Patent Application
20240287250
The present invention relates to a thermoplastic resin and an optical lens comprising the same. More specifically, the present invention relates to a polycarbonate resin, a polyester resin or a polyester carbonate resin, and an optical lens comprising the same.
As materials for optical lenses used in the optical systems of various types of cameras such as a camera, a film-integrated camera and a video camera, optical glasses or optical resins have been used. Such optical glasses are excellent in heat resistance, transparency, dimensional stability, chemical resistance and the like. However, the optical glasses are problematic in terms of high material costs, poor formability and low productivity.
On the other hand, an optical lens consisting of an optical resin is advantageous in that it can be produced in a large amount by injection molding, and as materials having a high refractive index for use in camera lenses, polycarbonate, polyester carbonate, and polyester resins, etc. have been used.
When such an optical resin is used as an optical lens, the used optical resin is required to have heat resistance, transparency, low water absorbability, chemical resistance, low birefringence, moist-heat resistance, etc., in addition to optical properties such as refractive index and Abbe number. In particular, in recent years, optical lenses having high refractive index and high heat resistance have been required, and thus, various resins have been developed (Patent Literatures 1 to 5).
Moreover, a thermoplastic resin made from 2,2′-bis(2-hydroxyethoxy)-1,1′-binaphthalene as a raw material has excellent optical properties and is useful as a material for various types of optical applications (Patent Literature 6). However, due to various molding processes and the expansion of usage environments, further improvement of heat resistance without impairing optical properties has been required.
It is an object of the present invention to provide a thermoplastic resin that is excellent in optical properties such as refractive index and Abbe number and is also excellent in heat resistance, and an optical lens using the same.
As a result of intensive studies directed towards solving the conventional problem, the present inventors have found that a thermoplastic resin that is excellent in optical properties such as refractive index and Abbe number and is also excellent in heat resistance can be obtained by using a raw material, in which an aromatic ring is introduced into a diol compound having a binaphthalene structure, thereby completing the present invention.
Specifically, the present invention includes the following aspects.
According to the present invention, there can be provided: a thermoplastic resin that is excellent in optical properties such as refractive index and Abbe number and is also excellent in heat resistance; and an optical lens comprising the same.
Hereinafter, the present invention will be described in detail by exemplifying Synthetic Examples, Examples, and the like, but the present invention is not limited to the exemplified Synthetic Examples, Examples, and the like. The methods described below can be changed to any methods within a range that does not greatly deviate from the contents of the present invention.
One embodiment of the present invention relates to a thermoplastic resin comprising a constituent unit (A) derived from a monomer represented by the following general formula (1):
In the above general formula (1), preferably, R1 to R12, Rk, and Rp each independently represent a hydrogen atom, a methyl group, or a phenyl group, and more preferably, all of R1 to R12, Rk, and Rp represent hydrogen atoms.
In the above general formula (1), X and Y represent a single bond or an alkylene group containing 1 to 5 (preferably 1 to 3) carbon atoms, preferably represent a single bond, a methylene group or an ethylene group, and more preferably represent a single bond or a methylene group.
In the above general formula (1), i and ii each independently represent an integer of 0 to 4, and preferably represent an integer of 0 to 2.
In the above general formula (1), K1 and K2 each independently represent —OH, —COOH, or —COORq, and herein, Rq represents an alkyl group containing 1 to 5 (preferably 1 to 3) carbon atoms. Rq preferably represents a methyl group, an ethyl group or a propyl group, and more preferably represents a methyl group.
In one embodiment of the present invention, an aspect, wherein, in the general formula (1), R1 to R12, Rk, and Rp each represent a hydrogen atom, X and Y represent a methylene group, and K1 and K2 represent —OH, is preferable.
In addition, an aspect, wherein, in the general formula (1), R1 to R12, Rk, and Rp each represent a hydrogen atom, X and Y represent a single bond, and K1 and K2 represent —COOH or —COORq, wherein Rq represents an alkyl group containing 1 to 5 (preferably 1 to 3) carbon atoms, is also preferable.
Particularly preferred specific compounds as monomers represented by the general formula (1) are shown below, but the present invention is not limited to these compounds.
The monomer represented by the general formula (1) can be produced according to the method described in Adv. Synth. Catal. 2004, 346, 195-198. The monomer represented by the general formula (1) can be produced, for example, as shown in the following reaction formula.
As shown in the above reaction formula, the monomer represented by the general formula (1) is obtained by allowing 2,2-binaphthol to react with p-bromobenzaldehyde in pyridine in the presence of copper, copper oxide and potassium carbonate to obtain 4,4′-([1,1′-binaphthalene]-2,2′-diylbis(oxy))dialdehyde, and then by reducing the obtained 4,4′-([1,1′-binaphthalene]-2,2′-diylbis(oxy))dialdehyde with a reducing agent such as lithium aluminum hydride (LiAlH4). Besides, an isomer is obtained by replacing p-bromobenzaldehyde with o-bromobenzaldehyde or m-bromobenzaldehyde.
