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Polycarbonate Resin And Method For Producing Same

Abstract: A polycarbonate resin which has a high biogenic matter content, excellent moisture absorption resistance, heat resistance, heat stability and moldability, and high surface energy, as well as a production process thereof. The polycarbonate resin contains 30 to 100 mol% of a unit represented by the following formula (1) in all the main chains and has (i) a biogenic matter content measured in accordance with ASTM D6866 05 of 25 to 100 % (ii) a specific viscosity at 20°C of a solution prepared by dissolving 0.7 g of the resin in 100 ml of methylene chloride of 0.2 to 0.6 and (iii) an OH value of 2.5 x 103 or less.

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Patent Information

Application #
Filing Date
02 August 2012
Publication Number
46/2015
Publication Type
INA
Invention Field
POLYMER TECHNOLOGY
Status
Email
Parent Application

Applicants

TEIJIN LIMITED
6-7  Minamihommachi 1-chome  Chuo-ku  Osaka-shi  OSAKA 5410054

Inventors

1. MASAMI KINOSHITA
c/o Teijin Chemicals Ltd.  2-1  Kasumigaseki 3-chome  Chiyoda-ku  TOKYO 100-0013
2. MIZUHO SAITO
c/o Teijin Chemicals Ltd.  2-1  Kasumigaseki 3-chome  Chiyoda-ku  TOKYO 100-0013
3. FUMITAKA KONDO
c/o Teijin Chemicals Ltd.  2-1  Kasumigaseki 3-chome  Chiyoda-ku  TOKYO 100-0013

Specification

DESCRIPTION POLYCARBONATE RESIN AND PRODUCTION PROCESS THEREOF 5 TECHNICAL FIELD The present invention relates to a polycarbonate resin. More specifically, it relates to a polycarbonate resin containing a recurring unit derived from sugar which is biogenic matter and having excellent moisture absorption 10 resistance, heat resistance, heat stability and moldability. BACKGROUND ART Polycarbonate resins are polymers in which aromatic or aliphatic dioxy compounds are connected to each other by 15 a carbonate ester. Out of these, a polycarbonate resin (may be referred to as "CPC-A" hereinafter) obtained from 2,2-bis(4-hydroxyphenyl)propane (commonly known as wbisphenol A") is used in many fields because it has excellent transparency, heat resistance and impact resistance. 20 Polycarbonate resins are generally produced by using raw materials obtained from oil resources. Because of the concern about the depletion of oil resources, it is desired to produce a polycarbonate resin by using raw materials obtained from biogenic matter such as plants. A 25 polycarbonate resin obtained from an ether diol which can be-produced from sugar is now under study. For example, an ether diol represented by the following formula (5) is easily produced from biogenic matter such as sugar or starch. HO 30 OH (5) It is known that this ether diol has three stereoisomers. In concrete terms, they are 1, 4 :3, 6-dianhydro-D-sorbitol (to be referred to as "isosorbide" hereinafter) represented by the following formula (9), 1, 4: 3, 6-dianhydro-D-mannitol (to be referred to as "isomannide" hereinafter) represented by 5 the following formula (10), and 1, 4: 3, 6-dianhydro-L-iditol (to be referred to as "isoidide" hereinafter) represented by the following formula (11). (9) 10 (10) 15 Isosorbide, isomannide and isoidide are obtained from 20 D-glucose, D-mannose and L-idose, respectively. For example, isosorbide can be obtained by hydrogenating D-glucose and then dehydrating it by using an acid catalyst. The incorporation of especially isosorbide out of the ether diols represented by the formula (5) into a 25 polycarbonate resin has been studied (Patent Documents 1 to 5) However, an isosorbide-containing polycarbonate resin contains a large number of oxygen atoms and has higher polarity than a polycarbonate resin obtained from a diol 30 having no ether moiety, such as PC-A. Therefore, the isosorbide-containing polycarbonate resin has higher hygroscopic nature than PC-A, whereby it readily causes the deterioration of the dimensional stability of a molded article by moisture absorption and the degradation of heat resistance at the time of wet heating. Further, as the isosorbide-containing polycarbonate resin has low surface energy, a molded article is easily stained and susceptible to abrasion. This surface energy can be evaluated by contact 5 angle with water. The isosorbide-containing polycarbonate resin has room for the further improvement of moisture absorption resistance, heat resistance, heat stability and moldability as described above. The isosorbide-containing 10 polycarbonate resin also has room for the improvement of a defect caused by low surface energy. (Patent Document 1) JP-A 56-055425 (Patent Document 2) JP-A 56-110723 (Patent Document 3) JP-A 2003-292603 15 (Patent Document 4) W02004/111106 (Patent Document 5) JP-A 2006-232897 DISCLOSURE OF THE INVENTION It is therefore an object of the present invention to 20 provide a polycarbonate resin which has a high content of biogenic matter, excellent moisture absorption resistance, heat resistance, heat stability and moldability, and high surface energy. It is still another object of the present invention to provide a molded article such as film which has 25 a low photoelastic constant, high phase difference developability and phase difference controllability, and excellent view angle characteristics as well as high heat resistance and heat stability. The inventors of the present invention found that, in 30 a polycarbonate resin containing a recurring unit represented by the following formula (1) in the main chain, the amount of a polymer terminal hydroxyl group (OH value) greatly contributes to the water absorption coefficient of a polymer and that a polycarbonate resin having excellent moisture absorption resistance, heat resistance, heat stability and moldability, and high surface energy is obtained by setting the OH value in particular to 2.5 x 103 or less. The present invention was accomplished based on 5 this finding. That is, the present invention is a polycarbonate resin which contains 30 to 100 mol% of a unit represented by the following formula (1) in all the main chains and has (i) a biogenic matter content measured in accordance with ASTM 10 D6866 05 of 25 to 100 (ii) a specific viscosity at 20°C of a solution prepared by dissolving 0.7 g of the resin in 100 m1 of methylene chloride of 0.2 to 0.6 and (iii) an OH value of 2.5 x 103 or less. 15 (1) 0 Further, the present invention is a process for producing a polycarbonate resin by reacting (A) an ether diol 20 (component A) represented by the following formula (5), (B) a dial and/or a diphenol (component B) except for the component A, (C) a diester carbonate (component C) , and (D) 0.01 to 7 mol o based on the total of the component. A and the component B of a hydroxy compound (component D) represented 25 by the following formula (6) or (7). HO 0 (5) HO-R1 ( 6 ) HO 7 { In the above formulas (6) and (7), Rl is an alkyl group having 4 to 30 carbon atoms, aralkyl group having 7 to 30 carbon atoms, perfluoroalkyl group having 4 to 30 carbon atoms, 5 phenyl group or group represented by the following formula (4) , X is at least one bond selected from the group consisting of a single bond, ether bond, thioether bond, ester bond, amino bond and amide bond, and a is an integer of 1 to 5.1 (CH2)b El4 1 -SHR5 C (4) 10 (In the above formula (4), R2, R3, Rd, R5 and R6 are each independently at least one group selected from the group consisting of an alkyl group having 1 to 10 carbon atoms, cycloalkyl group having 6 to 20 carbon atoms, alkenyl group having 2 to 10 carbon atoms, aryl group having 6 to 10 carbon 15 atoms and aralkyl group having 7 to 20 carbon atoms, b is an integer of 0 to 3, and c is an integer of 4 to 100.) Further, the present invention is a process for producing a polycarbonate resin by reacting (A) an ether diol (component A) represented by the following formula (5), (B) 20 a diol and/or a diphenol (component B) except for the component A, and (E) phosgene (component E) in an inactive solvent in the presence of an acid binder, wherein (D) a hydroxy compound (component D) represented by the following formula (6) or (7) is reacted as an end-sealing 25 agent. (5) HO-R1 (6) HO -X (Hs}a ( 7 ) 5 (In the above formulas (6) and (7), R' is an alkyl group having 4 to 30 carbon atoms, aralkyl group having 7 to 30 carbon atoms, perfluoroalkyl group having 4 to 30 carbon atoms, phenyl group or group represented by the following formula (4) , X is at least one bond selected from the group consisting 10 of a single bond, ether bond, thioether bond, ester bond, amino bond and amide bond, and a is an integer of 1 to 5.) (H2)b (4) (In the above formula (4), R2, R3, R4, R5 and R6 are each independently at least one group selected from the group 15 consisting of an alkyl group having l to 10 carbon atoms, cycloalkyl group having 6 to 20 carbon atoms, alkenyl group having 2 to 10 carbon atoms, aryl group having 6 to 10 carbon atoms and aralkyl group having 7 to 20 carbon atoms, b is an integer of 0 to 3, and c is an integer of 4 to 100.) 