Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – At least one aryl ring which is part of a fused or bridged...
Reexamination Certificate
2000-06-07
2002-03-26
Buttner, David J. (Department: 1712)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
At least one aryl ring which is part of a fused or bridged...
C524S451000, C524S456000, C524S508000, C524S537000, C525S067000, C525S146000, C525S439000
Reexamination Certificate
active
06362269
ABSTRACT:
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a resin composition. More particularly, the present invention relates to a resin composition which contains an aromatic polycarbonate resin as a resin component and is reinforced with a filler and which is superior in wet heat fatigue and impact properties.
PRIOR ART
Aromatic polycarbonate resins are superior in mechanical properties (e.g. impact resistance), heat resistance, transparency, etc. and are widely used. As the process for production of such an aromatic polycarbonate resin, there are known, for example, a process which comprises reacting a dihydric phenol (e.g. bisphenol A) with phosgene (interfacial polymerization) and a process which comprises subjecting a dihydric phenol (e.g. bisphenol) and a diaryl carbonate (e.g. diphenyl carbonate) to ester interchange reaction in a molten state (this process may be referred hereinafter to as melt polymerization). Of these processes, the process in which a dihydric phenol and a diaryl carbonate are subjected to ester interchange is advantageous, as compared with the interfacial polymerization, in that it uses no phosgene and halogen compound such as methylene chloride or the like, gives little burden to the environment, and can be produced at a low cost. It, therefore, is a promising technique.
An aromatic polycarbonate resin composition obtained by reinforcing an aromatic polycarbonate with a glass filler is described in Japanese Patent No. 2683662. The aromatic polycarbonate resin constituting this composition is composed substantially of an aromatic polycarbonate resin produced by the melt polymerization. It is disclosed that the composition is superior in Izod impact resistance to compositions of an aromatic polycarbonate resin obtained by interfacial polymerization. However, it could not be said that a composition comprising an aromatic polycarbonate resin obtained by melt polymerization gives a molded article sufficient in wet heat fatigue or in impact resistance of flat.
Meanwhile, resin mixtures composed of an aromatic polycarbonate resin and a styrene-based resin were developed as a material superior in impact resistance and moldability to aromatic polycarbonate resins, and are widely used in various application fields such as OA appliances, automobiles and the like. Resin compositions obtained by reinforcing the above resin mixtures with a filler also in widely used.
In JP-B-7-98892 is described a resin composition composed of an aromatic polycarbonate resin and an aromatic vinyl-diene-vinyl cyanide copolymer (ABS resin). The above publication discloses that the aromatic polycarbonate resin used in the mixture is composed substantially of an aromatic polycarbonate resin produced by melt polymerization and that the resin is superior in weld strength to mixtures of an aromatic polycarbonate resin obtained by the interfacial polymerization. However, this mixture is difficult to say to be also satisfactory in melt stability and moreover, has had drawbacks in that its fatigue strength and mechanical strength decrease strikingly when used at a high temperature and at a high humidity. Therefore, the there was limitation in applications of the above resin mixture to automobile parts (e.g. outer handle, inner handle and instrument panel), OA parts (e.g. inner parts of copying machine and casing of notebook type personal computer), machine parts (e.g. electric tool cover), etc., all requiring good fatigue strength under high temperatures and high humidities (i.e. wet heat fatigue) and good mechanical strength under high temperatures and high humidities (i.e. retention of wet heat strength).
Further, resin mixtures composed of an aromatic polycarbonate resin and an aromatic polyester resin were developed as a material superior in chemical resistance and impact resistance to aromatic polycarbonate resins, and are in wide use for various applications fields such as automobiles, OA appliances and the like. Resin compositions obtained by reinforcing such a resin mixture with a filler are also widely used.
In JP-B-7-68441 is described a resin mixture composed of an aromatic polycarbonate resin and an aromatic polyester resin. This publication discloses that the aromatic polycarbonate resin used in the mixture is composed substantially of an aromatic polycarbonate resin produced by melt polymerization and that the resin is superior in melt stability to mixtures of an aromatic polycarbonate resin obtained by the interfacial polymerization. However, such a mixture is difficult to say to be satisfactory in melt stability and moreover, has had a drawback in wet heat fatigue. Therefore, sufficient care must be taken in use of the mixture for applications such as automobile parts (e.g. outer handle and inner handle), machine parts (e.g. electric tool cover), etc., all requiring mechanical strengths, chemical resistance, wet heat fatigue, etc. No material fully satisfying such requirements is not yet developed.
As mentioned above, though aromatic polycarbonate resins, or their mixtures with a styrene-based resin or an aromatic polyester resin have superior mechanical properties, they are unsatisfactory in wet heat fatigue, melt stability, impact resistance of flat, etc., when an aromatic polycarbonate resin produced by melt polymerization is used. They, therefore, have found limited use in application fields where such properties are required.
Problems to be solved by the invention
An object of the present invention is to provide a resin composition improved in the problem of an aromatic polycarbonate resin produced by melt polymerization or a resin mixture containing the resin, that is, fatigue under high temperatures and high humidities.
Other object of the present invention is to further improve, in a resin composition comprising the above aromatic polycarbonate resin or the above resin mixture containing the resin and a reinforcing filler, its fatigue under high temperatures and high humidities to increase its strength retention.
Still other object of the present invention is to provide a resin mixture or a resin composition, which is further excellent in melt stability, chemical resistance and mechanical properties.
Means for solving the problems
The present inventors made studies in order to achieve the above objects. As a result, it has been found that, in the aromatic polycarbonate resin produced by melt polymerization, a unique bond considered to be formed by the melt polymerization is measured from the fluorescent spectrum of the resin and the fluorescence intensity measured has an influence on the physical properties of a resin mixture or composition containing the aromatic polycarbonate resin. That is, it was found that a resin mixture or composition obtained by using an aromatic polycarbonate resin having a fluorescence intensity of certain level or lower is extremely improved in physical properties, particularly in wet heat fatigue. The finding has led to the completion of the present invention.
According to the present invention, there are provided the following resin composition-I and resin composition-II.
Resin composition-I
A resin composition composed substantially of
(1) 100 parts by weight of a resin component selected from:
(a) an aromatic polycarbonate resin (A-1 component) obtained by melt polymerization and, when measured for fluorescent spectrum at an exciting wavelength of 320 nm, having a relative fluorescence intensity of 4×10
−3
or less at 465 nm relative to a standard substance,
(b) a resin mixture composed of 10 to 90 parts by weight of said aromatic polycarbonate resin (A-1 component) and 90 to 10 parts by weight of a styrene-based resin (A-2 component), or
(c) a resin mixture composed of 10 to 90 parts by weight of said aromatic polycarbonate resin (A-1 component) and 90 to 10 parts by weight of an aromatic polyester resin (A-3 component), and
(2) 5 to 200 parts by weight of at least one kind of reinforcing filler selected from the group consisting of a fibrous filler (B-1 component) and a platy filler (B-2 component).
Res
Ishihata Koji
Ono Tetsushi
Shimizu Hisanaga
Takagi Makoto
Buttner David J.
Teijin Chemicals Ltd.
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