WO2013161843A1 - Light-diffusing resin composition and part molded using same - Google Patents
Light-diffusing resin composition and part molded using same Download PDFInfo
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- WO2013161843A1 WO2013161843A1 PCT/JP2013/061976 JP2013061976W WO2013161843A1 WO 2013161843 A1 WO2013161843 A1 WO 2013161843A1 JP 2013061976 W JP2013061976 W JP 2013061976W WO 2013161843 A1 WO2013161843 A1 WO 2013161843A1
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- fine particles
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- light diffusing
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/02—Diffusing elements; Afocal elements
- G02B5/0273—Diffusing elements; Afocal elements characterized by the use
- G02B5/0278—Diffusing elements; Afocal elements characterized by the use used in transmission
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L69/00—Compositions of polycarbonates; Compositions of derivatives of polycarbonates
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/02—Diffusing elements; Afocal elements
- G02B5/0205—Diffusing elements; Afocal elements characterised by the diffusing properties
- G02B5/0236—Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place within the volume of the element
- G02B5/0242—Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place within the volume of the element by means of dispersed particles
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/22—Mixtures comprising a continuous polymer matrix in which are dispersed crosslinked particles of another polymer
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
- F21V3/00—Globes; Bowls; Cover glasses
- F21V3/04—Globes; Bowls; Cover glasses characterised by materials, surface treatments or coatings
- F21V3/06—Globes; Bowls; Cover glasses characterised by materials, surface treatments or coatings characterised by the material
- F21V3/062—Globes; Bowls; Cover glasses characterised by materials, surface treatments or coatings characterised by the material the material being plastics
- F21V3/0625—Globes; Bowls; Cover glasses characterised by materials, surface treatments or coatings characterised by the material the material being plastics the material diffusing light, e.g. translucent plastics
Definitions
- the present invention relates to a light diffusing resin composition and a molded product thereof. More specifically, the present invention relates to a light diffusing resin composition that exhibits good light diffusibility and diffusion efficiency, and is excellent in heat resistance, impact resistance, and flame retardancy, and a molded product thereof.
- a diffusion plate in which a light diffusing agent is dispersed in a matrix made of a transparent resin such as polymethyl methacrylate, polystyrene, and polycarbonate in order to uniformly diffuse light from a light source. It is used.
- a transparent resin such as polymethyl methacrylate, polystyrene, and polycarbonate
- inorganic particles such as crystalline silica, amorphous silica, calcium carbonate, barium sulfate, aluminum hydroxide, and titanium oxide, or inorganic fibers such as glass fibers have been used as the light diffusing agent.
- Patent Document 1 discloses a light diffusing plate using polymer particles having an average particle size of 3 to 20 ⁇ m and a narrow particle size distribution with a CV value of 20% or less as a light diffusing agent.
- Patent Document 2 discloses that the average particle diameter is 0.6 to 1.5 ⁇ m, the standard deviation of the particle diameter is 0.01 ⁇ m to 0.5 ⁇ m, and the styrene monomer / methacrylic acid copolymer and A light diffusing plate containing a diffusing agent having an absolute value of the refractive index difference of 0.05 or more is disclosed.
- Patent Document 3 discloses a composition in which acrylic resin-based fine particles having an average particle size of 1 to 4 ⁇ m as a light diffusing agent and having a specific particle size distribution are dispersed in a polycarbonate resin.
- Patent Document 4 discloses a composition containing crosslinked polymer fine particles having a refractive index different from that of polycarbonate resin and having an average particle diameter in the range of 0.5 to 100 ⁇ m.
- Patent Document 5 discloses a composition in which polymer fine particles having a refractive index in the range of 1.495 to 1.504 are dispersed in a polycarbonate resin.
- Patent Document 6 discloses a composition containing crosslinked resin fine particles comprising a specific (meth) acrylate ester resin having a volume average particle size of 0.7 to 2.5 ⁇ m and a narrow particle size distribution. Has been.
- a cover for a lighting fixture there is a demand for a molding material that exhibits good light diffusibility in a wide range of total light transmittance.
- a molding material containing a light diffusing agent that can achieve a target light diffusibility (dispersion degree) with a small amount of addition.