The thermoplastic resin of one embodiment of the present invention is not particularly limited, and it includes a polyester resin, a polycarbonate resin, a polyester carbonate resin, an epoxy resin, a polyurethane resin, a polyacrylic acid ester resin, and a polymethacrylic acid ester resin. The thermoplastic resin of one embodiment of the present invention is preferably a polycarbonate resin, a polyester resin or a polyester carbonate resin, and more preferably comprises a constituent unit (A) represented by the following formula:
In the thermoplastic resin of one embodiment of the present invention, the ratio of the constituent unit (A) represented by the above formula in all constituent units is not particularly limited. The ratio of the constituent unit (A) is preferably 1% to 90% by mole, more preferably 1% to 80% by mole, further preferably 5% to 70% by mole, and particularly preferably 10% to 60 by mole, in all constituent units.
That is to say, the thermoplastic resin of one embodiment of the present invention may comprise constituent units derived from aliphatic dihydroxy compounds and constituent units derived from aromatic dihydroxy compounds, which are generally used as constituent units of polycarbonate resins or polyester carbonate resins, in addition to the constituent unit (A) represented by the above-described formula.
Specifically, the aliphatic dihydroxy compound includes various compounds, and particular examples thereof may include 1,4-cyclohexanedimethanol, tricyclodecanedimethanol, 1,3-adamantanedimethanol, 2,2-bis(4-hydroxycyclohexyl)-propane, 3,9-bis(2-hydroxy-1,1-dimethylethyl)-2,4,8,10-tetraoxaspiro[5.5]undecane, 2-(5-ethyl-5-hydroxymethyl-1,3-dioxan-2-yl)-2-methylpropan-1-ol, isosorbide, 1,3-propanediol, 1,4-butanediol, and 1,6-hexanediol.
The aromatic dihydroxy compound includes various compounds, and particular examples thereof may include 2,2-bis(4-hydroxyphenyl)propane [bisphenol A], bis(4-hydroxyphenyl)methane, 1,1-bis(4-hydroxyphenyl)ethane, 2,2-bis(4-hydroxy-3,5-dimethylphenyl)propane, 4,4′-dihydroxydiphenyl, bis(4-hydroxyphenyl)cycloalkane, bis(4-hydroxyphenyl)oxide, bis(4-hydroxyphenyl)sulfide, bis(4-hydroxyphenyl)sulfone, bis(4-hydroxyphenyl)sulfoxide, and bis(4-hydroxyphenyl)ketone, and bisphenoxyethanol fluorene.
Moreover, the thermoplastic resin of one embodiment of the present invention preferably comprises a constituent unit (B) derived from a monomer represented by the following general formula (2).
In the general formula (2), Ra and Rb are each independently selected from the group consisting of a halogen atom, an alkyl group containing 1 to 20 carbon atoms and optionally having a substituent, an alkoxy group containing 1 to 20 carbon atoms and optionally having a substituent, a cycloalkyl group containing 5 to 20 carbon atoms and optionally having a substituent, a cycloalkoxy group containing 5 to 20 carbon atoms and optionally having a substituent, an aryl group containing 6 to 20 carbon atoms and optionally having a substituent, a heteroaryl group containing 6 to 20 carbon atoms and optionally having a substituent, which comprises one or more heterocyclic atoms selected from O, N and S, an aryloxy group containing 6 to 20 carbon atoms and optionally having a substituent, and —C≡C—Rh. Herein, Rh represents an aryl group containing 6 to 20 carbon atoms and optionally having a substituent, or a heteroaryl group containing 6 to 20 carbon atoms and optionally having a substituent, which comprises one or more heterocyclic atoms selected from O, N and S.
Ra and Rb are preferably a hydrogen atom, an aryl group containing 6 to 20 carbon atoms and optionally having a substituent, or a heteroaryl group containing 6 to 20 carbon atoms and optionally having a substituent, which comprises one or more heterocyclic atoms selected from O, N and S; more preferably, a hydrogen atom, or an aryl group containing 6 to 20 carbon atoms and optionally having a substituent; and further preferably, a hydrogen atom, or an aryl group containing 6 to 12 carbon atoms and optionally having a substituent.
In the above general formula (2), X represents a single bond or a fluorene group optionally having a substituent. X is preferably a single bond, or a fluorene group optionally having a substituent, in which a total carbon number is 12 to 20.
In the above general formula (2), A and B each independently represent an alkylene group containing 1 to 5 carbon atoms and optionally having a substituent, and each independently preferably represent an alkylene group containing 2 or 3 carbon atoms.
In the above general formula (2), m and n each independently represent an integer of 0 to 6, preferably an integer of 0 to 3, and more preferably 0 or 1.
In the above general formula (2), a and b each independently represent an integer of 0 to 10, preferably an integer of 1 to 3, and more preferably 1 or 2.
Specific examples of the constituent unit (B) may include those derived from 2,2′-bis(2-hydroxyethoxy)-1,1′-binaphthalene (BNE), DPBHBNA, and the like.
Furthermore, the thermoplastic resin of one embodiment of the present invention preferably has a constituent unit (C) derived from a monomer represented by the following general formula (3).