20 Further, the present invention is a process for producing a polycarbonate resin by reacting a dihydroxy component consisting of 30 to 100 mol% of an ether diol (component A) represented by the following formula (5) HO O (5) 5 and 0 to 70 mol% of a diol or a diphenol (component B) except for the ether diol (component A) with a diester carbonate component (component C) by heating at normal pressure and then melt polycondensing the reaction product under reduced pressure by heating at 180 to 280°C in the presence of a 10 polymerization catalyst, wherein (i) the weight ratio of the component C to the dihydroxy component (component C/ (component A + component B) ) is set to,1.05 to 0.97 at the start of polymerization; and (ii) the component C is further added to ensure that the 15 weight ratio of the component C to the dihydroxy component (component C/(component A + component B)) during polymerization becomes 1.08 to 1.00. The present invention includes a molded article formed of the above polycarbonate resin. 20 BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described in detail hereinunder. 25 (main chain) The polycarbonate resin of the present invention contains a unit represented by the following formula (1) in the main chain. The content of the unit represented by the 30 following formula (1) in the main chain is 30 to 100 mol%, preferably 50 to 95 molt; more preferably 55 to 90 mol%. O OH 0 0-c (1) The unit represented by the formula (1) is preferably a unit derived from isosorbide, isomannide or isoidide. It is particularly preferably a unit derived from isosorbide 5 (1,4:3,6-dianhydro-D-sorbitol). The polycarbonateresin of the present invention contains 0 to 70 mol%, preferably 5 to 50 mol%, more preferably 10 to 45 mol% of a unit represented by the following formula (12) derived from a diphenol or a unit represented by the 10 following formula (16) derived from a diol besides the unit represented by the above formula (1) in the main chain. (formula (12)) (12) In the formula (12), R1 and F', 2 are each independently 15 at least one group selected from the group consisting of a hydrogen atom, halogen atom, alkyl group having 1 to 10 carbon atoms, alkoxy group having 1 to 10 carbon atoms, cycloalkyl group having 6 to 20 carbon atoms, cycloalkoxy group having 6 to 20 carbon atoms, alkenyl group having 2 to 10 carbon 20 atoms, aryl group having 6 to 10 carbon atoms, aryloxy group having 6 to 10 carbon atoms, aralkyl group having 7 to 20 carbon atoms, aralkyloxy group having 7 to 20 carbon atoms, nitro group, aldehyde group, cyano group and carboxyl group, and when there are R1's and R2's, they may be the same or 25 different. R1 and R2 are preferably each independently at least one group selected from the group consisting of a hydrogen atom, halogen atom, alkyl group having 1 to 10 carbon atoms, alkoxy group having 1 to 10 carbon atoms, cycloalkyl group having 6 to 20 carbon atoms, cycloalkoxy group having 6 to 20 carbon atoms, aryl group having 6 to 10 carbon atoms, 5 aryloxy group having 6 to 10 carbon atoms, aralkyl group having 7 to 20 carbon atoms and aralkyloxy group having 7 to 20 carbon atoms, and when there are R1's and R2's, they may be the same or different. a and b are each independently an integer of 1 to 4. 10 W is at least one bonding group selected from the group consisting of a single bond and bonding groups represented by the following formulas (13). -L c' R q C 8 R5 /^ 7 f '1 i C C 0.0^ u q^^ 0 0 0 --0- -Sor -A-(CH2)e R1` R13 1 Si O Rio R15 1 -Si-(CH2).-AR1 s f (13) In the above formulas (13), R3, R4, R5, R6, R7, R8, R9 15 and R10 are each independently at least one group selected from the group consisting of a hydrogen atom, alkyl group having 1 to 10 carbon atoms, aryl group having 6 to 10 carbon atoms and aralkyl group having 7 to 20 carbon atoms. When there are R3' s, R4's, RS's, R6' s, R7' s, R3' s, R9' s and R10' s, 20 they may the same or different. - R11 and R''2 are each independently at least one group selected from the group consisting of a hydrogen atom, halogen atom, alkyl group having 1 to 10 carbon atoms, alkoxy group having 1 to 10 carbon atoms, cycloalkyl group having 25 6 to 20 carbon atoms, cycloalkoxy group having 6 to 20 carbon atoms, alkenyl group have-,fig 2 to 10 carbon atoms, aryl group having 6 to 10 carbon atoms, aryloxy group having 6 to 10 carbon atoms, aralkyl group having 7 to 20 carbon atoms, aralkyloxy group having 7 to 20 carbon atoms, nitro group, 10 aldehyde group, cyano group and carboxyl group. R13, R14, R15 and R16 are each independently at least one group selected from the group consisting of an alkyl group having 1 to 10 carbon atoms, cycloalkyl group having 6 to 5 20 carbon atoms, alkenyl group having 2 to 10 carbon atoms, aryl group having 6 to 10 carbon atoms and aralkyl group having 7 to 20 carbon atoms. When there are R13' s, R19' s, R15' s and R16's, they may be the same or different. c is an integer of 1 to 10, d is an integer of 4 to 10 7, e is an integer of 1 to 3, and f is an integer of 1 to 100. W is particularly preferably at least one bonding group selected from the group consisting of a, single bond and bonding groups represented by the following formulas (14) R17 CH C -CR18 Y CH3 1 CH3 C 9 O -S FCCH3 D R19 i(C)d ,R20 9 C^ \S^ S 1s 0 0 00 R2 ,i 22 \ R (1 4) In the above formulas (14), R17 and R18 are each independently a hydrogen atom or hydrocarbon group having 1 to 10 carbon atoms. When there are R17's and R18's, they 20 may be the same or different. R19 and R20 are each independently a hydrogen atom or alkyl group having 1 to 3 carbon atoms. When there are Rig' s and R20's, they may be the same or different. R21 and R22 are each independently a hydrogen atom or 25 alkyl group having 1 to 3 carbon atoms. When there are R21's and R22' s, they may be the same or different. c is an integer of 1 to 10, and d is an integer of 4 to 7. W is particularly preferably at least one bonding group selected from the group consisting of bonding groups represented by the following formulas (15). R17 CH \ CH3 ^ I \ ^ C (i C- S 8 CH3 CH3 i(C)d^R20 00 22 (15) In the above formulas (15), R].7, R18, R19, R20, R21, Rzz c and d are as defined in the above formulas (14). O O-Z-O--II (16) 5 In the formula (16), Z is a divalent aliphatic group having 2 to 20 carbon atoms, preferably an aliphatic group having 3 to 15 carbon atoms. The aliphatic group is preferably an alkanediyl group having 2 to 20 carbon atoms, 10 more preferably an alkanediyl group having 3 to 15 carbon atoms. Specific examples thereof include linear alkanediyl groups such as 1,3-propanediyl group, 1,4-butanediyl group, 1,5-pentanediyl group and 1,6-hexanediyl group. Alicyclic alkanediyl groups such as cyclohexanediyl group and dimethyl 15 cyclohexanediyl group may also be used. Out of these, 1,3-propanediyl group, 1,4-butanediyl group, hexanediyl group, spiroglycolyl group and dimethyl cyclohexanediyl group are preferred. These aliphatic groups may be used alone or in combination of two or more. 20 (biogenic matter content) The polycarbonate resin of the present invention has a biogenic matter content measured in accordance with ASTM D6866 05 of 25 to 100 %, preferably 40 to 100 %, more preferably 25 50 to 100 %. (specific viscosity) The specific viscosity at 20°C of a solution prepared by dissolving 0. 