- the light diffusibility of a resin composition in which a light diffusing agent particle is blended with a transparent resin and a molded product made from the resin composition are the refractive index difference between the resin and the light diffusing agent particle, the particle size of the light diffusing agent particle, and the light diffusing agent particle.
- the refractive index difference between the resin and the light diffusing agent particle is larger, and the particle size of the light diffusing agent particle is larger, the light from one light diffusing agent particle is known.
- the diffusion coefficient increases. However, if the particle size of the light diffusing agent particles is large, the mass of the light diffusing agent particles becomes large.
- the mass ratio of the light diffusing agent particles in the resin is constant, the large particles contained in the resin The number of light diffusing agent particles having a smaller diameter is reduced, and the overall light diffusibility based on the product of the light diffusion coefficient of each light diffusing agent particle and the number of light diffusing agent particles contained in the resin is not necessarily high. Don't be.
- the particle size of the light diffusing agent particles contained in the transparent resin is too small, the light diffusion coefficient decreases exponentially, so that sufficient light diffusibility cannot be obtained.
- the degree of dispersion tends to decrease, but a material exhibiting a high degree of dispersion in a wide range of total light transmittance is preferable, and the light diffusing agent has a total light transmittance of, for example, There is a demand for performance that shows a high degree of dispersion even in a high region of 85% and that can be used in a wide range of total light transmittance.
- the difference between the refractive index of the transparent resin and the refractive index of the light diffusing agent particles becomes too large, the amount of reflected light from the molded body increases. Then, the total light transmittance is reduced, and for example, sufficient brightness cannot be obtained in a light diffusing plate of a display, a transmissive screen, a cover of a lighting fixture, an electric signboard, and the like. Furthermore, since the light diffusing plate may be molded under a high temperature condition exceeding 300 ° C., the light diffusing agent has excellent heat resistance such that decomposition or the like hardly occurs even under a high temperature condition. Is also required.
- Patent Document 1 Japanese Patent Document 1
- Patent Document 2 shows good light diffusibility with a relatively small amount of light diffusing agent, but the light diffusibility in a region where the total light transmittance is 70% or more is not sufficient. For this reason, it cannot be used for applications that require high light transmission, such as covers for lighting fixtures.
- the light diffusing agents described in Patent Documents 3 to 5 need to be added in an amount in order to obtain good light diffusibility in a region where the total light transmittance is less than 80%. There was a problem from the aspect.
- Patent Document 6 although it is possible to express good light diffusibility in a wide range of total light transmittance with a small amount of light diffusing agent, there is room for improvement in terms of heat resistance.
- An object of the present invention is to provide a light diffusing resin composition that exhibits high dispersion in a wide range of total light transmittance, has excellent light diffusibility, and has excellent heat resistance, impact resistance, and flame retardancy, and a molded product thereof. It is to be.
- the present inventors have used light-diffusing properties, heat resistance, impact resistance by using crosslinked resin fine particles having a specific particle size, particle size distribution, refractive index and the like as a light diffusing agent. It has been found that a light diffusing resin composition having excellent properties and the like can be obtained.
- the present invention is as follows. 1. An absolute value of a difference between the refractive index of the transparent resin (X) and the refractive index of the crosslinked resin fine particles (Y) (hereinafter referred to as “ ⁇ n”) including the transparent resin (X) and the crosslinked resin fine particles (Y). 0.095 to 0.115, the volume average particle diameter of the crosslinked resin fine particles (Y) is 1.5 to 3.3 ⁇ m, and the coefficient of variation of the particle diameter of the crosslinked resin fine particles (Y) is 20%.
- the cross-linked resin fine particles (Y) are characterized in that the temperature at which the mass is halved is 320 ° C. or higher when pyrolyzed in a nitrogen gas atmosphere at a temperature rising rate of 10 ° C./min.
- a light diffusing resin composition 2. 2. The light diffusing resin composition as described in 1 above, wherein the crosslinked resin fine particles (Y) contain a structural unit derived from a (meth) acrylic acid ester. 3. A sheet of 1.5 mm thickness produced using the light diffusing resin composition, which has a total light transmittance of 85% for white light, is irradiated with light in a vertical direction using a goniometer. 3. The light diffusing resin composition according to 1 or 2 above, wherein an angle at which the emitted light having a luminance of 50% with respect to the emitted light at 0 degree is 20 degrees or more when the incident light is incident. 4).