In the general formula (3), Rc and Rd are each independently selected from the group consisting of a halogen atom, an alkyl group containing 1 to 20 carbon atoms and optionally having a substituent, an alkoxy group containing 1 to 20 carbon atoms and optionally having a substituent, a cycloalkyl group containing 5 to 20 carbon atoms and optionally having a substituent, a cycloalkoxy group containing 5 to 20 carbon atoms and optionally having a substituent, and an aryl group containing 6 to 20 carbon atoms and optionally having a substituent.
Rc and Rd are preferably a hydrogen atom, an aryl group containing 6 to 20 carbon atoms and optionally having a substituent, or a heteroaryl group containing 6 to 20 carbon atoms and optionally having a substituent, which comprises one or more heterocyclic atoms selected from O, N and S; more preferably, a hydrogen atom, or an aryl group containing 6 to 20 carbon atoms and optionally having a substituent; and further preferably, a hydrogen atom, or an aryl group containing 6 to 12 carbon atoms and optionally having a substituent.
In the general formula (3), Y1 represents a single bond, a fluorene group optionally having a substituent, or any one of structural formulae represented by the following formulae (4) to (11); and preferably represents a single bond, or a structural formula represented by the following general formula (4).
In the formulae (4) to (11), R61, R62, R71 and R72 each independently represent a hydrogen atom, a halogen atom, an alkyl group containing 1 to 20 carbon atoms and optionally having a substituent, or an aryl group containing 6 to 30 carbon atoms and optionally having a substituent, or represent a C1-C20 carbon ring or heterocyclic ring optionally having a substituent, which is formed as a result that R61 and R62, or R71 and R72 bind to each other, and Raa and Rbb are the same as Ra and Rb in the above general formula (2).
In the formulae (4) to (11), r and s each independently represent an integer of 0 to 5000.
In the above general formula (3), A and B each independently represent an alkylene group containing 1 to 5 carbon atoms and optionally having a substituent, and preferably, an alkylene group containing 2 or 3 carbon atoms. In the above general formula (3), p and q each independently represent an integer of 0 to 4, and preferably 0 or 1. In addition, in the above general formula (3), a and b each independently represent an integer of 0 to 10, preferably an integer of 0 to 5, more preferably an integer of 0 to 2, and for example, 0 or 1.
Specific examples of the constituent unit (C) may include those derived from BPEF (9,9-bis(4-(2-hydroxyethoxy)phenyl)fluorene), BPPEF (9,9-bis(4-(2-hydroxyethoxy)-3-phenylphenyl)fluorene), 9,9-bis [6-(2-hydroxyethoxy)naphthalen-2-yl]fluorene (BNEF), bisphenol A, bisphenol AP, bisphenol AF, bisphenol B, bisphenol BP, bisphenol C, bis(4-hydroxyphenyl)-2,2-dichloroethylene, bisphenol E, bisphenol F, bisphenol G, bisphenol M, bisphenol S, bisphenol P, bisphenol PH, bisphenol TMC, bisphenol P-AP (4,4′-(1-phenylethylidene)bisphenol), bisphenol P-CDE (4,4′-cyclododecylidenebisphenol), bisphenol P-HTG (4,4′-(3,3,5-trimethylcyclohexylidene)bisphenol), bisphenol P-MIBK (4,4′-(1,3-dimethylbutylidene)bisphenol), bisphenol PEO-FL (bisphenoxyethanolfluorene), bisphenol P-3MZ (4-[1-(4-hydroxyphenyl)-3-methylcyclohexyl]phenol), bisphenol OC-FL (4,4′-[1-[4-[1-(4-hydroxypheny 1)-1-methylethyl]phenyl]ethylidene]bisphenol), bisphenol Z, BP-2EO (2,2′-[[1,1′-biphenyl]-4,4′-diylbis(oxy)bisethanol), S-BOC (4,4′-(1-meth ylethylidene)bis(2-methylphenol)), and TrisP-HAP (4,4′,4″-ethylidenetrisphenol). Among these, the constituent units (C) are preferably those derived from BPEF or BNEF.
The thermoplastic resin of one embodiment of the present invention essentially comprises the constituent unit (A). The thermoplastic resin of one embodiment of the present invention may also be a polymer that contains the constituent unit (B) and does not contain the constituent unit (C), a polymer that contains the constituent unit (C) and does not contain the constituent unit (B), a copolymer having the constituent unit (B) and the constituent unit (C), a mixture of a polymer having the constituent unit (B) and a polymer having the constituent unit (C), or a combination thereof. Examples of the polymer that contains the constituent unit (C) and does not contain the constituent unit (B) may include those having constituent un its represented by the following formulae (I-1) to (I-3). Examples of the copolymer having the constituent unit (B) and the constituent unit (C) may include those having constituent units represented by formulae (II-1) to (II-4) as shown below.
In the formula (I-1), m and n each represent an integer of 1 to 10, preferably an integer of 1 to 5, and more preferably 1; and
Moreover, as a polymer having multiple types of constituent units, both a block copolymer, in which the values of m and n are large (for example, 100 or more), and a random copolymer, may be adopted. Of these, a random copolymer is preferable, and more preferably, a random copolymer, in which the values of m and n are 1,
In the above formulae (II-1) to (II-4), m and n each independently represent an integer of 1 to 10, preferably an integer of 1 to 5, and more preferably 1.
