POLYCARBONATE RESIN COMPOSITION AND OPTICAL MOLDED ARTICLE USING THE SAME

Abstract

The present invention relates to a polycarbonate resin composition and an optical molded article comprising the same. The polycarbonate resin composition according to the present invention is excellent in transmittance and color stability and thus can ensure high transparency, and further can enhance the stability of a polycarbonate resin.

Claims

1. A polycarbonate resin composition comprising: a polycarbonate; a cyclic phosphite ester compound; a linear phosphite ester compound; a vinyl-based polymer including a (meth)acrylate repeating unit containing an epoxy functional group; and a photoreactive compound containing a phenylene functional group, wherein the linear phosphite ester compound is contained in an amount of 40 to 90 parts by weight relative to 100 parts by weight of the cyclic phosphite ester compound.

2. The polycarbonate resin composition of claim 1, comprising 10 to 300 parts by weight of the vinyl-based polymer including a (meth)acrylate repeating unit containing an epoxy functional group, based on 100 parts by weight of the cyclic phosphite ester compound and the linear phosphite ester compound.

3. The polycarbonate resin composition of claim 1, comprising 10 to 300 parts by weight of the photoreactive compound containing a phenylene functional group, based on 100 parts by weight of the cyclic phosphite ester compound and the linear phosphite ester compound.

4. The polycarbonate resin composition of claim 1, wherein the cyclic phosphite ester compound includes two phosphite groups and a tetravalent organic functional group bonded to the two phosphite groups.

5. The polycarbonate resin composition of claim 1, wherein the cyclic phosphite ester compound is represented by the following chemical formula 1. ##STR00008## in the chemical formula 1, X.sub.1 is a tetravalent organic functional group, and R.sub.1 and R.sub.2 are the same or different from each other and are each independently an aryl group having 6 to 40 carbon atoms.

6. The polycarbonate resin composition of claim 5, wherein the X.sub.1 is represented by the following chemical formula 1-1. ##STR00009## in the chemical formula 1-1, * is a point of a bonding position.

7. The polycarbonate resin composition of claim 1, wherein the linear phosphite ester compound includes a phosphite functional group and an aryl group having 6 to 40 carbon atoms bonded to the phosphite functional group.

8. The polycarbonate resin composition of claim 1, wherein the linear phosphite ester compound is represented by the following chemical formula 2. ##STR00010## in the chemical formula 2, R.sub.3, R.sub.4 and R.sub.5 are the same or different from each other and are each independently an aryl group having 6 to 40 carbon atoms.

9. The polycarbonate resin composition of claim 1, wherein the (meth)acrylate repeating unit containing the epoxy functional group includes a repeating unit represented by the following chemical formula 3: ##STR00011## in the chemical formula 3, R.sub.11, R.sub.12 and R.sub.13 are hydrogen or a linear or branched alkyl group having 1 to 10 carbon atoms, R.sub.14 is a linear or branched alkylene group having 1 to 10 carbon atoms, and x is an integer of 1 to 20.

10. The polycarbonate resin composition of claim 1, wherein the vinyl-based polymer including a (meth)acrylate repeating unit containing an epoxy functional group includes an aromatic vinyl-based repeating unit represented by the following chemical formula 4 and a (meth)acrylic-based repeating unit represented by the following chemical formula 5: ##STR00012## in the chemical formula 4, R.sub.15 to R.sub.18 are each independently hydrogen or a linear or branched alkyl group having 1 to 10 carbon atoms, and y is an integer of 1 to 20, ##STR00013## in the chemical formula 5, R.sub.21 to R.sub.24 are each independently hydrogen or a linear or branched alkyl group having 1 to 10 carbon atoms, and z is an integer of 1 to 20.

11. The polycarbonate resin composition of claim 1, wherein the vinyl-based polymer including a (meth)acrylate repeating unit containing an epoxy functional group has a weight average molecular weight of 1,000 g/mol to 10,000 g/mol.

12. The polycarbonate resin composition of claim 1, wherein the vinyl-based polymer including a (meth)acrylate repeating unit containing an epoxy functional group has an epoxy equivalent weight of 100 g/mol to 500 g/mol.

