Thermoplastic resin composition having excellent shock resistance and light resistance

Abstract

The present invention can provide a thermoplastic resin composition which contains (A) a polyester resin, (B) a white pigment, and (C) a silicon-containing graft copolymer, and thus has excellent light efficiency, discoloration resistance, and light stability, without degrading shock resistance and molding processability.

Claims

1. A reflector comprising a thermoplastic resin composition comprising: (A) a polyester resin comprising a diol component comprising 15 mol % to 100 mol % of 1,4-cyclohexanedimethanol and 0 mol % to 85 mol % of ethylene glycol; (B) a white pigment; and (C) a silicone-containing graft copolymer having a core-shell structure in which a vinyl monomer is grafted to a silicone-based rubber core to form a shell, the silicone-based rubber core having a silicon content of 50 wt % to 85 wt %, wherein the reflector has a difference of 10 or less between initial reflectivity measured at a wavelength of 450 nm using a colorimeter and reflectivity measured after irradiation with an LED light source for 500 hours in a thermo-hygrostat oven at 170 C. and 85% relative humidity (RH).

2. The reflector according to claim 1, comprising: 0.1 parts by weight to 10 parts by weight of the silicone-containing graft copolymer (C) based on 100 parts by weight of a base resin comprising 30 wt % to 80 wt % of the polyester resin (A) and 20 wt % to 70 wt % of the white pigment (B).

3. The reflector according to claim 1, wherein the silicone-containing graft copolymer (C) has a silicon content of 20 wt % to 85 wt % based on the total weight of the silicone-containing graft copolymer.

4. The reflector according to claim 1, wherein the silicone-based rubber core of the silicone-containing graft copolymer (C) is prepared from a cyclosiloxane compound selected from the group consisting of hexamethylcyclotrisiloxane, octamethylcyclotetrasiloxane, decamethylcyclopentasiloxane, dodecamethylcyclohexasiloxane, trimethyltriphenylcyclosiloxane, tetramethyltetraphenylcyclotetrasiloxane, octaphenylcyclotetrasiloxane, and mixtures thereof.

5. The reflector according to claim 1, wherein the polyester resin is polycyclohexanedimethylene terephthalate (PCT).

6. The reflector according to claim 1, wherein the white pigment is selected from the group consisting of titanium oxide, zinc oxide, zinc sulfide, white lead, zinc sulfate, barium sulfate, calcium carbonate, aluminum oxide, and mixtures thereof.

7. The reflector according to claim 1, further comprising: filler selected from the group consisting of glass fibers, carbon fibers, glass beads, glass flakes, carbon black, clay, kaolin, talc, mica, calcium carbonate, wollastonite, and mixtures thereof.

8. The reflector according to claim 1, wherein the vinyl monomer grafted to the silicone-based rubber core to form the shell of the silicone-containing graft copolymer (C) is selected from the group consisting of -methylstyrene, halogen-substituted styrene, alkyl-substituted styrene, acrylonitrile, methacrylonitrile, C.sub.1 to C.sub.8 methacrylic acid alkyl ester, C.sub.1 to C.sub.8 acrylic acid alkyl ester, maleic anhydride, C.sub.1 to C.sub.4 alkyl, and/or N-substituted phenyl maleimide.

9. The reflector according to claim 8, wherein the vinyl monomer grafted to the silicone-based rubber core to form the shell of the silicone-containing graft copolymer (C) consists of one or more of C.sub.1 to C.sub.8 methacrylic acid alkyl esters and/or C.sub.1 to C.sub.8 acrylic acid alkyl esters.

10. The reflector according to claim 8, wherein the vinyl monomer grafted to the silicone-based rubber core to form the shell of the silicone-containing graft copolymer (C) consists of one or more of methacrylic acid methyl ester, methacrylic acid ethyl ester, and/or methacrylic acid propyl ester.