Furthermore, as a polymer having multiple types of constituent units, both a block copolymer, in which the values of m and n are large (for example, 100 or more), and a random copolymer, may be adopted. Of these, a random copolymer is preferable, and more preferably, a random copolymer, in which the values of m and n are 1, is used.
In such a copolymer, the molar ratio between the constituent unit (B) and the constituent unit (C) is preferably 1:99 to 99:1, more preferably 10:90 to 90:10, further preferably 15:85 to 85:15, and particularly preferably 30:70 to 70:30. In addition, in the mixture, the mass ratio between a polymer having the constituent unit (B) and a polymer having the constituent unit (C) is preferably 1:99 to 99:1, more preferably 10:90 to 90:10, further preferably 15:85 to 85:15, and particularly preferably 30:70 to 70:30.
Also, the thermoplastic resin of one embodiment of the present invention preferably comprises a constituent unit derived from at least one monomer selected from the following monomer group.
The polycarbonate resin or polyester carbonate resin of one preferred embodiment of the present invention may comprise, as impurities, an alcoholic compound that may be generated as a by-product upon the production thereof, such as a phenolic compound, or a diol component or a carbonic acid diester that has not reacted and re mains, in some cases.
Such an alcoholic compound such as a phenolic compound, and such a carbonic acid diester, which are comprised as impurities, may cause a reduction in the strength of the resulting molded body or generation of odors. Accordingly, the smaller the contents of these compounds, the better.
The content of the remaining phenolic compound is preferably 3000 ppm by mass or less, more preferably 1000 ppm by mass or less, particularly preferably 300 ppm by mass or less, with respect to 100% by mass of the polycarbonate resin.
The content of the remaining diol component is preferably 1000 ppm by mass or less, more preferably 100 ppm by mass or less, and particularly preferably 10 ppm by mass or less, with respect to 100% by mass of the polycarbonate resin.
The content of the remaining carbonic acid diester is preferably 1000 ppm by mass or less, more preferably 100 ppm by mass or less, and particularly preferably 10 ppm by mass or less, with respect to 100% by mass of the polycarbonate resin.
In particular, it is preferable that the contents of compounds such as phenol and t-butyl phenol are small, and it is preferable that the contents of these compounds are within the above-described range.
The content of a phenolic compound remaining in the polycarbonate resin can be measured by a method of analyzing a phenolic compound extracted from the polycarbonate resin, using gas chromatography.
The content of an alcoholic compound remaining in the polycarbonate resin can also be measured by a method of analyzing an alcoholic compound extracted from the polycarbonate resin, using gas chromatography.
The contents of a diol component and a carbonic acid diester remaining in the polycarbonate resin can also be measured by a method of extracting these compounds from the polycarbonate resin, and then analyzing them using gas chromatography.
The contents of a by-product alcoholic compound such as a phenolic compound, a diol component, and a carbonic acid diester may be reduced to such an extent that these compounds are undetectable. However, from the viewpoint of productivity, the polycarbonate resin may comprise very small amounts of these compounds in a range in which the compounds do not impair the effects of the present invention. In addition, plasticity can be improved upon the melting of the resin, if the resin may comprise very small amounts of the compounds.
The content of the remaining phenolic compound, diol component or carbonic acid diester may each be, for example, 0.01 ppm by mass or more, 0.1 ppm by mass or more, or 1 ppm by mass or more, with respect to 100% by mass of the polycarbonate resin.
The content of the remaining alcoholic compound may be, for example, 0.01 ppm by mass or more, 0.1 ppm by mass or more, or 1 ppm by mass or more, with respect to 100% by mass of the polycarbonate resin.
Besides, the contents of the by-product alcoholic compound such as a phenolic compound, the diol component and the carbonic acid diester in the polycarbonate resin can be regulated to be within the above-described ranges by appropriately adjusting conditions for polycondensation or the setting of apparatuses. Otherwise, the contents of these compounds can also be regulated by determining conditions for an extrusion step after completion of the polycondensation.
For example, the amount of the remaining by-product alcoholic compound such as a phenolic compound is related to the type of carbonic acid diester used in the polymerization of the polycarbonate resin, the temperature applied to the polymerization reaction, the polymerization pressure, etc. By adjusting these conditions, the amount of the remaining by-product alcoholic compound such as a phenolic compound can be reduced.