- the light diffusing resin composition of the present invention exhibits a high degree of dispersion in a wide range of total light transmittance and is excellent in light diffusibility. Moreover, the light diffusable resin composition of this invention is excellent also in heat resistance, impact resistance, and a flame retardance.
- the light diffusing resin composition of the present invention comprises crosslinked resin fine particles (Y) having a specific particle size, particle size distribution, refractive index, composition and the like as a light diffusing agent, and a transparent resin (X).
- the present invention relates to a light diffusing resin composition that exhibits good light diffusivity and diffusion efficiency and is excellent in heat resistance and the like, and a molded body using the same.
- the crosslinked resin fine particles (Y) have an action as a light diffusing agent.
- the transparent resin (X) according to the present invention is not particularly limited, and examples thereof include acrylic resins such as polymethyl methacrylate (PMMA), styrene resins such as polystyrene and styrene / methacrylic acid copolymers, Polycarbonate resin etc. are mentioned. Of these, styrene resins are preferred when importance is placed on cost, but polycarbonate resins are preferred when impact resistance and flame retardancy are required.
- acrylic resins such as polymethyl methacrylate (PMMA)
- styrene resins such as polystyrene and styrene / methacrylic acid copolymers
- Polycarbonate resin etc. are mentioned.
- styrene resins are preferred when importance is placed on cost, but polycarbonate resins are preferred when impact resistance and flame retardancy are required.
- the content ratio of the structural unit derived from the styrenic monomer from the viewpoint of the melt fluidity, moldability, heat resistance, moisture absorption resistance, refractive index, etc. of the composition is styrene resin. It is preferable to use a resin that is 80% by mass or more with respect to a total amount of 100% by mass of all the structural units to be configured. More preferred is 90% by mass or more, and particularly preferred is 95 to 100% by mass.
- styrene monomer forming the styrene resin examples include styrene, ⁇ -methyl styrene, p-methyl styrene, o-methyl styrene, m-methyl styrene, vinyl toluene, p-ethyl styrene, p-tert.
- the styrenic resin may contain only one type of structural unit derived from these styrenic monomers, or may contain two or more types. Of these, styrene is preferable from the viewpoint of availability of styrene-based resin, cost, polymerizability, and the like.
- the styrenic resin may be either a homopolymer or a copolymer. In the latter case, a copolymer obtained by copolymerizing a monomer containing a styrene monomer and methacrylic acid can be used.
- the content of the styrene monomer unit constituting the copolymer is preferably 80 to 95 mol%, more preferably 85 to 95 mol% from the viewpoint of heat resistance.
- the copolymer may contain a structural unit derived from another monomer copolymerizable with these, in addition to the styrene monomer and methacrylic acid.
- Other monomers include methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, cyclohexyl (meth) acrylate, (meth) acrylic acid (Meth) acrylic acid esters such as benzyl and 2-hydroxyethyl (meth) acrylate; acrylic acid, maleic anhydride, (meth) acrylonitrile and the like.
- Other monomers can be used alone or in combination of two or more.
- the molecular weight of the styrene resin is not particularly limited.
- the weight average molecular weight (Mw) in terms of polystyrene measured by gel permeation chromatography (GPC) is 50,000 to 1 in terms of the moldability of the composition, particularly melt moldability, and the strength of the resulting molded product. It is preferably 1,000,000, more preferably 100,000 to 500,000.
- the molecular weight distribution (Mw / Mn) of the styrenic resin is preferably 1.5 to 3.5 from the viewpoint of the strength of the obtained molded article.
- polycarbonate resin examples include aromatic polycarbonate resin, aliphatic polycarbonate resin, and aromatic-aliphatic copolymer polycarbonate resin.
- An aromatic polycarbonate resin is often used for the light diffusing resin composition. Specifically, it is an aromatic polycarbonate resin obtained by a reaction between a divalent phenol compound and phosgene or diphenyl carbonate.
- divalent phenol examples include 2,2- (4-hydroxyphenyl) propane (bisphenol A), 2,2- (4-hydroxyphenyl) butane, and 2,2- (4-hydroxyphenyl).