7 g of the polycarbonate resin of the present 30 invention in 100 ml of methylene chloride is 0.2 to 0.6, 12 preferably 0.2 to 0.45, more preferably 0.22 to 0.4. When the specific viscosity is lower than 0.2, it is difficult to provide sufficiently high mechanical strength to the obtained molded article. When the specific viscosity is 5 higher than 0.6, the ratio of the terminal group inevitably lowers, thereby making it impossible to obtain a satisfactory terminal modification effect, and melt flowability becomes too high, whereby the melting temperature required for molding becomes higher than the decomposition temperature 10 disadvantageously. (OH value) The polycarbonate resin of the present invention has an OH value of 2.5 x 103 or less, preferably 2.0 x 103 or less, 15 more preferably 1.5 x 103 or less. When the OH value is larger than 2.5 x 103, the water absorbability of the polycarbonate resin increases and the heat stability thereof degrades disadvantageously. The OH value is calculated from a terminal ratio obtained by NMR measurement. 20 (water absorption coefficient) The water absorption coefficient at 23°C after 24 hours of the polycarbonate resin of the present invention is preferably 0.75 % or less, more preferably 0.7 % or less. 25 When the water absorption coefficient falls within the above range, the polycarbonate resin is preferred from the viewpoints of wet heat resistance and a low dimensional change rate. 30 (saturation water absorption coefficient) The polycarbonate resin of the present invention has a saturation water absorption coefficient in 23°C water of preferably 0 to 5 %, more preferably 0 to 4.8 %, much more preferably 0 to 4 .5 %. When the water absorption coefficient 13 falls within the above range, the polycarbonate resin is preferred from the viewpoints of wet heat resistance and a low dimensional change rate. 5 (contact angle with water) The contact angle with water of the polycarbonate resin of the present invention is preferably 70 to 180 , more preferably 72 to 180*. When the contact angle with water falls within the above range, the polycarbonate resin is 10 preferred from the viewpoints of antifouling property, abrasion resistance and releasability. (molecular weight retention) The molecular weight retention at 120°C and 100 %RH 15 after 11 hours of the polycarbonate resin of the present invention is preferably 80 % or more, more preferably 85 % or more. (glass transition temperature: Tg) 20 The glass transition temperature (Tg) of the polycarbonate resin of the present invention is preferably 100°C or higher, more preferably 100 to 170°C, much more preferably 110 to 160°C. When Tg is lower than 700°C, the polycarbonate resin deteriorates in heat resistance and when 25 Tg is higher than 170°C, the polycarbonate resin deteriorates in-melt flowability at the time of molding. (terminal group) The polycarbonate resin of the present invention 30 preferably contains a terminal group represented by the following formula (2) or(3). -0-R9 (2) 14 (3) In the formulas (2) and (3), R' is an alkyl group having 4 to 30 carbon atoms, aralkyl group having 7 to 30 carbon 5 atoms, perfluoroalkyl group having 4 to 30 carbon atoms, phenyl group or group represented by the following formula (4). R2 1 -(CH2)b i`O (4) The number of carbon atoms of the alkyl group 10 represented by R1 is preferably 4 to 22, more preferably 8 to 22. Examples of the alkyl group include hexyl group, octyl group, nonyl group, decyl group, undecyl group, dodecyl group, pentadecyl group, hexadecyl group and octadecyl group. The number of carbon atoms of the aralkyl group 15 represented by R1 is preferably 8•to 20, more preferably 10 to 20. Examples of the aralkyl group include benzyl group, phenethyl group, methylbenzyl group, 2-phenylpropan-2-yl group and diphenylmethyl group. The number of carbon atoms of the perfluoroalkyl group 20 represented by R1 is preferably 2 to 20. Examples of the perfluoroalkyl group include 4,4,5,5,6,6,7,7,7-nonafluoroheptyl group, 4,4,5,5,6,6,7,7,8,8,9,9,9-tridecafluorononyl group and 4,4,5,5,6,6,7,7,8,8,9,9,10,10,11,11,11-heptadecafluround 25 ecyl group. In the formula (4). R2, R3, R4, R' and R6 are each independently at least one group selected from the group consisting of an alkyl group having 1 to 10 carbon atoms, cycloalkyl group having 6 to 20 carbon atoms, alkenyl group 15 having 2 to 10 carbon atoms, aryl group having 6 to 10 carbon atoms and aralkyl group having 7 to 20 carbon atoms. Exmaples of the alkyl group having 1 to 10 carbon atoms in the formula (4) include methyl group, ethyl group, propyl 5 group, butyl group and heptyl group. Examples of the cycloalkyl group having 6 to 20 carbon atoms include cyclohexyl group, cyclooctyl group, cyclononyl group and cyclodecyl group. Examples of the alkenyl group having 2 to 10 carbon atoms include ethenyl group, propenyl group, 10 butenyl group and heptenyl group. Examples of the aryl group having 6 to 10 carbon atoms include phenyl group, tolyl group, dimethylphenyl group and naphthyl group. Examples of the aralkyl group having 7 to 20 carbon atoms include benzyl group, phenethyl group, methylbenzyl group, 2-phenylpropan-2-yl 15 group and diphenylmethyl group. In the formula (4), preferably, R2, R3, R4, R5 and R6 are each independently at least one group selected from the group consisting of an alkyl group having 1 to 10 carbon atoms and aryl group having 6 to 10 carbon atoms. Particularly 20 preferably, they are each independently at least one group selected from the group consisting of methyl group and phenyl group. b is an integer of 0 to 3, preferably 1 to 3, more preferably 2 to 3. c is an integer of preferably 4 to 100, 25 more preferably 4 to 50, much more preferably 8 to 50. X in the formula (3) is at least one bond selected from the group consisting of a single bond, ether bond, thioether bond, ester bond, amino bond and amide bond. X is preferably at least one bond selected from the group consisting of a 30 single bond, ether bond and ester bond. X is particularly preferably a single bond or an ester bond. a is an integer of preferably 1 to 5, more preferably 1 to 3, much more preferably 1. The terminal group represented by the above formula 16 (2) or (3) is preferably derived from biogenic matter. Examples of the biogenic matter include long-chain alkyl alcohols having 14 or more carbon atoms such as cetanol, stearyl alcohol and behenyl alcohol. 5 The content of the terminal group represented by the formula (2) or (3) is preferably 0.01 to 7 mol%, more preferably 0.05 to 7 mol%, much more preferably 0.1 to 6.8 mol% based on the polymer main chain. When the content of the terminal group represented by the formula (2) or (3) falls 10 within the above range, effects (moldability, high contact angle and moisture absorption resistance) caused by terminal modification are advantageously obtained. 15 The polycarbonate resin of the present invention can be produced by reacting (A) an ether diol (component A) represented by the following formula (5), (B) a diol and/or a diphenol (component B) except for the component A, (C) a diester carbonate (component C) and (D) 0.01 to 7 mol% based 20 on the total of the component A and the component B of a hydroxy compound (component D) represented by the following formula(6) or (7) (production process (I)). (5) 25 HO-R1 (6) H® _0- I In the formulas ( 6) and ( 7), R', X and a are as defined in the formulas ( 2) and (3). 