For example, when the polycarbonate resin is produced using dialkyl carbonate such as diethyl carbonate, the molecular weight is hardly increased, and low-molecular-weight polycarbonate is thereby obtained, so that the content of an alcoholic compound generated as a by-product tends to be increased. Such alkyl alcohol has high volatility, and thus, if it remains in the polycarbonate resin, the moldability of the resin tends to be deteriorated. In addition, when the amount of the remaining by-product alcoholic compound such as a phenolic compound is large, it is likely that problems regarding odor occur upon the molding of the resin, or it is also likely that the cleavage reaction of a resin skeleton progresses upon compounding, and a reduction in the molecular weight thereby occurs. Therefore, the content of the by-product alcoholic compound remaining in the obtained polycarbonate resin is preferably 3000 ppm by mass or less, with respect to the amount of the polycarbonate resin (100% by mass). The content of the remaining alcoholic compound is preferably 3000 ppm by mass or less, more preferably 1000 ppm by mass or less, and particularly preferably 300 ppm by mass or less, with respect to 100% by mass of the polycarbonate resin.
In one embodiment of the present invention, one characteristic of the thermoplastic resin is that it has a high refractive index. The refractive index is preferably 1.64 to 1.70, more preferably 1.64 to 1.69, and particularly preferably 1.65 to 1.68. In the present invention, the refractive index can be measured by the method described in the after-mentioned Examples.
In one embodiment of the present invention, the Abbe number of the thermoplastic resin is preferably 15.0 to 26.0, more preferably 15.0 to 24.0, and particularly preferably 18.0 to 22.0. In the present invention, the Abbe number can be measured by the method described in the after-mentioned Examples.
In one embodiment of the present invention, one characteristic of the thermoplastic resin is that it has high heat resistance. The glass transition temperature (Tg) is preferably 130° C. to 180° C., more preferably 135° C. to 170° C., and particularly preferably 140° C. to 160° C. In the present invention, the glass transition temperature can be measured by the method described in the after-mentioned Examples.
In one embodiment of the present invention, the polystyrene-converted weight average molecular weight of the thermoplastic resin is preferably 10,000 to 200,000, more preferably 10,000 to 100,000, and particularly preferably 10,000 to 80,000.
Another embodiment of the present invention relates to a thermoplastic resin composition comprising the aforementioned thermoplastic resin and additives. The thermoplastic resin composition of the present embodiment may also comprise a resin other than the thermoplastic resin of the present invention comprising the aforementioned constituent unit (A), in a range in which such a resin does not impair the desired effects of the present embodiment. Such a resin is not particularly limited, and it may be, for example, at least one resin selected from the group consisting of a polycarbonate resin, a polyester resin, a polyester carbonate resin, a (meth)acrylic resin, a polyamide resin, a polystyrene resin, a cycloolefin resin, an acrylonitrile-butadiene-styrene copolymer resin, a vinyl chloride resin, a polyphenylene ether resin, a polysulfone resin, a polyacetal resin, and a methyl methacrylate-styrene copolymer resin. Various types of known resins can be used as such resins, and one type of such resin alone can be added to, or a combination of two or more types of such resins can be added to the thermoplastic resin composition.
The thermoplastic resin composition preferably comprises an antioxidant as an additive described above.
As such an antioxidant, the thermoplastic resin composition preferably comprises at least one of a phenolic antioxidant and a phosphite-based antioxidant.
Examples of the phenolic antioxidant may include 1,3,5-tris(3,5-di-tert-butyl-4-hydroxyphenylmethyl)-2,4,6-trimethylbenzene, 1,3,5-tris(3,5-di-tert-butyl-4-hydroxybenzyl)-1,3,5-triazine-2,4,6(1H,3H,5H)-trione, 4,4′,4″-(1-methylpropanyl-3-ylidene)tris(6-tert-butyl-m-cresol), 6,6′-di-tert-butyl-4,4′-butylidenedi-m-cresol, octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, pentaerythritol-tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], 3,9-bis{2-[3-(3-tert-butyl-4-hydroxy-5-methylphenyl)propionyloxy]-1,1-dimethylethyl}-2,4,8,10-tetraoxospiro[5.5]undecane, and pentaerythritol-tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate]. Among these, pentaerythritol-tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate] is preferable.
Examples of the phosphite-based antioxidant may include 2-ethylhexyl diphenyl phosphite, isodecyl diphenyl phosphite, triisodecyl phosphite, triphenyl phosphite, 3,9-bis(octadecyloxy)-2,4,8,10-tetraoxy-3,9-diphosphaspiro[5.5]undecane, 3,9-bis(2,6-di-tert-butyl-4-methylphenoxy)-2,4,8,10-tetraoxa-3,9-diphosphaspiro[5.5]undecane, 2,2′-methylenebis(4,6-di-tert-butylphenyl)2-ethylhexyl phosphite, tris(2,4-ditert-butylphenyl) phosphite, tris(nonylphenyl) phosphite, tetra-C12-15-alkyl(propane-2,2-diylbis(4,1-phenylene)) bis(phosphite), and 3,9-bis(2,6-di-tert-butyl-4-methylphenoxy)-2,4,8,10-tetraoxa-3,9-diphosphaspiro[5.5]undecane. Among these, 3,9-bis(2,6-di-tert-butyl-4-methylphenoxy)-2,4,8,10-tetraoxa-3,9-diphosphaspiro[5.5]undecane is preferable.
As such antioxidants, the aforementioned compounds may be used alone as a single type, or may also be used as a mixture of two or more types.
