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