17 (ether diol: component A) The ether diol (component A) is preferably one of isosorbide, isomannide and isoidide. These ether diols 5 derived from sugar are also obtained from biomass in the natural world and so-called "renewable resources". Isosorbide can be produced by hydrogenating D-glucose obtained from starch and then dehydrating it_ The other ether diols are obtained through a similar reaction except 10 for the starting material. The component A is particularly preferably isosorbide (1,4:3,6-dianhydro-D-sorbitol). Isosorbide is an ether diol which can be easily produced from starch, can be acquired abundantly as a resource and is superior to isommanide and isoidide in production ease, 15 properties and application range. The amount of the component A is preferably 30 to 100 mol%, more preferably 50 to 95 mol%, much more preferably 55 to 90 mol% based on the total of the component A and the component B. 20 (diol, diphenol: component B) The polycarbonate resin of the present invention is produced by using a diol and/or a diphenol (component B) except for the component A besides the ether diol (component 25 A) represented by the above formula (5)). The amount of the component B is preferably 0 to 70 mol%, more preferably 5 to 50 mol%, much more preferably 10 to 45 mol% based on the total of the component A and the component B. 30 (diol) The diol except for the ether diol (component A) is preferably a diol represented by the following formula (18). HO-Z---OH (18) 18 In the above formula (18), Z is as defined in the above formula (16). The diol is preferably an aliphatic diol having 2 to 5 20 carbon atoms, more preferably an aliphatic diol having 3 to 15 carbon atoms. Specific examples thereof include linear diols such as 1,3-propanediol, 1,4-butanediol, 1, 5-pentanediol and 1, 6-hexanediol, and alicyclic alkylenes such as cyclohexanediol and cyclohexanedimethanol. Out of 10 these, 1,3-propanediol, 1,4-butanediol, hexanediol, spiroglycol and cyclohexanedimethanol are preferred. These diols may be used alone or in combination of two or more. (diphenol) 15 The diphenol is preferably a bisphenol represented by the following formula (17). W (17) (R^)a (R') b In the formula (17), W, Rl, R2, a and b are as defined in the above formula (12). 20 Examples of the bisphenol include 4,4'-biphenol, 3,3',5,5'-tetrafluoro-4,4'-biphenol, a,a'-bis(4-hydroxyphenyl)-o-diisopropylbenzene, a,a'-bis(4-hydroxyphenyl)-m-diisopropylbenzene (commonly known as "bisphenol M"), 25 2,2-bis(4-hydroxyphenyl)-4-methylpentane, a,a'-bis(4-hydroxyphenyl)-p-diisopropylbenzene, a,a'-bis(4-hydroxyphenyl)-m-bis(1,1,1,3,3,3- hexafluoroisopropyl)benzene, 9,9-bis(4-hydroxyphenyl) fluorene, 9,9-bis(4-hydroxy-3-methylphenyl)fluorene, 30 9,9-bis(3-fluoro-4-hydroxyphenyl)fluorene, 19 9,9-bis(4-hydroxy-3-trifluoromethylphenyl)fluorene, 1,1-bis(4-hydroxyphenyl)cyclohexane, 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, 1,1-bis(4-hydroxyphenyl)-4-isopropylcyclohexane, 5 1,1-bis(3-cyclohexyl-4-hydroxypheny)cyclohexane, 1,1-bis(4-hydroxyphenyl)cyclopentane, 1,1-bis(3-fluoro-4-hydroxyphenyl)cyclohexane, 1,1-bis(4-hydroxyphenyl)perfluorocyclohexane, 4,4'-dihydroxydiphenyl ether, 10 4,4'-dihydroxy-3,3'-dimethyldiphenyl ether, 4,4'-dihydroxydiphenyl sulfone, 4,4'-dihydroxydiphenyl sulfoxide, 4,4'-dihydroxydiphenyl sulfide, 3,3'-dimethyl-4,4'-dihydroxydiphenyl sulfide, 3,3'-dimethyl-4,4'--dihydroxydiphenyl sulfone, 15 4,4'-dihydroxydiphenyl sulfone, 4,4'-dihydroxy-3,3'-diphenyl sulfide, 4,4'-dihydroxy-3,3'-diphenyl sulfoxide, 4,4'-dihydroxy-3,3'-diphenyl sulfone, 1,1-bis(4-hydroxyphenyl)nettane, 20 1,1-bis(4-hydroxyphenyl) ethane, 2,2-bis(4-hydroxyphenyl)propane (commonly known as "bisphenol A"), 1,1-bis(4-hydroxyphenyl)-1-phenylethane, 2,2-bis(4-hydroxy-3-methylphenyl)propane (commonly known as "bisphenol C"), 2,2-bis(4-hydroxyphenyl)butane, 25 2,2-bis(4-hydroxyphenyl)pentane, 2,2-bis(4-hydroxy-3-phenylphenyl)propane, 2,2-bis(3-isopropyl-4-hydroxyphenyl)propane, 2,2-bis(3-tert-butyl-4-hydroxyphenyl) propane, 2,2-bis(4-hydroxyphenyl)butane, 30 4,4-bis(4-hydroxyphenyl)heptane, 2,2-bis(4-hydroxyphenyl),octane, 1,1-bis(4-hydroxyphenyl)decane, 1,1-bis(3-methyl-4-hydroxyphenyl)decane, 1,1-bis(2,3-dimethyl-4-hydroxyphenyl)decane, 20 2,2-bis(3-bromo-4-hydroxyphenyl)propane, bis(4-hydroxyphenyl) diphenylmethane, 1,1-bis(4-hydroxyphenyl)-4-isopropylcyclohexane, 2,2-bis(4-hydroxyphenyl)-1,1,1,3,3,3-hexafluoropropane 5 (commonly known as "bisphenol AF"), 2,2-bis(4-hydroxy-3-methylphenyl)-1,1,1,3,3,3-hexafluoro propane, 2,2-bis(3,5-dimethyl-4-hydroxyphenyl)-1,1,1,3,3,3- hexafluoropropane, 10 2,2-bis(3-fluoro-4-hydroxyphenyl)-1,1,1,3,3,3-hexafluoro propane, 2,2-bis(3,5-difluoro-4-hydroxyphenyl)-1,1,1,3,3,3- hexafluoropropane, 2,2-bis(3,5-dibromo-4-hydroyphenyl)propane, 15 2,2-bis(3,5-dichloro-4-hydroxyphenyl)propane, 2,2-bis(3,5-dimethyl-4--hydroxyphenyl)propane and 2,2-bis(3-cyclohexyl-4-hydroxyphenyl)propane. Out of these, bisphenol M, 9,9-bis(4-hydroxy-3-methylphenyl)fluorene, 20 1,1-bis(4-hydroxyphenyl)cycolohexane, 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, 2,2-bis(4-hydroxyphenyl)-4-methylpentane, 3,3'-dimethyl--4,4'-dihydroxydiphenyl sulfide, bisphenol A, bisphenol C, bisphenol AF and 25 1,1-bis(4-hydroxyphenyl)decane are preferred. These bisphenols may be used alone or in combination of two or more . (diester carbonate: component C) The polycarbonate resin of the present invention is 30 produced by using a diester carbonate (component C) to form a carbonate bond. The diester carbonate (component C) is, for example, a diester carbonate having an aryl group or aralkyl group having 6 to 12 carbon atoms, or an alkyl group having 1 to 4 carbon atoms, all which may he substituted. Specific examples thereof include diphenyl carbonate, bis(chlorophenyl)carbonate, m-cresyl carbonate, dinaphthyl carbonate, bis(diphenyl)carbonate, dimethyl carbonate, 5 diethyl carbonate and dibutyl carbonate. Out of these, diphenyl carbonate is particularly preferred. As for the amount of the diester carbonate (component C) , the (component C/ (component A + component B) ) molar ratio of the diester carbonate (component C) to the total of the 10 ether diol (component A) and the diol and the diphenol (component B) except for the component A is preferably 1.05 to 0.97, more preferably 1.03 to 0.97, much more preferably 1.03 to 0.99. When the amount of the component C is larger than 1.05 mols, a sufficiently high degree of polymerization 15 is not obtained. When the amount of the component C is smaller than 0.97 mol, not only polymerization does not proceed but also an unreated ether diol or an unreacted hydroxy compound remains. 20 (hydroxy compound: component D) The polycarbonate resin of the present invention is produced by using a hydroxy compound (component D) represented by the following formula (6) or (7) b( :,;ides the components A to C. 25 In the hydroxy compound (component D) represented by the formula (6) or (7), R1, X, a, R2, R3, R4, R5, R6, b and c are as defined in the formulas (2) and (3) The hydroxy compounds (component D) may be used alone or in combination of two or more. When two or more hydroxy compounds are used, 30 the hydroxy compound (component D) represented by the formula (6) or (7) and another hycroxy compound except for the above hydroxy compound may be used in combination. The hydroxy compound (component D) improves the heat resistance, heat stability, moldability and water absorption resistance of 22 the polycarbonate. HO-R1 (6) He X-(RI )a ( 7 ) 5 Since the polycarbonate resin of the present invention has a recurring unit derived from a raw material obtained from a renewable resource such as a plant in the main chain structure, preferably, the hydroxy compound (component D) constituting the terminal structure is also derived from 10 biogenic matter such as a plant. Hydroxy compounds obtained from plants include long-chain alkyl alcohols having 14 or more carbon atoms obtained from vegetable oils (such as cetanol, stearyl alcohol and behenyl alcohol). The amount of the hydroxy compound (component D) is 15 preferably 0.01 to 7 mol%, more preferably 0.05 to 7 mol%, much more preferably 0.1 to 6.8 mol% based on the total amount of the ether diol (component A) and the diol and diphenol (component B) except for the ether diol. When the amount of the hydroxy compound is smaller than 0.01 mol%, the 20 terminal modification effect is not obtained. When the amount of the hydroxy compound is larger than 7 mol%, the amount of an end-sealing agent is too large, thereby making it impossible to obtain a polycarbonate resin having a polymerization degree high enough for molding. The time when 25 the hydroxy compound (component D) is added may be the initial stage or the latter stage of a reaction. The reaction may be carried out by melt polymerization. The melt polymerization may be carried out by distilling off an alcohol or a phenol formed by the transesterification 30 reaction of the components A to D at a high temperature under reduced pressure. 