The antioxidant is preferably comprised in the thermoplastic resin composition in an amount of 1 ppm by weight to 3000 ppm by weight, with respect to the total weight of the resin composition. The content of the antioxidant in the thermoplastic resin composition is more preferably 50 ppm by weight to 2500 ppm by weight, further preferably 100 ppm by weight to 2000 ppm by weight, particularly preferably 150 ppm by weight to 1500 ppm by weight, and further particularly preferably 200 ppm by weight to 1200 ppm by weight.
The thermoplastic resin composition preferably comprises a release agent as an additive described above.
Examples of the release agent may include ester compounds including glycerin fatty acid esters such as mono/diglyceride of glycerin fatty acid, glycol fatty acid esters such as propylene glycol fatty acid ester and sorbitan fatty acid ester, higher alcohol fatty acid esters, full esters of aliphatic polyhydric alcohol and aliphatic carboxy acid, and monofatty acid esters. When an ester of aliphatic polyhydric alcohol and aliphatic carboxy acid is used as a release agent, any of a monoester, a full ester, and the like can be adopted. For example, those other than full esters, such as a monoester, may be used.
Specific examples of the release agent may include the following substances: namely,
The release agent is preferably comprised in the thermoplastic resin composition in an amount of 1 ppm by weight to 5000 ppm by weight, with respect to the total weight of the resin composition. The content of the release agent in the thermoplastic resin composition is more preferably 50 ppm by weight to 4000 ppm by weight, further preferably 100 ppm by weight to 3500 ppm by weight, particularly preferably 500 ppm by weight to 13000 ppm by weight, and further particularly preferably 1000 ppm by weight to 2500 ppm by weight.
Additives other than the aforementioned antioxidant and release agent may also be added to the thermoplastic resin composition. Examples of the additives that may be comprised in the thermoplastic resin composition may include a compounding agent, a catalyst inactivator, a thermal stabilizer, a plasticizer, a filler, an ultraviolet absorber, a rust inhibitor, a dispersant, an antifoaming agent, a leveling agent, a flame retardant, a lubricant, a dye, a pigment, a bluing agent, a nucleating agent, and a clearing agent.
The content of additives other than the antioxidant and the release agent in the thermoplastic resin composition is preferably 10 ppm by weight to 5.0% by weight, more preferably 100 ppm by weight to 2.0% by weight, and further preferably 1000 ppm by weight to 1.0% by weight, but is not limited thereto.
The aforementioned additives are likely to adversely affect transmittance. Thus, it is preferable not to add such additives excessively, and more preferably, the total additive amount is, for example, within the aforementioned range.
Further, another embodiment of the present invention relates to a thermoplastic resin composition comprising a modifier represented by the following general formula (1) and a thermoplastic resin:
In one embodiment of the present invention, the above-described modifier can be mixed with the thermoplastic resin, so that the mass ratio between the thermoplastic resin and the modifier becomes the thermoplastic resin:the modifier=99.9:0.1 to 70:30. The mass ratio may be preferably 99:1 to 70:30, and more preferably 98:2 to 70:30, and it may be, for example, 99:1, 98:2, 97:3, 96:4, 95:5, 94:6, 93:7, 92:8, 91:9, 90:10, 85:15, 80:20, 75:25, 70:30, or the like. In the present invention, if the mass ratio between the thermoplastic resin and the modifier is within the above-described range, a resin composition having high fluidity and good moldability can be provided.
The thermoplastic resin or the thermoplastic resin composition of the present invention (hereinafter simply abbreviated as a “resin composition”) can be preferably used in an optical member. In one embodiment of the present invention, an optical member comprising the resin composition of the present invention is provided. In one embodiment of the present invention, the optical member may include, but is not limited to, an optical disk, a transparent conductive substrate, an optical card, a sheet, a film, an optical fiber, a lens, a prism, an optical film, a substrate, an optical filter, a hard coat film, and the like. The resin composition of the present invention has high fluidity, and can be molded according to a cast method. Hence, the present resin composition is preferably used, in particular, in production of a thin optical member. In a preferred embodiment of the present invention, the optical member produced using the resin composition of the present invention may be an optical lens. In another preferred embodiment of the present invention, the optical member produced using the resin composition of the present invention may be an optical film.
When an optical member comprising the resin composition of the present invention is produced according to injection molding, the optical member is preferably molded under conditions of a cylinder temperature of 260° C. to 350° C. and a mold temperature of 90° C. to 170° C. The optical member is more preferably molded under conditions of a cylinder temperature of 270° C. to 320° C. and a mold temperature of 100° C. to 160° C. When the cylinder temperature is higher than 350° C., the resin composition is decomposed and colored. On the other hand, when the cylinder temperature is lower than 260° C., the melt viscosity becomes high, and it easily becomes difficult to mold the optical member. Moreover, when the mold temperature is higher than 170° C., it easily becomes difficult to remove a molded piece consisting of the resin composition from a mold. On the other hand, when the mold temperature is lower than 90° C., the resin is hardened too quickly in a mold upon the molding thereof, and it becomes difficult to control the shape of a molded piece, or it easily becomes difficult to sufficiently transcribe a vehicle placed in a mold.