- examples include pentane, 4,4′-biphenol, hydroquinone, resorcinol and the like.
- 2,2- (4-hydroxyphenyl) propane (bisphenol A) is preferred because of its good impact resistance and the like.
- the polycarbonate resin may be a polycarbonate resin obtained by any method of interfacial polymerization and melt transesterification.
- the viscosity average molecular weight of the polycarbonate resin is not particularly limited, but is preferably 1 ⁇ 10 4 to 1 ⁇ 10 5 , more preferably 1.3 ⁇ 10 4 to from the viewpoint of mechanical properties and fluidity during injection molding. 3 ⁇ 10 4 .
- Polycarbonate resin is excellent in transparency, impact resistance, heat resistance, flame retardancy, etc., and is relatively inexpensive for its performance, so it is widely used in optical applications such as lighting equipment and displays. . Accordingly, the transparent resin (X) according to the present invention is particularly preferable.
- the cross-linked resin fine particles (Y) are not limited as long as they are fine particles made of a resin having a cross-linked structure. Since the selectivity of the monomer to be used is high and the refractive index can be easily adjusted, the fine particles are composed of a (meth) acrylate crosslinked resin containing a structural unit derived from (meth) acrylate. preferable.
- the crosslinked structure contained in the fine particles can be based on cleavage by polymerization of a polyfunctional polymerizable unsaturated compound containing a plurality of carbon-carbon double bonds, or can be based on a siloxane bond.
- the content ratio of the structural unit derived from the (meth) acrylic acid ester constituting the (meth) acrylic acid ester-based crosslinked resin is preferably 50% by mass or more, more preferably 80% by mass or more, and further preferably 90% by mass. % Or more, particularly preferably 95 to 100% by mass.
- the refractive index of the crosslinked resin fine particles (Y) is easily adjusted to the range of 1.460 to 1.510. This is preferable because it can be performed.
- the method for producing the crosslinked resin fine particles (Y) used in the present invention is not particularly limited, but the following methods can be exemplified.
- the crosslinked resin fine particles obtained by the above methods (i) and (ii) may be used alone or in combination.
- the method for producing (meth) acrylic ester-based crosslinked resin fine particles is generally suspension polymerization, but in the case of suspension polymerization, it is necessary to produce crosslinked resin fine particles having a narrow particle size distribution and uniform size. Is generally difficult.
- crosslinked resin fine particles having a narrow particle size distribution and a uniform size can be produced smoothly by polymerization in an alcohol solvent, particularly a mixed solvent of alcohol and water. Further, the particle size and particle size distribution can be controlled by adjusting the ratio of alcohol and water. From this point, in the present invention, the above methods (i) and (ii) are preferably used.
- the seed particle is preferably a (meth) acrylic acid ester resin and is produced by subjecting the vinyl monomer (m1) to dispersion polymerization in a water / alcohol polar solvent. can do.
- a carboxyl group-containing macromonomer is used as a dispersion stabilizer, dispersion polymerization proceeds more smoothly.
- the carboxyl group-containing macromonomer is not particularly limited as long as it has a radical polymerizable unsaturated bond at the molecular end or side chain. Examples of the radical polymerizable unsaturated bond include a terminal vinylidene group, a terminal (meth) acryloyl group, a side chain (meth) acryloyl group, and a terminal styryl group.
- Examples of the vinyl monomer (m1) forming the seed particles include (meth) acrylic acid esters and aromatic vinyl compounds. Specific monomers include methyl (meth) acrylate, (meta ) Ethyl acrylate, propyl (meth) acrylate, n-butyl (meth) acrylate, isobutyl (meth) acrylate, tert-butyl (meth) acrylate, pentyl (meth) acrylate, (meth) acrylic acid 2 -Alkyl esters of (meth) acrylic acid such as ethylhexyl, lauryl (meth) acrylate and stearyl (meth) acrylate; alicyclics of (meth) acrylic acid such as cyclohexyl (meth) acrylate and isobornyl (meth) acrylate Group-containing ester; (meth) such as glycidyl (meth) acrylate and tetrahydrofurfuryl
- Examples include hydroxyalkyl esters of (meth) acrylic acid; alkoxyalkyl esters of (meth) acrylic acid such as 2-methoxyethyl (meth) acrylate. These compounds may be used alone or in combination of two or more.