23 (reaction temperature) The reaction temperature is preferably as low as possible in order to suppress the decomposition of the ether diol and obtain a resin which is rarely colored and has high 5 viscosity. However, to make the polymerization reaction proceed properly, the polymerization temperature is preferably 180 to 280°C, more preferably 180 to 270°C. Preferably, after the ether diol and the diester carbonate are heated at normal pressure to be pre-reacted 10 with each other in the initial stage of the reaction, the pressure is gradually reduced to about 1.3 x 10-3 to 1.3 x 10-5 MPa in the latter stage of the reaction so as to facilitate the distillation-off of the formed alcohol or phenol. The reaction time is generally about 1 to 4 hours. 15 (polymerization catalyst) A polymerization catalyst may be used to accelerate the polymerization rate. Examples of the polymerization catalyst include alkali metal compounds such as sodium 20 hydroxide, potassium hydroxide, sodium carbonate, potassium carbonate, sodium hydrogen carbonate, sodium salts of a dihydric phenol and potassium salts of a dihydric phenol. Alkali earth metal compounds such as calcium hydroxide, barium hydroxide and magnesium hydroxide are also included. 25 Nitrogen-containing basic compounds such as tetramethylammonium hydroxide, tetarettylammonium hydroxide, tetrabutylammonium hydroxide, trimethylamine and triethylamine may also be used. Alkoxides of an alkali metal or an alkali earth metal, 30 and organic acid salts, zinc compounds, boron compounds, aluminum compounds, silicon compounds, germanium compounds, organic tin compounds, lead compounds, osmium compounds, antimony compounds, manganese compounds, titanium compounds and zirconium compounds of an alkali metal or an alkali earth 24 metal may also be used. They may be used alone or in combination of two or more. At least one compound selected from the group consisting of a nitrogen-containing basic compound, an 5 alkali metal compound and an alkali earth metal compound is preferably used as the polymerization catalyst. Out of these, a combination of a nitrogen-containing basic compound and an alkali metal compound is particularly preferably used. The amount of the polymerization catalyst is 10 preferably 1 x 10-9 to 1 x 10-3 equivalent, more preferably 1 x 10-8 to 5 x 10-4 equivalent based on 1 mot of the diester carbonate (component C). The reaction system is preferably maintained in a gas atmosphere such as nitrogen inactive to raw materials, a 15 reaction mixture and a reaction product. Inert gases except for nitrogen include argon. Additives such as an antioxidant may be further added as required. (catalyst deactivator) 20 A catalyst deactivator may be:added to the polycarbonate resin of the present invention. Known catalyst deactivators may be used as the catalyst deactivator. Out of these, ammonium salts and phosphonium salts of sulfonic acid are preferred. Ammonium salts and phosphonium 25 salts of dodecylbenzenesulfonic acid such as tetrabutylphosphonium salts of dodecylbenzenesulfonic acid are more preferred. Ammonium salts and phosphonium salts of paratoluenesulfonic acid such as tetrabutylammonium salts of paratoluenesulfonic acid are also preferred. Methyl 30 benzenesulfonate, ethyl benzenesulfonate, butyl benzenesulfonate, octyl benzenesulfonate, phenyl benzenesulfonate, methyl paratoluenesulfonate, ethyl paratoluenesulfonate, butyl paratoluenesulfonate, octyl paratoluenesulfonate and phenyl paratoluenesulfonate are 25 preferably used as the ester of sulfonic acid. Out of these, tetrabutylphosphonium salts of dodecylbenzenesulfonic acid are most preferably used. The amount of the catalyst deactivator is preferably 0.5 to 50 mols, more preferably 5 0.5 to 10 mols, much more preferably 0.8 to 5 mols based on 1 mol of the polymerization catalyst selected from an alkali metal compound and/or an alkali earth metal compound. Therefore, it is preferred that an ether diol (component A) , a diol and/or a diphenol (component B) except 10 for the ether diol, a diester carbonate (component C) and a hydroxy compound (component D) should be reacted by heating at normal pressure and then melt polycondensed while they are heated at 180 to 280°C under reduced pressure. 15 The polycarbonate resin of the present invention can be produced by reacting an ether diol (component A), a diol and/or a diphenol (component B) except for the component A and phosgene (component E) in an inert solvent in the presence 20 of an acid binder such as pyridine.. That is, the polycarbonate resin of the present invention can be produced by reacting (A) an ether diol (component A) represented by the following formula (5), (B) a diol and/or a diphenol (component B) except for the component A, and (E) phosgene 25 (component E) in an inert solvent in the presence of an acid binder, wherein a hydroxy compound (component D) represented by the following formula (6) or (7) is reacted as an end-sealing agent (production process (II)). HO- 30 OH (5) 26 HO-RI ( 6 ) ^j^ (R')a H®- ^) (7) 5 In the formulas (6) and (7), R', X, a, R2, R3, R9, R5, R6, b and c are as defined in the above formulas (2) and (3). The components A, B and D are the same as those used in the production process (I). The ether diol (component A) is preferably isosorbide (1, 4: 3, 6-dianhydro-D-sorbitol) 10 The hydroxy compound (component D) is preferably derived from biogenic matter. Heat stability is improved by using the hydroxy compound (component D) represented by the formula (6) or (7) as an end-sealing agent. 15 (acid binder) The acid binder is preferably at least one selected from the group consisting of pyridine, quinoline and dimethylaniline. The acid binder is particularly preferably pyridine. The amount of the acid binder is 20 preferably 2 to 100 mols, more preferably 2 to 50 mols based on 1 mol of phosgene (component E). (inert solvent) Examples of the inert solvent include hydrocarbons 25 such as benzene, toluene and xylene, and halogenated hydrocarbons such as methylene chloride, chloroform, dichloroethane, chlorobenzene and dichlorobenzene. Out of these, halogenated hydrocarbons such as methylene chloride, chloroform, dichloroethane, chlorobenzene and 30 dichlorobenzene are preferred. Methylene chloride is most preferred. The reaction temperature is preferably 0 to 40'C, more preferably 5 to 30°C. The reaction time is generally 27 a few minutes to a few days, preferably 10 minutes to 5 hours. The polycarbonate resin having a low OH value of the 5 present invention can be produced without using an end-sealing agent. That is, the polycarbonate resin of the present invention can be produced by reacting a dihydroxy component consisting of 30 to 100 mol% of an ether diol (component A) 10 represented by the following formula (5) OH (5) HO---- ^\11^ O and 0 to 70 mol% of a diol or a diphenol (component B) except 15 for the component A with a diester carbonate component (component C) by heating at normal pressure in the presence of polymerization catalyst and then melt polycondensing the reaction product while heating at 180 to 280°C under reduced pressure, wherein 20 (i) the (component C/ (component A + component B) ) ratio of the component C to the dihydroxy component becomes 1.05 to 0.97 at the start of polymerization; and (ii) the component C is further added to ensure that the (component C/(component A + component B)) ratio of the 25 component C to the dihydroxy component during polymerization becomes 1.08 to 1.00. Although the reaction temperature is preferably as low as possible in order to suppress the decomposition of the ether diol (component A) and obtain a resin which is rarely 30 colored and has high viscosity, the polymerization temperature is preferably, 180 to 280°C, more preferably 180 to 270°C in order to make a polymerization reaction proceed properly. Preferably, the dihydroxy component and the diester 28 carbonate are heated at normal pressure in the initial stage of the reaction to be pre-reacted with each other, and the pressure is gradually reduced to about 1.3 x 10-3 to 1.3 x 10-5 MPa in the latter stage of the reaction to facilitate 5 the distillation-off of the formed alcohol or phenol. The reaction time is generally about 0.5 to 4 hours. The diester carbonate (component C) includes an ester such as an aryl group or aralkyl