In one embodiment of the present invention, the resin composition can be preferably used in an optical lens. Since the optical lens produced using the resin composition of the present invention has a high refractive index and is excellent in terms of heat resistance, it can be used in fields in which expensive glass lenses having a high refractive index have been conventionally used, such as telescopes, binoculars and TV projectors, and thus, the optical lens produced using the present resin composition is extremely useful.
For instance, regarding a lens used for smart phones, a lens molded from a thermoplastic resin comprising the constituent unit (A) is overlapped with a lens molded from a resin comprising the constituent unit represented by any one of the formulae (II-1) to (II-4) or a resin comprising a constituent unit derived from a monomer represented by any one of the following formulae, so that the lenses can be used as a lens unit:
A lens molded from a resin containing a structural unit derived from any of the monomers of the above formula can be used as a lens unit by being superimposed on each other.
The optical lens of the present invention is preferably used in the shape of an aspherical lens, as necessary. Since the aspherical lens can reduce spherical aberration to substantially zero with a single lens thereof, it is not necessary to eliminate the spherical aberration by a combination of a plurality of spherical lenses, and thereby, it becomes possible to achieve weight saving and a reduction in production costs. Therefore, among the optical lenses, the aspherical lens is particularly useful as a camera lens.
Moreover, since the optical lens of the present invention has high molding fluidity, the present optical lens is particularly useful as a material of a thin and small optical lens having a complicated shape. Regarding the specific size of a lens, the thickness of the central portion is preferably 0.05 to 3.0 mm, more preferably 0.05 to 2.0 mm, and further preferably 0.1 to 2.0 mm. In addition, the diameter is preferably 1.0 mm to 20.0 mm, more preferably 1.0 to 100 mm, and further preferably, 3.0 to 10.0 mm. Further, regarding the shape thereof, the optical lens of the present invention is prefer ably a meniscus lens, in which one surface is a convex, and the other surface is a concave.
The optical lens of the present invention is molded according to any given method such as die molding, cutting, polishing, laser machining, electrical discharge machining, or etching. Among these methods, die molding is more preferable in terms of production costs.
In one embodiment of the present invention, the resin composition can be preferably used in optical films. In particular, since the optical film produced using the polycarbonate resin of the present invention is excellent in terms of transparency and heat resistance, it can be preferably used for films for use in liquid crystal substrates, optical memory cards, etc.
In order to avoid the mixing of foreign matters into the optical lens, the molding environment must be naturally a low-dust environment, and the class is preferably 6 or less, and more preferably 5 or less.
Hereinafter, the examples of the present invention will be shown together with comparative examples, and the contents of the invention will be described in detail. However, the present invention is not limited to these examples.
A polycarbonate resin was molded according to JIS B 7071-2: 2018, to obtain a V block, which was then used as a test piece. The refractive index (nD) was measured at 23° C. using a refractometer (KPR-3000, manufactured by Shimadzu Corporation).
The same test piece (V block) as that used in the measurement of a refractive index was used, and the refractive indexes at wavelengths of 486 nm, 589 nm, and 656 nm were measured at 23° C. using a refractometer. Thereafter, the Abbe number was calculated according to the following equation:
The glass transition temperature (Tg) was measured according to JIS K7121-1987, using a differential scanning calorimeter (X-DSC7000, Hitachi High-Tech Science Corporation) by a temperature-increasing program of 10° C./min.
The weight average molecular weight of a resin was measured by applying gel permeation chromatography (GPC) and then calculating the weight average molecular weight in terms of standard polystyrene. The used apparatus, columns and measurement conditions are as follows.
Raw materials, namely, 7.50 kg (15.04 mol) of (([1,1′-binaphthalene]-2,2′-diylbis(oxy))bis(4,1-phenylene))dimethanol represented by the following structural formula (hereinafter referred to as “BINOL-DBAL”), 6.60 kg (15.04 mol) of 9,9-bis[4-(2-hydroxyethoxy)phenyl]fluorene represented by the following structural formula (hereinafter referred to as “BPEF”), 6.64 kg (30.99 mol) of diphenyl carbonate (hereinafter referred to as “DPC”), and 12 ml (2.5×10−2 mol/L) of an aqueous solution of sodium hydrogen carbonate (3.0×10−4 mol, i.e., 10×10−6 mol with respect to a total of 1 mol of a dihydroxy compound) were placed in a 50-L reactor equipped with a stirrer and a distillation apparatus, and the inside of the reactor was then substituted with nitrogen. Thereafter, the mixture was heated to 205° C. over 1 hour in a nitrogen atmosphere under a pressure of 760 Torr, and was stirred. After the raw materials had been completely dissolved, the pressure reduction degree was adjusted to 150 Torr over 15 minutes, and the reaction mixture was then retained under conditions of 205° C. and 150 Torr for 20 minutes, so as to carry out a transesterification reaction. Further, the temperature was increased to 240° C. at a rate of 37.5° C./hr, and the reaction mixture was then retained at 240° C. under a pressure of 150 Torr for 10 minutes. Thereafter, the pressure reduction degree was adjusted to 120 Torr over 10 minutes, and the reaction mixture was then retained at 240° C. under a pressure of 120 Torr for 70 minutes. Thereafter, the pressure reduction degree was adjusted to 100 Torr over 10 minutes, and the reaction mixture was then retained at 240° C. under a pressure of 100 Torr for 10 minutes. Further, the pressure reduction degree was adjusted to 1 Torr or less over 40 minutes, and a polymerization reaction was then carried out at 240° C. under a pressure of 1 Torr for 10 minutes. After completion of the reaction, nitrogen was introduced into the reaction system in the reactor, followed by pressurization. The generated polycarbonate resin was extracted while pelletizing, so as to obtain a polycarbonate resin. The physical properties of the obtained polycarbonate resin are shown in Table 1 below.