11. A reflector comprising: 100 parts by weight of a base resin comprising (A) 30 wt % to 80 wt % of polycyclohexanedimethylene terephthalate (PCT); (B) 20 wt % to 70 wt % of titanium oxide; and 5 wt % to 50 wt % of glass fibers; and 0.1 parts by weight to 10 parts by weight of (C) a silicone-containing graft copolymer having a core-shell structure in which a vinyl monomer is grafted to a silicone-based rubber core to form a shell, wherein the vinyl monomer grafted to the silicone-based rubber core to form the shell of the silicone-containing graft copolymer (C) consists of one or more C.sub.1 to C.sub.8 methacrylic acid alkyl esters and/or C.sub.1 to C.sub.8 acrylic acid alkyl esters.

12. The thermoplastic resin composition according to claim 11, wherein the vinyl monomer grafted to the silicone-based rubber core to form the shell of the silicone-containing graft copolymer (C) consists of methacrylic acid methyl ester, methacrylic acid ethyl ester, and/or methacrylic acid propyl ester.

13. The thermoplastic resin composition according to claim 11, wherein the silicone-based rubber core has a silicon content of 50 wt % to 85 wt %.

14. The thermoplastic resin composition according to claim 11, wherein the reflector produced using the thermoplastic resin composition has a difference of 10 or less between initial reflectivity measured at a wavelength of 450 nm using a colorimeter and reflectivity measured after irradiation with an LED light source for 500 hours in a thermo-hygrostat oven at 170 C. and 85% relative humidity (RH).

15. A reflector comprising: 100 parts by weight of a base resin comprising (A) 30 wt % to 80 wt % of polycyclohexanedimethylene terephthalate (PCT); (B) 20 wt % to 70 wt % of titanium oxide; and 5 wt % to 50 wt % of glass fibers; and 0.1 parts by weight to 10 parts by weight of (C) a silicone-containing graft copolymer having a core-shell structure in which a vinyl monomer is grafted to a silicone-based rubber core to form a shell, wherein the vinyl monomer grafted to the silicone-based rubber core to form the shell of the silicone-containing graft copolymer (C) consists of one or more C.sub.1 to C.sub.8 methacrylic acid alkyl esters and/or C.sub.1 to C.sub.8 acrylic acid alkyl esters and wherein the silicone-based rubber core has a silicon content of 50 wt % to 85 wt %, wherein the reflector produced using the thermoplastic resin composition has a difference of 10 or less between initial reflectivity measured at a wavelength of 450 nm using a colorimeter and reflectivity measured after irradiation with an LED light source for 500 hours in a thermo-hygrostat oven at 170 C. and 85% relative humidity (RH).

Description

BEST MODE

(1) Hereinafter, embodiments of the present invention will be described in detail. It should be understood that the following embodiments are provided for complete disclosure and thorough understanding of the invention by those skilled in the art. In addition, unless otherwise stated, technical and scientific terms as used herein have a meaning generally understood by those skilled in the art. Descriptions of known functions and constructions which may unnecessarily obscure the subject matter of the present invention will be omitted.

(2) As used herein, unless otherwise stated, the term substituted means that at least one hydrogen atom among functional groups of the present invention is substituted with a substituent selected from among a halogen atom, a hydroxyl group, a nitro group, a cyano group, an amino group, an azido group, an amidino group, a hydrazine group, a hydrazone group, a carbonyl group, a carbamoyl group, a thiol group, an ester group, a carboxyl group or a salt thereof, a sulfonic acid or a salt thereof, a phosphoric acid group or a salt thereof, a C.sub.1 to C.sub.20 alkyl group, a C.sub.2 to C.sub.20 alkenyl group, a C.sub.2 to C.sub.20 alkinyl group, a C.sub.1 to C.sub.20 alkoxy group, a C.sub.6 to C.sub.30 aryl group, a C.sub.6 to C.sub.30 aryloxy group, a C.sub.3 to C.sub.30 cycloalkyl group, a C.sub.3 to C.sub.30 cycloalkenyl group, a C.sub.3 to C.sub.30 cycloalkinyl group, or a combination thereof.