group having 6 to 20 carbon atoms, or an alkyl group having 1 to 18 carbon atoms, all 10 of which may be substituted. Specific examples of the diester carbonate include diphenyl carbonate, bis (chlorophenyl) carbonate, m-cresyl carbonate, dinaphthyl carbonate, bis (p-butylphenyl) carbonate, dimethyl carbonate, diethyl carbonate and dibutyl carbonate. Out of these, 15 diphenyl carbonate is particularly preferred. The diester carbonate (component C) is divided into two to be added in the initial stage of the reaction (start of polymerization) and the middle stage of the reaction (during polymerization). At the start of polymerization, 20 the (component C/ (component A + component B)) ratio of the diester carbonate to the dihydroxy component is set to 1..05 to 0.97. During polymerization, the diester carbonLiee (component C) is further added to ensure that the (component 25 C/ (component A + component B)) ratio of the diester carbonate (component C) to the dihydroxy component becomes 1.08 to 1.00. The weight ratio of the diester carbonate (component C) added at the start of polymerization to the diester 30 carbonate (component C) added during polymerization is preferably 99:1 to 90:10, more preferably 98:2 to 95:5. When the diester carbonate (component C) is not added in the middle stage of the reaction, the OH value exceeds the preferred range with the result that the polycarbonate resin exhibits 29 high water absorbability, thereby causing a dimensional change or the deterioration of heat stability. When the diester carbonate is added at a time at the start of polymerization without being further added during 5 polymerization to ensure that the ratio of the diester carbonate to the dihydroxy component becomes higher than 1. 05, molar balance is lost and a sufficiently high degree of polymerization is not obtained disadvantageously. At least one polymerization catalyst selected from the 10 group consisting of a nitrogen-containing basic compound, an alkali metal compound and an alkali earth metal compound is used. Examples of the alkali metal compound include sodium hydroxide, potassium hydroxide, sodium carbonate, potassium 15 carbonate, sodium hydrogen carbonate, and sodium salts and potassium salts of a dihydric phenol. Examples of the alkali earth metal compound include calcium hydroxide, barium hydroxide and magnesium hydroxide. Examples of nitrogen-containing basic compound include 20 tetramethylammonium hydroxide, tetarethylammonium hydroxide, tetrabutylammonium hydroxide, trimethylamine and triethylamine. They may be used alone or in combination of two or more. Out of these, a combination of i nitrogen-containing basic compound and an alkali metal 25 compound is preferably used. The amount of the polymerization catalyst is preferably 1 x 10-9 to 1 x 10-3 equivalent, more preferably 1 x 10-8 to 5 x 10-4 equivalent based on 1 mol of the diester carbonate (component C) . The reaction system is preferably 30 maintained in a gas atmosphere inactive to raw materials, a reaction mixture and a reaction product, such as nitrogen. Inert gases except for nitrogen include argon. Additives such as an antioxidant may be further added as required. A catalyst deactivator may also be added to the 30 polycarbonate resin obtained by the above production process. Known catalyst deactivators may be used effectively as the catalyst deactivator. Out of these, ammonium salts and phosphonium salts of sulfonic acid are preferred, and the 5 above salts of dodecylbenzenesulfonic acid such as tetrabutylphosphonium salts of dodecylbenzenesulfonic acid and the above salts of paratoluenesulfonic acid such as tetrabutylammonium salts of paratoluenesulfonic acid are 10 more preferred. benzenesulfonate, Methyl benzenesulfonate, butyl benzenesulfonate, ethyl octyl benzenesulfonate, phenyl benzenesulfonate, methyl paratoluenesulfonate, ethyl paratoluenesulfonate, butyl paratoluenesulfonate, octyl paratoluenesulfonate and phenyl paratoluenesulfonate are preferably used as the ester 15 of sulfonic acid. Out of these, tetrabutylphosphonium salts of dodecylbenzenesulfonic acid are most preferably used. The amount of the catalyst deactivator is preferably 0.5 to 50 mols, more preferably 0. 5 to 10 mols, much more preferably 0.8 to 5 mols based on 1 mol of the polymerization catalyst 20 selected from an alkali metal compound and/or an alkali earth metal compound. The polycarbonate resin of the present invention may be copolymerized with an aliphatic diol and/or an aromatic bisphenol. The amount of the aliphatic diol and/or the 25 aromatic bisphenol is 70 mol% or less, preferably 50 mol% or `Tess, more preferably 35 mol% or less of the whole hydroxy component. They may be used alone or in combination of two or more. Examples of the aliphatic diol include linear diols 30 such as ethylene glycol, 1,3-propanediol, 1,4-butanediol, 1, 5-pentanediol and 1,6-hexanediol, and alicyclic diols such as cyclohexanediol, cyclohexanedimethanol and terpene-based dimethylol. Out of these, 1,3-propanediol, 1,4-butanediol, hexanediol, cyclohexanedimethanol, spiro 31 glycol and terpene-based dimethylol are preferred, and 1,3-propaneidol, 1,4-butanediol and terpene-based dimethylol are particularly preferred as they may be derived from biogenic matter. 5 Examples of the aromatic bisphenol include 2,2-bis(4-hydroxyphenyl)propane (commonly known as "bisphenol A"), 1,1-bis(4-hydroxyphenyl)cyclohexane, 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, 4,4'-(m-phenylenediisopropylidene)diphenol, 10 9,9-bis(4-hydroxy-3-methylphenyl)fluorene, 2,2-bis(4-hydroxy-3-methylphenyl)propane, 2,2-bis(4-hydroxyphenyl)-4-methylpentane, 1,1-bis(4-hydroxyphenyl)decane and 1,3-bis{2-(4-hydroxyphenyl)propyl}benzene. Out of these, 15 2,2-bis(4-hydroxyphenyl)propane, 4,41-(m-phenylenediisopropylidene)diphenol, 2,2-bis(4-hydroxyphenyl)-4-methylpentane and 1,1-bis(4-hydroxyphenyl)decane are particularly preferred. 20 (other components) Various functionalizing agents may be added to the resin composition of the present invention according to application purpose. The agents include a heat sL,,bilizer, a stabilizing aid, a plasticizer, an antioxidant, an optical 25 stabilizer, a nucleating agent, a heavy metal inactivating agent, a flame retardant, a lubricant, an antistatic agent and an ultraviolet absorbent. Further, the polycarbonate resin of the present invention may be combined with an organic or inorganic filler 30 or fiber to be used as a composite according to application purpose. Examples of the filler include carbon, talc, mica, wollastonite, montmorillonite and hydrotalcite. Examples of the fiber include natural fibers such as kenaf, synthetic fibers, glass fibers, quartz fibers and carbon fibers. 32 The resin composition of the present invention may be mixed with, for example, an aliphatic polyester, an aromatic polyester, an aromatic polycarbonate resin, a polyamide, polystyrene, a polyolefin, a polyacryl, ABS, a polyurethane 5 or a polymer derived from biogenic matter such as polylactic acid to be alloyed. The present invention includes a molded article formed 10 from the above polycarbonate resin. The molded article of the present invention can be obtained by injection molding. According to purpose, injection molding methods such as injection compression molding, injection press molding, gas assist injection molding, foam molding (including what 15 comprises the injection of a super-critical fluid), insert molding, in-mold coating molding, insulated runner molding, quick heat and cool molding, two-color molding, sandwich molding and super high-speed injection molding may be employed to obtain the molded article. The advantages of 20 these molding methods have already been widely known. Both' cold-runner systems and hot-runner systems may be used. The molded article of the present invention may be a profile extrusion molded article, a sheet or a film obtained by extrusion molding. For the molding of a sheet or a film, 25 an inflation, calendering or casting method may be used. Further, the resin composition may be molded into a heat shrinkable tube by carrying out specific stretching operation. The resin composition of the present invention can be formed into a molded article