It is to be noted that the monomer represented by the general formula (1), “BINOL-DBAL,” was obtained by the method described in Adv. Synth. Catal. 2004, 346, 195-198.
A polycarbonate resin was obtained in the same manner as that of Example 1, with the exception that 6.00 kg (16.02 mol) of 2,2′-bis(2-hydroxyethoxy)-1,1′-binaphthalene represented by the following structural formula (hereinafter referred to as “BINOL-2EO”), 7.03 kg (16.02 mol) of 9,9-bis[4-(2-hydroxyethoxy)phenyl]fluorene represented by the above structural formula (“BPEF”), 7.07 kg (33.01 mol) of diphenyl carbonate (“DPC”), and 13 ml (2.5×10−2 mol/L) of an aqueous solution of sodium hydrogen carbonate (3.2×10−4 mol, i.e., 10×10−6 mol with respect to a total of 1 mol of a dihydroxy compound) were used as raw materials. The physical properties of the obtained polycarbonate resin are shown in Table 1 below.
The polycarbonate resins of Examples 2 to 6 were obtained in the same manner as that of Example 1, with the exception that the raw materials shown in Table 1 were used in amounts shown in Table 1. The physical properties of the obtained polycarbonate resins are shown in Table 1 below.
Raw materials, namely, 8.33 kg (16.71 mol) of BINOL-DBAL, 2.00 kg (3.71 mol) of 2,2′-(((9H-fluorene-9,9-diyl)bis(naphthalene-6,2-diyl))bis(oxy))bis(ethanol-1-ol) represented by the following structural formula (hereinafter referred to as “NOLE” or “BNEF”), 6.72 kg (16.71 mol) of 1,1′-binaphthalene-2,2′-diylbisoxybisacetic acid represented by the following structural formula (hereinafter referred to as “BINOL-DC”), 0.96 kg (4.47 mol) of DPC, 1.41 g of aluminum(III) acetylacetonate serving as a catalyst (wherein the amount of Al was 7 ppm with respect to the amount of a resin generated), and 1.69 ml of diethyl (4-methylbenzyl)phosphonate (wherein the amount of P was 14 ppm with respect to the amount of a resin generated) were placed in a 50-L reactor equipped with a stirrer and a distillation apparatus, and the inside of the reactor was then substituted with nitrogen. Thereafter, the mixture was heated to 205° C. over 1 hour in a nitrogen atmosphere under a pressure of 760 Torr, and was stirred. After the raw materials had been completely dissolved, the pressure reduction degree was adjusted to 300 Torr over 15 minutes, and the reaction mixture was then retained under conditions of 205° C. and 300 Torr for 90 minutes, so as to carry out a transesterification reaction. Further, the temperature was increased to 240° C. at a rate of 37.5° C./hr, and the reaction mixture was then retained at 240° C. under a pressure of 300 Torr for 10 minutes. Thereafter, the pressure reduction degree was adjusted to 150 Torr over 10 minutes, and the reaction mixture was then retained at 240° C. under a pressure of 150 Torr for 1 hour. Thereafter, the pressure reduction degree was adjusted to 100 Torr over 20 minutes, and the reaction mixture was then retained at 240° C. under a pressure of 100 Torr for 10 minutes. Further, the pressure reduction degree was adjusted to 1 Torr or less over 40 minutes, and a polymerization reaction was then carried out at 240° C. under a pressure of 1 Torr for 10 minutes. After completion of the reaction, nitrogen was blown into the reactor, followed by pressurization. The generated polyester carbonate resin was extracted while pelletizing, so as to obtain a polyester carbonate resin. The physical properties of the obtained polyester carbonate resin are shown in Table 1 below.
The polyester carbonate resin of Example 8 was obtained in the same manner as that of Example 7, with the exception that the raw materials shown in Table 1 were used in amounts shown in Table 1. The physical properties of the obtained polyester carbonate resin are shown in Table 1 below.
From the results shown in Table 1, it is found that, in Examples 1 to 8 in which the monomer represented by the general formula (1) was used, thermoplastic resins, which had a higher glass transition temperature and were more excellent not only in optical properties but also in heat resistance, could be obtained than the thermoplastic resin of Comparative Example 1 in which the aforementioned monomer was not used.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2021-103298 | Jun 2021 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2022/023882 | 6/15/2022 | WO |