13. The polycarbonate resin composition of claim 1, wherein the photoreactive compound containing a phenylene functional group includes an aromatic compound having 6 to 20 carbon atoms or an ester compound having 4 to 20 carbon atoms bonded to the phenylene functional group, together with the phenylene functional group.

14. The polycarbonate resin composition of claim 13, wherein the aromatic compound having 6 to 20 carbon atoms includes benzoxazinone, and the ester compound having 4 to 20 carbon atoms includes a methylene malonic acid ester.

15. The polycarbonate resin composition of claim 1, wherein the polycarbonate has a weight average molecular weight of 14,000 g/mol to 30,000 g/mol.

16. The polycarbonate resin composition of claim 1, wherein the polycarbonate includes a repeating unit represented by the following chemical formula 6: ##STR00014## 1) in the chemical formula 6, a is an integer of 1 or more.

17. The polycarbonate resin composition of claim 1, further comprising one or more additives selected from the group consisting of an antioxidant, a heat stabilizer, a plasticizer, an antistatic agent, a nucleating agent, a flame retardant, a lubricant, an impact modifier, a fluorescent whitening agent, an ultraviolet absorber and a radiation absorber.

18. An optical molded article comprising the polycarbonate resin composition of claim 1.

19. The optical molded article of claim 18 wherein the optical molded article is a light emitting diode or a lens.

Description

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0093] Below, preferred embodiments will be provided in order to assist in the understanding of the present disclosure. However, these examples are provided only for illustration of the present invention, and should not be construed as limiting the present invention to these examples.

[0094] Materials Used

[0095] The following materials were used in Examples and Comparative Examples below. [0096] Polycarbonate Resin (PC)

[0097] A bisphenol A type linear polycarbonate having a weight average molecular weight of 29,000 g/mol and MFR (300 C., 1.2 kg) of 14 g/min was used. [0098] P-168 [0099] Tris(2,4-di-tert-butylphenyl)phosphite]; IRGAFOS 168 [0100] PEP36 [0101] Bis(2,6-di-tert-butyl-4-methylphenyl)pentaerythritol-di-phosphite]; ADK STAB [0102] ADR-4370F [0103] Joncryl ADR-4370F (epoxy equivalent weight: 285 g/mol) having a weight average molecular weight of 6,800 g/mol available from BASF was used. [0104] ADR-4468 [0105] Joncryl ADR-4468 available from BASF was used. The ADR-4468 has the same Cas No. as ADR 4370F, but product with slightly increased epoxy equivalent weight and molecular weight. [0106] C2021P

[0107] (3,4-Epoxycyclohexane)methyl 3,4-epoxycyclohexylcarboxylate [0108] UV3638

[0109] 2,2-(1,4-phenylene)bis(4H-3,1-benzoxazin-4-one) [0110] B-Cap

[0111] p-Phenylenebis(methylenemalonic acid)tetraethyl ester]; Hostavin B-CAP [0112] T329

[0113] 2-(2H-benzotriazol-2-yl)-4-(1,1,3,3-tetramethylbutyl)phenol; Tinuvin 329 [0114] T327

[0115] 2-(2-Hydroxy-3,5-di-tert-butylphenyl)-5-chlorobenzotriazole; Tinuvin 327 [0116] UV3030

[0117] 1,3-bis[(2-cyano-3,3-diphenylacryloyl)oxy]-bis[[(2-cyano-3,3-diphenylacryloyl)oxy]methyl]propane

Examples and Comparative Examples

[0118] After mixing the respective additive components with the content as shown in Table 1 below based on 100 parts by weight of the polycarbonate resin composition, pellet samples were prepared at a rate of 55 kg per hour in a twin screw extruder (L/D=36, =45, barrel temperature: 240 C.).