- the vinyl monomer (m1) preferably contains a (meth) acrylic acid ester, and methyl methacrylate and isobutyl methacrylate are particularly preferable.
- the amount of the (meth) acrylic acid ester used for the formation of the seed particles is preferably 50 to 100% by mass, more preferably 80 to 100% by mass, based on the total mass of the vinyl monomer (m1). It is.
- the seed particles are preferably 60% by mass or more, more preferably 65% by mass or more, and particularly preferably 70 to 100% by mass based on 100% by mass of the total amount of structural units constituting the seed particles. It is preferable from the point of the heat-resistant blocking property of a particle
- the macromonomer When producing the seed particles, the macromonomer is used in an amount of preferably 0.5 to 50 parts by mass, more preferably 1.0 to 20 parts by mass with respect to 100 parts by mass of the vinyl monomer (m1). Part.
- the weight average molecular weight (Mw) of the seed particles is preferably 1,000 to 2,000,000 in terms of polystyrene measured by gel permeation chromatography (GPC), preferably 5,000 to 1,000. 1,000 is more preferable.
- the vinyl monomer (m2) to be polymerized after being absorbed in the seed particles obtained by dispersion polymerization contains a polyfunctional vinyl monomer in order to form the crosslinked resin fine particles (Y).
- a polyfunctional (meth) acrylate compound excellent in polymerizability is preferably used. Specific examples include ethylene glycol di (meth) acrylate, propylene glycol di (meth) acrylate, 1,6-hexanediol di (meth) acrylate, polyethylene glycol di (meth) acrylate, polypropylene glycol di (meth) acrylate and the like.
- Di (meth) acrylate of dihydric alcohol trimethylolpropane tri (meth) acrylate, trimethylolpropane ethylene oxide modified tri (meth) acrylate, glycerol tri (meth) acrylate, pentaerythritol tri (meth) acrylate, pentaerythritol Examples include tri (meth) acrylates of trihydric or higher polyhydric alcohols such as tetra (meth) acrylate and poly (meth) acrylates such as tetra (meth) acrylate. Only 1 type may be used for a polyfunctional (meth) acrylate compound, and 2 or more types can be used for it.
- ethylene glycol di (meth) acrylate and trimethylolpropane tri (meth) acrylate can be easily absorbed into seed particles made of (meth) acrylic ester resin, and can increase the crosslinking density. It is preferably used in terms of being possible and excellent in polymerization stability.
- the vinyl monomer (m2) to be absorbed and polymerized in the seed particles contains a monofunctional vinyl monomer together with the polyfunctional vinyl monomer described above. This is preferable because the polymerization stability is advantageous.
- This monofunctional vinyl monomer is a monomer that is the same as or similar to the monomer such as (meth) acrylic acid ester constituting the seed particle, for example, methyl methacrylate and isobutyl methacrylate. Is preferred.
- the refractive resin is more refracted.
- a monofunctional vinyl monomer that forms a polymer having a low rate and for example, isobutyl methacrylate, tert-butyl methacrylate and the like are preferably used.
- the ratio of the preferred amount of seed particles and vinyl monomer (m2) used in the production of the crosslinked resin fine particles (Y) is not particularly limited, but the crosslinking structure is imparted to the particles and the monomer is absorbed into the seed particles. From the point of view, it is shown below.
- the vinyl monomer (m2) is preferably 0.5 to 10 parts by mass and more preferably 0.7 to 5 parts by mass with respect to 1 part by mass of the seed particles.
- the amount of the polyfunctional vinyl monomer used is preferably 3 to 95% by mass, particularly preferably 5 to 75% by mass, based on the total mass of the vinyl monomer (m2).
- the resin fine particles having a hydrolyzable silyl group are subjected to dispersion polymerization using a vinyl monomer having a hydrolyzable silyl group and (meth) acrylic acid ester or the like. It is preferable that it is the fine particle obtained by performing.
