載した。
[実施例5]
ブレンド重量比を共重合PC2/PC-A樹脂1=70/30に変更した以外は、実施例4と全く同様の操作を行い、同様の評価を行った。その結果を表1に記載した。
[実施例6]
ブレンド重量比を共重合PC1/PC-A樹脂2=10/90に変更した以外は、実施例1と全く同様の操作を行い、同様の評価を行った。その結果を表1に記載した。
[実施例7]
ブレンド重量比を共重合PC1/PC-A樹脂2=20/80に変更した以外は、実施例1と全く同様の操作を行い、同様の評価を行った。その結果を表1に記載した。
[実施例8]
ブレンド重量比を共重合PC1/PC-A樹脂2=30/70に変更した以外は、実施例1と全く同様の操作を行い、同様の評価を行った。その結果を表1に記載した。
[比較例1]
BCF51.41部、SPG80.26部、DPC89.29部、および触媒としてテトラメチルアンモニウムヒドロキシド1.8×10-2部と水酸化ナトリウム1.6×10-4部を窒素雰囲気下180℃に加熱し溶融させた。その後、30分かけて減圧度を13.4kPaに調整した。その後、20℃/hrの速度で260℃まで昇温を行い、10分間その温度で保持した後、1時間かけて減圧度を133Pa以下とした。合計6時間撹拌下で反応を行った。
ブレンド重量比を共重合PC3/PC-A樹脂1=30/70として押出してブレンドペレットを得た以外は、実施例1と全く同様の操作を行い未延伸フィルムを得たが、透明性がなく白濁しており、相溶しなかった。結果を表2に記載した。
[比較例2]
ブレンドせずに共重合PC1のみに変更した以外は、実施例1と全く同様の操作を行い、同様の評価を行った。その結果を表2に記載した。位相差は低いが非常に脆く、手で折り曲げると容易に割れるものであった。
[比較例3]
ブレンドせずに共重合PC2のみに変更した以外は、実施例1と全く同様の操作を行い、同様の評価を行った。その結果を表2に記載した。位相差は低いが非常に脆く、手で折り曲げると容易に割れるものであった。
[比較例4]
ブレンドせずにPC-A樹脂1のみに変更した以外は、実施例1と全く同様の操作を行い、同様の評価を行った。その結果を表2に記載した。実施例と比べて位相差Re、複屈折率(Δn)が高いものであった。
Claims (13)
- 主たる繰り返し単位が、フルオレン環を側鎖に有するカーボネート単位(a-1)、下記式(a-2)
で表されるカーボネート単位(a-2)および2,2-ビス(4-ヒドロキシフェニル)プロパンから誘導されるカーボネート単位(a-3)を含み、
1)カーボネート単位(a-1)とカーボネート単位(a-2)とのモル比が50/50~80/20であり、
2)カーボネート単位(a-1)とカーボネート単位(a-2)との合計とカーボネート単位(a-3)とのモル比が1:99~70:30であるポリカーボネート系樹脂組成物または共重合体。 - 主たる繰り返し単位が、フルオレン環を側鎖に有するカーボネート単位(a-1)と下記式(a-2)
で表されるカーボネート単位(a-2)である共重合ポリカーボネート樹脂(A)および主たる繰り返し単位が2,2-ビス(4-ヒドロキシフェニル)プロパンであるポリカーボネート樹脂(B)を含有し、
1)ポリカーボネート樹脂(A)におけるカーボネート単位(a-1)とカーボネート単位(a-2)とのモル比が50/50~80/20であり、
2)ポリカーボネート樹脂(A)とポリカーボネート樹脂(B)との重量比が1:99~70:30であるポリカーボネート系樹脂組成物。 - カーボネート単位(a-1)が9,9-ビス[4-(2-ヒドロキシエトキシ)フェニル]フルオレンまたは9,9-ビス(4-ヒドロキシ-3-メチルフェニル)フルオレンから誘導される単位である請求項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または共重合体。
- カーボネート単位(a-2)が3,9-ビス(2-ヒドロキシ-1,1-ジメチルエチル)-2,4,8,10-テトラオキサスピロ(5.5)ウンデカンから誘導される単位である請求項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または共重合体。
- ガラス転移温度が単一で且つその範囲が130℃~150℃である請求項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または共重合体。
- 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または共重合体からなる光学フィルム。
- 光学フィルムの厚みが20~500μmである請求項7に記載の光学フィルム。
- 光学フィルムの面内位相差が100nm以下である請求項7または8に記載の光学フィルム。
- 光学フィルムのヘイズが5%以下である請求項7~9のいずれかに記載の光学フィルム。
- 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または共重合体からなる光学フィルムを用いた光学部材。
- 請求項7~10のいずれかに記載の光学フィルムを用いた液晶表示装置または有機EL表示装置。
- 請求項7~10のいずれか記載の光学フィルムを用いたヘッドアップディスプレイ装置。
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KR102574566B1 (ko) | 2023-09-04 |
JP7219291B2 (ja) | 2023-02-07 |
EP3926000A4 (en) | 2022-08-10 |
JPWO2020166408A1 (ja) | 2021-10-14 |
US20220135795A1 (en) | 2022-05-05 |
CN113423757B (zh) | 2023-04-04 |
KR20210124386A (ko) | 2021-10-14 |
EP3926000A1 (en) | 2021-12-22 |
EP3926000B1 (en) | 2024-04-03 |
TW202043329A (zh) | 2020-12-01 |
CN113423757A (zh) | 2021-09-21 |
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