TABLE-US-00001 TABLE 1 Additive composition (unit: ppm) of the polycarbonate resin compositions of Examples and Comparative Examples Category P-168 PEP36 ADR-4370F ADR-4468 C2021P UV3638 B-Cap T329 T327 UV3030 Example 1 500 750 500 1200 Example 2 500 750 500 1200 Example 3 500 750 500 1200 Comparative 750 500 1200 Example 1 Comparative 750 500 1200 Example 2 Comparative 750 250 250 1200 Example 3 Comparative 750 500 1200 Example 4 Comparative 750 500 1200 Example 5 Comparative 750 500 1200 Example 6 Comparative 750 500 1200 Example 7 Comparative 750 500 500 1200 Example 8 Comparative 100 1150 500 1200 Example 9

Experimental Example

[0119] The properties of the pellets prepared in the above Examples and Comparative Examples were measured by the following methods. [0120] Transmittance of long-wavelength light (T %) and color of long-wavelength light (YI):

[0121] Each of the samples (width/length/thickness=150 mm/80 mm/4 mm) was injection-molded. the transmittance of long-wavelength light (T %) and the color of long-wavelength light (YI) were measured by irradiating in a perpendicular direction to a thickness of the sample using a spectrophotometer U-4100 available from Hitachi. The results are shown in Table 2 below. [0122] Occurrence of white turbidity:

[0123] Each of the samples (width/length/thickness=30 mm/60 mm/3 mm) was injection-molded and kept in an autoclave under conditions of 120 C. and 100% RH for 168 hours, and then haze was measured according to the measurement standard of ASTM D1003 using a hazemeter (NIPPON DENSHOKU, NDH5000SP), and the results are shown in Table 2 below.

TABLE-US-00002 TABLE 2 Results of Experimental Examples Color of Transmittance of long-wavelength long-wavelength Category light (YI) light (T %) Haze (%) Example 1 8.12 80.12 1.76 Example 2 8.23 79.87 1.79 Example 3 8.02 81.23 1.75 Comparative 10.27 75.93 99.27 Example 1 Comparative 11.03 75.35 2.07 Example 2 Comparative 11.20 75.55 2.15 Example 3 Comparative 8.48 78.32 99.15 Example 4 Comparative 8.53 79.40 99.48 Example 5 Comparative 11.88 76.21 1.98 Example 6 Comparative 12.01 75.64 2.18 Example 7 Comparative 10.58 76.95 2.11 Example 8 Comparative 11.21 73.28 85.49 Example 9

[0124] As shown in Table 2, in the case of Examples according to the present invention, as ADR-4370F or ADR-4468 was added while adding the P-168 additive and the PEP36 additive together, and UV-3638 or B-Cap was used as an ultraviolet stabilizer, it could be confirmed that they had a low color of long-wavelength light (8.02 to 8.23) and a high transmittance of long-wavelength light (79.87 to 81.23), and the haze value of the finally produced optical molded article was as low as 1.79% or less, as compared with Comparative Examples, and thereby the white turbidity did not occur.

[0125] On the other hand, in the case of Comparative Example 1, Comparative Example 4 and Comparative Example 5, in which only one kind of PEP 36 additive was used, it was confirmed that the haze value was as high as 99% or more and thus the white turbidity occurred, and that it was not suitable for application to an optical molded article.

[0126] Further, in the case of Comparative Example 6 and Comparative Example 7, in which only one kind of P-168 additive was used, the transmittance of long-wavelength light decreased to less than 77%, and the color of long-wavelength light increased to 11 or more, thereby making it difficult to secure a color stability (transparency).

[0127] Further, even in the case of Comparative Example 2 and Comparative Example 3, in which other ultraviolet stabilizers rather than UV3638 or B-Cap were used, it could be confirmed that they exhibited a lower transmittance and a higher color of long-wavelength light, as compared with Examples.

[0128] On the other hand, Comparative Example 8 in which 150 parts by weight of P-168, which is a linear phosphite ester compound, was added relative to 100 parts by weight of PEP36 which is a cyclic phosphite ester compound, and Comparative Example 9 in which 8.7 parts by weight of P-168, which is a linear phosphite ester compound, was added relative to 100 parts by weight of PEP36 which is a cyclic phosphite ester compound, the color of long-wavelength light was increased, the transmittance of long-wavelength light was decreased and the haze value increased, as compared with Examples, which is disadvantageous for application to an optical molded article.