- the hydrolyzable silyl group means a functional group that can be crosslinked by forming a siloxane bond by hydrolysis condensation reaction, and includes methoxysilane, ethoxysilane, and the like.
- Any vinyl compound having at least one hydrolyzable silyl group can be used as the vinyl monomer having a hydrolyzable silyl group.
- vinyl silane such as vinyltrimethoxysilane, vinyltriethoxysilane, vinylmethyldimethoxysilane, vinyldimethylmethoxysilane, etc .
- the vinyl monomer having a hydrolyzable silyl group a hydrolyzable silyl group-containing acrylate ester and a hydrolyzable silyl group-containing methacrylate ester are preferable. These monomers are preferable because they are excellent in copolymerizability with (meth) acrylic acid esters and the like, and fine particles excellent in heat resistance and weather resistance are obtained.
- trimethoxysilylpropyl methacrylate also known as trimethoxysilylpropyl methacrylate
- the amount of vinyl monomer having a hydrolyzable silyl group is generally based on the total mass of monomers (including macromonomers) used for the production of resin fine particles having hydrolyzable silyl groups. Thus, it is preferably 2 to 50% by mass, particularly 5 to 30% by mass.
- Examples of monomers other than vinyl monomers having hydrolyzable silyl groups used in the production of resin fine particles having hydrolyzable silyl groups include (meth) acrylic acid esters. The monomer is as described above.
- a macromonomer type dispersion stabilizer having a (meth) acryloyl group it is preferable to use a macromonomer type dispersion stabilizer having a (meth) acryloyl group.
- a macromonomer type dispersion stabilizer having a (meth) acryloyl group a (meth) acrylic acid ester system having a target particle size and a hydrolyzable silyl group having a narrow particle size distribution with a small amount of use. Resin fine particles can be obtained smoothly.
- the macromonomer type dispersion stabilizer more preferably has a carboxyl group.
- the (meth) acryloyl group may be bonded to any position of the end of the polymer chain and the side chain.
- a macromonomer type dispersion stabilizer with a (meth) acryloyl group bonded to the side chain stably produces (meth) acrylic ester resin fine particles having the desired hydrolyzable silyl group with a smaller amount of use. It is preferable from the point which can be performed.
- a carboxyl group-containing prepolymer is synthesized by emulsion polymerization, and then the carboxyl group of this prepolymer, A method of reacting with an epoxy group in an epoxy group-containing (meth) acrylate such as glycidyl (meth) acrylate to give a (meth) acryloyl group can be mentioned. At this time, a part of the carboxyl group of the prepolymer may remain. With this method, a high-performance macromonomer can be easily produced. In the case of using an epoxy group-containing (meth) acrylate, it is preferable to add 0.6 to 2.0 per polymer chain, whereby fine particles having a narrower particle size distribution and a uniform particle size can be produced. .
- the polystyrene equivalent weight average molecular weight (Mw) of the macromonomer measured by gel permeation chromatography (GPC) is preferably 500 to 50,000, more preferably 1,000 to 10,000.
- the macromonomer type dispersion stabilizer having a (meth) acryloyl group and a carboxyl group used for the production of resin fine particles having a hydrolyzable silyl group is preferably neutralized. This makes it possible to stably produce resin fine particles having hydrolyzable silyl groups due to the electrostatic repulsion effect of the neutralized carboxy anion.
- the amount of alkali used for neutralization is preferably not more than twice the equivalent of the carboxyl group. If it exceeds 2 equivalents, the alkalinity of the reaction solution becomes strong, and a hydrolyzable silyl group may react during polymerization to cause aggregation.
- Examples of the alkali for neutralization include ammonia and triethylamine. Among these, ammonia that can be easily removed is preferably used.
- a known polymerization initiator used in dispersion polymerization can be used.
- Specific examples include benzoyl peroxide, lauroyl peroxide, orthochlorobenzoyl peroxide, orthomethoxybenzoyl peroxide, 3,5,5-trimethylhexanoyl peroxide, tert-butylperoxy-2-ethylhexanoate , Organic peroxides such as di-tert-butyl peroxide, di-tert-hexyl peroxide, di-tert-amyl peroxide, tert-butyl peroxypivalate; azobisisobutyronitrile, azobiscyclohexa Examples thereof include azo compounds such as carbonitrile and azobis (2,4-dimethylvaleronitrile); persulfate compounds such as potassium persulfate.