by rotational molding 30 or blow molding. The molded article of the present invention is excellent in transparency and color. The molded article of the present invention has an arithmetic average surface roughness (Ra) of 0.03 pm or less and a haze measured for 33 a 2 mm-thick flat plate in accordance with JIS K7105 of preferably 0 to 20 %, more preferably 0 to 15 %. The b value of the flat plate is preferably 0 to 14, more preferably 0 to 13, much more preferably 0 to 12. The 5 b value can be measured by using the SE-2000 spectral color meter of Nippon Denshoku Industries Co., Ltd. (light source: C/2). When the molded article of the present invention has a length of 100 mm, a width of 50 mm and a thickness of 4 10 mm, its dimensional change rate at the time of saturation water absorption is preferably 1.5 % or less. The molded article may be a film. The film can be used for optical purpose. The film of the present invention can be manufactured by a solution casting method in which a 15 solution obtained by dissolving the polycarbonate resin of the present invention in a solvent is cast or a melt film forming method in which the,polycarbonate resin of the present invention is molten and cast as it is. To form a film by the solution casting method, a 20 halogen-based solvent, especially methylene chloride is preferably used as a solvent from the viewpoints of versatility and production cost. A solution prepared by dissolving 10 parts by weight of the polycarbonatc; resin of the present invention in 15 to 90 parts by weight of a solvent 25 containing 60 wt % or more of methylene chloride is preferred as -a -solution composition (dope) When the amount of the solvent is larger than 90 parts by weight, it may be difficult to obtain a cast film which is thick and has excellent surface smoothness and when the amount of the solvent is smaller than 30 15 parts by weight, the melt viscosity becomes too high, whereby it may be difficult to manufacture a film. Besides methylene chloride, another solvent may be added as required as long as film formability is not impaired. Examples of the solvent include alcohols such as methanol, 34 ethanol, 1-propanol and 2-propanol, halogen-based solvents such as chloroform and 1,2-dichloroethane, aromatic solvents such as toluene and xylene, ketone-based solvents such as acetone, methyl ethyl ketone and cyclohexanone, ester-based 5 solvents such as ethyl acetate and butyl acetate, and ether-based solvents such as ethylene glycol dimethyl ether. In the present invention, a film can be obtained by heating the dope to evaporate the solvent after the dope is cast over a support substrate. A glass substrate, a metal 10 substrate such as stainless steel or ferro type substrate, or a plastic substrate such as PET substrate is used as the support substrate, and the dope is cast over the support substrate uniformly with a doctor blade. A method in which the dope is continuously extruded onto a belt-like or 15 drum-like support substrate from a die is commonly used in the industry. Preferably, the dope cast over the support substrate is gradually heated from a low temperature to be dried so that foaming does not occur, most of. the solvent is removed 20 by heating so as to separate a self-supporting film from the support substrate, and further the film is heated from both sides to be dried so as to remove the residual solvent. Since it is fairly possible that stress is applied to the film by a dimensional change caused by heat shrinkage in the drying 25 step after the film is removed from the substrate, attention must be paid to the drying temperature and the film fixing conditions for film formation which requires the precise control of optical properties like an optical film for use in liquid crystal displays. In general, it is preferred that 30 the film should be dried by elevating the temperature from (Tg - 100°C) to Tg of thepolycarbonate in use stepwise in the drying step after removal. When the film is dried at a temperature higher than Tg, the thermal deformation of the film occurs disadvantageously, and when the film is dried 35 at a temperature lower than (Tg - 100°C), the drying temperature becomes too slow disadvantageously. The amount of the residual solvent contained in the film obtained by the solution casting method is preferably 5 2 wt% or less, more preferably 1 wt% or less. When the amount is larger than 2 wt%, the glass transition point of the film greatly lowers disadvantageously. To form a film by the melt film forming method, a melt solution is generally extruded from a T die to form a film. 10 The film forming temperature which can be determined by the molecular weight, Tg and melt flow characteristics of the polycarbonate is generally 180 to 350°C, preferably 200 to 320°C When the temperature is too low,. the viscosity becomes high, whereby the orientation and stress distortion 15 of the polymer may remain and when the temperature is too high, problems such as thermal deterioration, coloring and the formation of a die line (streak) from the T die may occur. The thickness of the unstretched film obtained as described above which is not particularly limited and may 20 be determined according to purpose is preferably 10 to 300 μm, more preferably 20 to 200 μm from the viewpoints of film production, physical properties such as toughness and cost. The polycarbonate resin of the present invention constituting the film has a photoelastic constant of 25 preferably 60 x 10-12 Pa-1 or less, more preferably 50 x 10-12 Pa 1 or less. When the photoelastic constant is higher than 60 x 10-12 Pa-1, a phase difference may be produced by tension generated when the optical film is laminated or by stress generated by a difference in dimensional stability between 30 the polycarbonate resin and another material, whereby long-term stability may deteriorate due to the occurrence of a phenomenon such as light leakage or the reduction of contrast. The wavelength dispersion of the phase difference 36 values of the film of the present invention satisfies preferably the following expression (i), more preferably the following expression (ii). 1.010 < R(450)/R(550) < 1.070 (i) 5 1.010 < R(450)/R(550) < 1.060 (ii) R(450) and R(550) are phase difference values within the film plane at wavelengths of 450 nm and 550 nm, respectively. When a phase difference film having a small wavelength dispersion of phase difference values is used, 10 a film having excellent view angle characteristics and contrast in the VA (vertical alignment) mode of a liquid crystal display is obtained. The value (An = R(550)/film thickness (μm)) obtained by dividing the phase difference by the thickness of the film 15 of the present invention satisfies preferably the following expression (iii), more preferably the following expression (iv) while it is unstretched. An < 0.3 x 10-3 (iii) An < 0.25 x 10-3 (iv) 20 The lower limit is not particularly limited as long as it is larger than "0". The film of the present invention is preferably obtained by stretching the unstretched film by a known stretching method such as monoaxial stretching or biaxial 25 stretching to orient the polymer. The film obtained by this stretching can be used as a phase difference film for liquid crystal displays. The stretching temperature is generally close to Tg of the polymer, specifically (Tg - 20°C) to (Tg + 20°C), and the draw ratio is generally 1.02 to 3 times in 30 the case of monoaxial stretching in the longitudinal direction. The thickness of the stretched film is preferably 20 to 200 μm. One of the preferred phase difference films obtained by the present invention is a phase difference film having 37 a phase difference R(550) within the film plane at a wavelength of 550 nmwhich satisfies the following expression (1) and a film thickness of 10 to 150 pm. 100 nm < R(550) < 2000 nm (1) 5 The phase difference R is defined by the following equation (5) and indicates a phase delay of light passing in a direction perpendicular to the film. R = (nx - nx) x d (5) [In the above equation, nx is the refractive index of a delay 10 phase axis (axis having the highest refractive index) within the film plane, ny is a refractive index in a direction perpendicular to