(3) The present inventors have conducted research to develop a thermoplastic resin composition, which exhibits excellent properties in terms of initial reflectivity, long-term reflectivity retention and discoloration resistance, and has improved impact resistance while maintaining intrinsic properties, and, from the results of such research, have found that a thermoplastic resin composition including a polyester resin, a white pigment, and a silicon-containing graft copolymer can realize optical efficiency and photostability for a long time while exhibiting improved impact resistance, thereby completing the present invention.

(4) A thermoplastic resin composition according to this invention includes (A) a polyester resin, (B) a white pigment, and (C) a silicon-containing graft copolymer.

(5) Hereinafter, each component of the thermoplastic resin composition according to the present invention will be described in more detail.

(6) (A) Polyester Resin

(7) The polyester resin may be used to improve heat resistance and mechanical properties of the resin composition at high temperature during a manufacturing process of LED components. The polyester resin contains a cyclic structure in a polymer backbone and thus has high melting point. The polyester resin may have a melting point of 200 C. or higher, preferably 220 C. to 380 C., more preferably 260 C. to 320 C. If the melting point of the polyester resin exceeds 380 C., the polyester resin can exhibit poor processability.

(8) The polyester resin may have a structure in which an aromatic ring and a cycloaliphatic ring are contained in the main chain. Specifically, the polyester resin may be prepared through polycondensation of an aromatic dicarboxylic acid component with a diol component including a cycloaliphatic diol.

(9) The dicarboxylic acid component may include aromatic dicarboxylic acids and derivatives thereof. For example, the dicarboxylic acid component may include terephthalic acid, isophthalic acid, phthalic acid, and naphthalene dicarboxylic acid, and terephthalic acid is preferably used as the dicarboxylic acid component.

(10) The diol component may include a cycloaliphatic diol to contain a cyclic repeat unit in the main chain. For example, 1,4-cyclohexanedimethanol (CHDM) is preferably used as the diol component.

(11) The diol component may further include an aliphatic diol in addition to 1,4-cyclohexanedimethanol. The aliphatic diol may include ethylene glycol. When ethylene glycol is included, the diol component may include 15 wt % to 100 wt % of 1,4-cyclohexanedimethanol and 0 wt % to 85 wt % of ethylene glycol. Preferably, the diol component may include 30 wt % to 80 wt % of 1,4-cyclohexanedimethanol and about 20 wt % to 70 wt % of ethylene glycol. The diol component including ethylene glycol can improve mechanical properties such as impact resistance without deterioration in heat resistance of the polyester resin.

(12) In addition, at least one C.sub.6 to C.sub.21 aromatic diol or C.sub.3 to C.sub.8 aliphatic diol may be further included as the diol component in order to modify the polyester resin. Examples of the C.sub.6 to C.sub.21 aromatic diol or the C.sub.3 to C.sub.8 aliphatic diol may include propane-1,3-diol, butane-1,4-diol, pentane-1,5-diol, hexane-1,6-diol, 3-methylpentane-2,4-diol, 2-methylpentane-1,4-diol, 2,2,4-trimethylpentane-1,3-diol, 2-ethylhexane-1,3-diol, 2,2-diethylpropane-1,3-diol, 1,4-cyclobutanedimethanol, 2,2-bis-(3-hydroxy ethoxyphenyl)-propane, 2,2-bis-(4-hydroxypropoxyphenyl)-propane, and the like.

(13) The polyester resin may be a compound which is obtained through polycondensation of terephthalic acid with 1,4-cyclohexanedimethanol and has a repeat unit represented by Formula 1:

(14) ##STR00001##

(15) wherein m is an integer from 10 to 500.

(16) Preferably, the polyester resin is polycyclohexanedimethylene terephthalate (PCT).

(17) The polyester resin (A) may have an intrinsic viscosity () of 0.4 dl/g to 1.5 dl/g, preferably 0.5 dl/g to 1.2 dl/g, as measured in an o-chlorophenol solution at 35 C. If the intrinsic viscosity () is less than 0.4 dl/g, the resin composition can exhibit poor mechanical properties, whereas if the intrinsic viscosity () exceeds 1.5 dl/g, the resin composition can exhibit poor moldability.