- the hydrolyzable silyl groups in the (meth) acrylic acid ester resin fine particles having hydrolyzable silyl groups obtained above are subjected to a crosslinking reaction to produce crosslinked resin fine particles (Y).
- the cross-linking reaction can be performed by adding a cross-linking catalyst to a dispersion containing (meth) acrylic ester resin fine particles having a hydrolyzable silyl group.
- a hydrolyzable silyl group can be subjected to a condensation reaction to form a siloxane bond.
- an alkaline material is preferable, and in particular, ammonia that can be easily removed after the crosslinking reaction or a low-boiling amine is preferably used.
- the amount of the alkali material used is preferably 3 times equivalent or more and 6 times equivalent or more with respect to the silyl group in the resin fine particles having a hydrolyzable silyl group from the viewpoint of increasing the degree of silyl crosslinking. More preferred.
- the method (ii) for carrying out the crosslinking reaction after obtaining the resin fine particles having hydrolyzable silyl groups by dispersion polymerization It is preferable because it can be produced simply and at low cost.
- the light diffusable resin composition of this invention can contain an additive so that it may mention later.
- the crosslinked resin fine particles (Y) may be particles containing an antioxidant, a light stabilizer and the like.
- a light diffusing resin composition containing these additives is a preferable embodiment because it is particularly excellent in heat decomposition stability and weather resistance.
- the antioxidant include phosphorus antioxidants, phenolic antioxidants, sulfur antioxidants, and the like. Of these, examples of phosphorus antioxidants include phosphite compounds.
- phosphite compound examples include triphenyl phosphite, trisnonylphenyl phosphite, tris (2,4-di-tert-butylphenyl) phosphite, tris [2-tert-4- (3-tert- 4-hydroxy-5-methylphenylthio) -5-methylphenyl] phosphite, trioctyl phosphite, tridecyl phosphite, trioctadecyl phosphite, octyl diphenyl phosphite, di (decyl) monophenyl phosphite, dioctyl mono Phenyl phosphite, diisopropyl monophenyl phosphite, di (tridecyl) pentaerythritol diphosphite, distearyl pentaerythritol diphosphite, mono
- phenolic antioxidant examples include n-octadecyl- ⁇ - (4′-hydroxy-3 ′, 5′-di-tert-butylphenyl) propionate, tetrakis [methylene-3- (3-tert-butyl- 4-hydroxy-5-methylphenyl) propionate] methane, octadecyl-3- (3,5-di-tert-butyl-4-hydroxyphenyl) propionate, 2-tert-butyl-6- (3′-tert-butyl -5′-methyl-2′-hydroxybenzyl) -4-methylphenyl acrylate, 2,6-di-tert-butyl-4- (N, N-dimethylaminomethyl) phenol, 3,5-di-tert- Butyl-4-hydroxybenzylphosphonate diethyl ester, 2,2′-methylenebis (4-methyl-6) tert-butylphenol), 2,2'-methylenebis (4-ethyl
- sulfur-based antioxidants examples include pentaerythritol tetrakis (3-mercaptopropionate), pentaerythritol tetrakis (3-laurylthiopropionate), and glycerol-3-stearylthiopropionate. .
- the said antioxidant can be used 1 type or in combination of 2 or more types.
- Examples of the light stabilizer include bis (2,2,6,6-tetramethyl-4-piperidyl) sebacate, bis (1,2,2,6,6-pentamethyl-4-piperidyl) sebacate, tetrakis (2 , 2,6,6-tetramethyl-4-piperidyl) -1,2,3,4-butanetetracarboxylate, tetrakis (1,2,2,6,6-pentamethyl-4-piperidyl) -1,2 , 3,4-Butanetetracarboxylate, poly ⁇ [6- (1,1,3,3-tetramethylbutyl) amino-1,3,5-triazine-2,4-diyl] [(2,2, 6,6-tetramethylpiperidyl) imino] hexamethylene [(2,2,6,6-tetramethylpiperidyl) imino] ⁇ , polymethylpropyl 3-oxy- [4- (2,2,6,6-tetra Methyl) piperi Sulfony
- the volume average particle diameter (dv) of the crosslinked resin fine particles (Y) according to the present invention is 1.5 to 3.3 ⁇ m, preferably 1.8 to 2.8 ⁇ m, more preferably 2.1 to 2.5 ⁇ m. It is.