nx within the film plane, and d is the thickness of the film.] R(550) is more preferably 100 to 600 nm. The thickness 15 of the film is more preferably 30 to 120 pm, much more preferably 30 to 100 pm. The phase difference film may be formed by monoaxial stretching or biaxial stretching and is suitable for use as a 1/4X plate, a 1/2k plate or a k plate. Another preferred phase difference film has a phase 20 difference R(550) within the film plane at a wavelength of 550 nm and a phase difference Rth(550) in the film thickness direction which satisfy the following expressions (2) and (3), respectively, and a film thickness of 10 to 150 pm. 0 nm < R(550) < 150 nm (2) 25 100 nm < Rth(550) < 400 nm (3) (In the above expressions, Rth(550) is a phase difference value in the film thickness direction at a wavelength of 550 am and is defined by the following equation (4).) Rth = {(nx + ny)/2-nz} x d (4) 30 (In the above equation, nx and ny are refractive indices in the x-axis and y-axis directions within the film plane, respectively, nz is a refractive index in the thickness direction perpendicular to the x-axis and y-axis directions, and d is the thickness of the film.) 38 The film can be manufactured by biaxial stretching. The film which is made of the resin of the present invention having characteristic properties which satisfy the above range of On easily produces a phase difference after 5 stretching, has high phase difference controllability and is suitable for industrial application. The film of the present invention has a total light transmittance of preferably 80 % or more, more preferably 85 % or more. The haze value of the film of the present 10 invention is preferably 5 % or less, more preferably 3 % or less. Since the film of the present invention has excellent transparency, it is suitable for use as an optical film. The film of the present invention may be used alone or two or more of the films may be laminated together. It 15 may be combined with an optical film made of another material. It may be used as a protective film for polarizing plates or a transparent substrate for liquid crystal displays. Examples 20 The following examples are provided for the purpose of further illustrating the present invention but are in no way to be taken as limiting. "Parts" in the examples means parts by weight and "%" means wt%. Evaluations were made by the following methods. 25 (1) Specific viscosity (rasp) A pellet was dissolved in methylene chloride to a concentration of 0.7 g/dL so as to measure the specific viscosity of the resulting solution at 20°C with an Ostwald's viscosimeter (RIGO AUTO VISCOSIMETER TYPE VMR-0525°PC). The 30 specific viscosity (rasp) was obtained from the following equation. rise = t/to-1 t: flow time of a specimen solution to: flow time of a solvent alone 39 (2) Terminal modification group content 1H-NMR of the pellet in a heavy chloroform solution was measured with the JNM-AL400 of JEOL LTD. to obtain a terminal modification group content from the integral ratio of a 5 specific proton derived from the main chain carbonate constituent unit and a specific proton derived from a hydroxyl-terminated compound. The terminal modification group content is the ratio (moi%) of the hydroxyl-terminated compound to the main chain carbonate constituent unit. 10 (3) Glass transition temperature (Tg) This was measured with the DSC (Model DSC2910) of TA Instruments Co., Ltd. by using the pellet. (4) 5 % weight loss temperature (Td) This was measured with the TGA (Model TGA2950) of TA 15 Instruments Co., Ltd. by using the pellet. (5) Moldability A pellet was injection molded by means of the JSWJ-75EIII of The Japan Steel Works, Ltd. to evaluate the shape of a 2 mm-thick molded plate visually (mold 20 temperature: 70 to 90°C, molding temperature: 220 to 260°C) Moldability o: no turbidity, cracking, shrinkage and silver streak by decomposition is seen x: turbidity, cracking, shrinkage and silver streak by 25 decomposition are seen (6) Contact angle The contact angle with pure water of the 2 mm-thick molded plate was measured by means of the drip type contact angle meter of Kyowa Interface Science Co., Ltd. 30 (7) Water absorption coefficient 24 hours after a 2 row-thick molded plate which had been dried at 100°C for 24 hours in advance was immersed in 25°C water, the weight of the molded plate was measured to calculate its water absorption coefficient from the 40 following equation. Water absorption coefficient = {weight of sample plate (after water absorption) - weight of sample plate (before water absorption)}/weight of sample plate 5 (before water absorption) x 100 (wt%) (8) Film thickness The thickness of the film was measured by means of the film thickness meter of Mitutoyo Corporation. (9) Photoelastic constant 10 A film having a width of 1 cm and a length of 6 cm was prepared, and the phase differences for light having a wavelength of 550 nm under no load and under loads of IN, 2N and 3N of this film were measured with the M220 spectroscopic ellipsometer of JASCO Corporation Co., Ltd. 15 to calculate (phase difference) x (film width)/(load) so as to obtain the photoelastic constant of the film. (10) total light transmittance and haze value of film They were measured with the NDH-2000 turbidimeter of Nippon Denshoku Industries Co., Ltd. 20 (11)phase difference values (R(450)), R(550)) and their wavelength dispersion (R(450)/R(550) They were measured at wavelengths of 450 nm and 550 nm with the M220 spectroscopic ellipsometer of JASCO Corporation. The phase difference values for light 25 vertically incident upon the film plane were measured. (12-) phase difference value Rth in film thickness direction The M220 spectroscopic ellipsometer of JASCO Corporation. was used for measurement at a wavelength of 550 nm. The in-plane phase difference value R was obtained by 30 measuring light incident upon the film plane at a right angle. The phase difference va]uie Rth in the film thickness direction was obtained by measuring phase difference values at each angle by changing the angle between incident light and the film plane little by little, curve fitting the 41 obtained values with the known formula of an index ellipsoid so as to obtain 3-D refractive indices nx, ny an n„ and inserting them into the equation Rth = {(nx + ny)/2-nz} x d. Since the average refractive index of the film was required, 5 it was measured by means of the Abbe refractometer 2-T of Atago Co., Ltd. (13) OH value 1H-NMR of a pellet in a heavy chloroform solution was measured by means of the JNM-AL400 of JEOL Corporation to 10 obtain the OH value from the specific proton of a hydroxyl terminal derived from a compound represented by the formula (5) and the specific proton of a terminal group derived from a compound (diester carbonate or another specific compound) except for the compound represented by the formula (5) based 15 on the following equation. OH value = Rm x RoH x 17 Rm: {1000000/polymerization degree (weight average molecular weight)} x 2 R01: ratio to all terminal groups of a 20 hydroxyl-terminated compound obtained from the integral ratio of 1H-NMR (a hydroxy compound terminal group derived from the compound represented by the formula (5) and a terminal group derived from

Documents

Application Documents

# Name Date
1 6790-DELNP-2012-AbandonedLetter.pdf 2018-01-23
1 Power of Authority.pdf 2012-08-06
2 6790-DELNP-2012-FER.pdf 2017-06-06
3 6790-delnp-2012-Correspondence Others-(27-11-2012).pdf 2012-11-27
4 Form-1.pdf 2012-08-06
4 6790-delnp-2012-Correspondence Others-(07-11-2012).pdf 2012-11-07
5 6790-delnp-2012-Form-18-(07-11-2012).pdf 2012-11-07
5 6790-delnp-2012-Form-3-(11-10-2012).pdf 2012-10-11
6 6790-delnp-2012-Correspondence-Others-(11-10-2012).pdf 2012-10-11
7 6790-delnp-2012-Form-18-(07-11-2012).pdf 2012-11-07
7 6790-delnp-2012-Form-3-(11-10-2012).pdf 2012-10-11
8 6790-delnp-2012-Correspondence Others-(07-11-2012).pdf 2012-11-07
8 Form-1.pdf 2012-08-06
9 6790-delnp-2012-Correspondence Others-(27-11-2012).pdf 2012-11-27
10 6790-DELNP-2012-FER.pdf 2017-06-06
11 Power of Authority.pdf 2012-08-06
11 6790-DELNP-2012-AbandonedLetter.pdf 2018-01-23

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1 6790delnp2012_06-06-2017.pdf