(18) The polyester resin may be prepared through a typical polycondensation process known in the art, and the polycondensation process may include direct polycondensation of an acid through transesterification using glycol or lower alkyl ester.

(19) The polyester resin may be present in an amount of 30 wt % to 80 wt % based on the total weight of a base resin including the polyester resin and the white pigment. If the amount of the polyester resin is less than 30 wt %, the thermoplastic resin composition can exhibit poor properties in terms of heat resistance and impact resistance, whereas if the amount of the polyester resin exceeds 80 wt %, the thermoplastic resin composition can exhibit poor properties in terms of moldability and photostability.

(20) (B) White Pigment

(21) The white pigment may be used to increase whiteness and reflectivity of the resin composition.

(22) The white pigment may include at least one selected from among titanium oxide, zinc oxide, zinc sulfide, white lead, zinc sulfate, barium sulfate, calcium carbonate, aluminum oxide, and a mixture thereof.

(23) The white pigment may be treated with a silane coupling agent or a titanium coupling agent. For example, the white pigment may be treated with a silane compound such as vinyltriethoxysilane, 3-aminopropyltriethoxysilane, and 3-glycidoxypropyltriethoxysilane.

(24) Preferably, the white pigment is titanium oxide. The titanium oxide may be used to improve optical properties such as reflectivity and concealment. The titanium oxide may include a typical titanium oxide product, without being limited thereto. Preferably, the titanium oxide is treated with an inorganic surface treatment agent or an organic surface treatment agent. Examples of the inorganic surface treatment agent may include aluminum oxide (alumina, Al.sub.2O.sub.3), silicon dioxide (silica, SiO.sub.2), zirconium dioxide (zirconia, ZrO.sub.2), sodium silicate, sodium aluminate, sodium aluminum silicate, zinc oxide, mica, and the like. Examples of the organic surface treatment agent may include polydimethylsiloxane, trimethylpropane (TMP), pentaerythritol, and the like. The inorganic surface treatment agent or the organic surface treatment agent may be used in an amount of 10 parts by weight or less based on 100 parts by weight of the titanium oxide. Preferably, the titanium oxide is coated with alumina (Al.sub.2O.sub.3). The alumina-treated titanium oxide may be further modified using an inorganic surface treatment agent such as silicon dioxide, zirconium dioxide, sodium silicate, sodium aluminate, sodium aluminum silicate, zinc oxide, and mica or an organic surface treatment agent such as polydimethylsiloxane, trimethylpropane (TMP), and pentaerythritol.

(25) The white pigment may be present in an amount of 20 wt % to 70 wt % based on the total weight of the base resin including the polyester resin and the white pigment. If the amount of the white pigment is less than 20 wt %, the thermoplastic resin composition can exhibit poor properties in terms of reflectivity and discoloration resistance, whereas if the amount of the white pigment exceeds 70 wt %, the thermoplastic resin composition can exhibit poor properties in terms of mechanical properties such as impact resistance.

(26) (C) Silicon-Containing Graft Copolymer

(27) The silicon-containing graft copolymer may be used to improve impact resistance without deterioration in long-term reflectivity and discoloration resistance in combination with other components of the resin composition.

(28) The silicon-containing graft copolymer may have a core-shell structure. The silicon-containing graft copolymer may be obtained by grafting a vinyl monomer to a rubbery core structure to form a shell. Specifically, the silicon-containing graft copolymer may have a structure in which a vinyl monomer is grafted to a silicon-based rubber core.

(29) The silicon-containing graft copolymer may be prepared by any suitable method known in the art. For example, the silicon-containing graft copolymer may be prepared by grafting at least one compound selected from the group consisting of -methylstyrene, halogen or alkyl-substituted styrene, acrylonitrile, methacrylonitrile, C.sub.1 to C.sub.8 methacrylic acid alkyl esters, C.sub.1 to C.sub.8 acrylic acid alkyl esters, maleic anhydride, C.sub.1 to C.sub.4 alkyls, and N-substituted phenyl maleimide to a silicon-based rubber, subsequent to polymerization of the rubber.

(30) The C.sub.1 to C.sub.8 methacrylic acid alkyl esters or the C.sub.1 to C.sub.8 acrylic acid alkyl esters are esters of methacrylic acid or acrylic acid, and may be esters prepared from C.sub.1 to C.sub.8 monohydric alcohols. Examples of the C.sub.1 to C.sub.8 methacrylic acid alkyl esters or the C.sub.1 to C.sub.8 acrylic acid alkyl esters may include methacrylic acid methyl ester, methacrylic acid ethyl ester, and methacrylic acid propyl ester. Preferably, methacrylic acid methyl ester is used.

(31) The silicon-based rubber of the silicon-containing graft copolymer may be prepared from a cyclosiloxane compound. For example, the silicon-based rubber may be prepared from a cyclosiloxane compound selected from the group consisting of hexamethylcyclotrisiloxane, octamethylcyclotetrasiloxane, decamethylcyclopentasiloxane, dodecamethylcyclohexasiloxane, trimethyltriphenylcyclosiloxane, tetramethyltetraphenylcyclotetrasiloxane, octaphenylcyclotetrasiloxane, and mixtures thereof.

(32) The silicon-based rubber may include 20 wt % to 95 wt % of silicon. Within this range, the silicon-containing graft copolymer can provide a synergistic effect by which the resin composition can have excellent impact resistance while exhibiting long-term photostability in combination with other components. If the amount of silicone is less than 20 wt %, the resin composition can exhibit poor long-term photostability, whereas if the amount of silicone exceeds 95 wt %, it is difficult to achieve impact resistance required for products.

(33) In addition, the silicon-based rubber core may have a silicon content of 5 wt % to 85 wt %, preferably 20 wt % to 85 wt %, more preferably 50 wt % to 85 wt %, based on the total weight of the silicon-containing graft copolymer. Within this range, the silicon-containing graft copolymer can provide a synergistic effect of simultaneously improving long-term photostability and impact resistance of the resin composition in combination with other components.

(34) The silicon-containing graft copolymer may be present in an amount of 0.1 to 10 parts by weight based on 100 parts by weight of the base resin including the polyester resin and the white pigment. If the amount of the silicon-containing graft copolymer is less than 0.1 parts by weight, improvement in impact resistance of the resin composition is insignificant, whereas if the amount of the silicon-containing graft copolymer exceeds 10 parts by weight, the resin composition can exhibit poor properties in terms of heat resistance, optical efficiency, and photostability.

(35) The thermoplastic resin composition according to the invention may further include fillers having various particle shapes to improve mechanical properties and moldability. The fillers may include any suitable organic or inorganic fillers known in the art. Specifically, the fillers may include at least one selected from among glass fibers, carbon fibers, glass beads, glass flakes, carbon black, clay, kaolin, talc, mica, calcium carbonate, wollastonite, and a mixture thereof. Thereamong, glass fibers, talc, and clay are preferably used, and, more preferably glass fibers are used.

(36) Although the glass fibers may have a circular shape in section, the shape of the glass fibers may vary depending upon desired applications. In other words, the glass fibers may have any suitable shape without limitation.

(37) The fillers may be present in an amount of 5 wt % to 50 wt % based on the total weight of the base resin. Within this range, the fillers can improve mechanical strength and moldability of the resin composition in combination with other components.

(38) In addition, the thermoplastic resin composition according to the present invention may further include typical additives without altering advantageous effects of the invention, and examples of the additives may include antioxidants, heat stabilizers, flame retardants, fluorescent brighteners, plasticizers, thickening agents, antistatic agents, release agents, dyes, and nucleating agents, without being limited thereto. Examples of the antioxidants may include phenol, amine, sulfur, and phosphorus antioxidants; examples of the heat stabilizers may include lactone compounds, hydroquinone compounds, halogenated copper, and iodine compounds; and examples of the flame retardants may include bromine-based, chlorine-based, phosphorus-based, antimony-based, and inorganic flame retardants.

(39) In accordance with another aspect of the present invention, there is provided a molded article produced using the thermoplastic resin composition as set forth above.

(40) The molded article may have a difference of 10 or less between initial reflectivity measured at a wavelength of 450 nm using a colorimeter and reflectivity measured after irradiation with an LED light source for 500 hours at 85 C./85% RH.

(41) The molded article may be a reflector for LEDs.

(42) Hereinafter, the present invention will be described in more detail with reference to some examples. It should be understood that these examples are provided for illustration only and are not to be construed in any way as limiting the present invention.

(43) Details of components used in the following Examples and Comparative Examples are as follows:

(44) (A) Polyester resin (PCT)

(45) PCT 0302 produced by SK Chemical was used.

(46) (B) White pigment

(47) CR-470 produced by Tronox Pigments LLC was used.

(48) (C) Silicon-containing graft copolymer

(49) KANE ACE MR-01 (produced by KANEKA Corporation) having a silicon content of 65 wt % was used.

(50) (D) Glass Fiber

(51) 910 produced by Owens-Corning Fiberglas Corp. was used.

Example 1

(52) The aforementioned components were added in amounts as listed in Table 1, followed by dry blending, thereby preparing a thermoplastic resin composition. Here, the silicon-containing graft copolymer (C) was included in an amount of 1 part by weight based on 100 parts by weight of a base resin including 52.5 wt % of the polyester resin (A) and 47.5 wt % of the white pigment (B). Then, the resin composition was subjected to processing using a twin-screw extruder (0=45 mm) at a nozzle temperature of 250 C. to 350 C., thereby preparing pellets. The prepared pellets were dried at 100 C. for 4 hours or more, followed by injection molding using a horizontal injection molding machine (at a molding temperature of 280 C. to 320 C.), thereby preparing a specimen having a size of 90 mm50 mm2.5 mm, which in turn was evaluated as to the following properties. Results are shown in Table 1.

Example 2

(53) A specimen was prepared in the same manner as in Example 1 except that the silicon-containing graft copolymer (C) was used in an amount of 5 parts by weight based on 100 parts by weight of the base resin.

Comparative Example 1

(54) A specimen was prepared in the same manner as in Example 1 except that the silicon-containing graft copolymer graft copolymer (C) was not used.

(55) (Property Evaluation)

(56) 1) Izod Impact Strength

(57) Impact strength was measured on a thick unnotched specimen at 23 C. in accordance with ASTM D256.

(58) 2) Reflectivity

(59) Reflectivity was measured on a plate-type specimen at a wavelength of 450 nm. Initial reflectivity was measured in the specular component included (SCI) mode, and reflectivity was measured on the specimen after irradiation with an LED light source at a wavelength of 450 nm for 200 hours and 500 hours in a thermo-hygrostat oven at 170 C. and 85% RH to perform evaluation of reflectivity retention properties. Here, as a reflectometer, a CM3600 CIE Lab. Colorimeter (produced by KONICA MINOLTA HOLDINGS, INC.) was used.

(60) TABLE-US-00001 TABLE 1 Comparative Item Example 1 Example 2 Example 1 (A) PCT 50 50 50 (B) White pigment 35 35 35 (C) Silicone-containing 1 3 graft copolymer (D) Glass fiber 15 15 15 IZOD impact kgf .Math. cm/cm 16.0 16.7 15.4 strength (Unnotched) Reflectivity Initial 93.2 93.9 93.0 200 hours 88.4 89.2 87.5 500 hours 83.5 85.1 82.1

(61) As shown in Table 1, it can be seen that Examples 1 and 2 exhibited improved impact resistance and had high initial reflectivity and excellent reflectivity retention properties as compared with Comparative Example 1.

(62) Although some embodiments have been described herein, it should be understood that these embodiments are provided for illustration only and are not to be construed in any way as limiting the present invention, and that various modifications, changes, alterations, and equivalent embodiments can be made by those skilled in the art without departing from the spirit and scope of the invention.

(63) Therefore, the scope of the present invention should be defined by the appended claims and equivalents thereof.