- the volume average particle diameter (dv) is less than 1.5 ⁇ m, the ratio of diffuse light per particle decreases, so the ratio of regular transmitted light that does not diffuse increases, and the total light transmittance is high. This is not preferable because the diffusibility (dispersion degree) decreases.
- the volume average particle diameter (dv) exceeds 3.3 ⁇ m, the number of particles at the same mass decreases, and the amount added to obtain the same total light transmittance increases, which is not preferable.
- fine-particles (Y) are large, since diffused transmission light increases more straightness, it is not preferable.
- the coefficient of variation (CV) is 20% or less, preferably 10% or less.
- the degree of dispersion in the high transmittance region tends to decrease.
- the coefficient of variation (CV) can be used as an index representing the spread of the particle size distribution. The smaller the coefficient of variation (CV), the narrower the particle size distribution. If it is 20% or less, it can be said that the distribution width is very narrow.
- the coefficient of variation (CV) is 0, but about 2% is considered to be the lower limit as what is actually obtained.
- volume average particle diameter (dv) and coefficient of variation (CV) of the crosslinked resin fine particles (Y) in the present specification are measured or measured using a laser diffraction scattering type particle size distribution meter and a scanning electron microscope, respectively. It is calculated and its detailed method is as described in the examples described later.
- the temperature at which the mass becomes half that is, 50% by weight.
- the temperature reduction (Td 50 ) is 320 ° C. or higher, preferably 350 ° C. or higher.
- the upper limit temperature is 400 ° C. for general acrylic fine particles.
- Td 50 can be measured, for example, using a thermogravimetric / differential thermal analyzer.
- methacrylic polymers are known to have a higher decomposition rate when heated compared to other polymer materials, and the Td 50 of crosslinked resin fine particles consisting only of methacrylic monomers is low.
- the copolymerization of acrylic monomer, styrene monomer, etc. by about several mass% reduces the decomposition rate at the time of heating, so that the value of Td 50 can be increased.
- the light diffusing resin composition of the present invention includes the transparent resin (X) and the crosslinked resin fine particles (Y), and the refractive index of the transparent resin (X) and the refractive index of the crosslinked resin fine particles (Y)
- the absolute value ( ⁇ n) of the difference is 0.095 to 0.115, preferably 0.100 to 0.110.
- the amount of the light diffusing agent added is too small, it is not preferable because the regular transmitted light that does not hit the particles in the resin composition and is transmitted increases and the diffuse transmitted light decreases. In such a case, the degree of dispersion tends to decrease in a region where the total light transmittance is high. If ⁇ n exceeds 0.115, these problems may occur. On the other hand, when ⁇ n is less than 0.095, the ratio of the diffused light per particle is reduced, so that it is necessary to increase the amount of the light diffusing agent, which is not preferable.
- the content ratio of the transparent resin (X) and the crosslinked resin fine particles (Y) in the light diffusing resin composition of the present invention is shown.
- the content of the crosslinked resin fine particles (Y) is preferably 0.1 to 2.0 parts by mass, more preferably 0.3 to 1.5 parts by mass, and still more preferably 100 parts by mass of the transparent resin (X). Is 0.3 to 1.0 part by mass.
- the content of the crosslinked resin fine particles (Y) exceeds 2.0 parts by mass, impact resistance and flame retardancy tend to be lowered.
- it is less than 0.1 parts by mass the light diffusibility tends to be insufficient.
- the light diffusing resin composition of the present invention may contain fine particles other than the crosslinked resin fine particles (Y) (hereinafter referred to as “other fine particles”) as necessary.
- the light diffusibility can be finely adjusted by including other fine particles.
- the other fine particles include cross-linked (meth) acrylate-based fine particles, cross-linked polystyrene-based fine particles, cross-linked polyorganosiloxane-based fine particles, and silica fine particles. These other fine particles may be used alone or in combination of two or more.
- the light diffusing resin composition of the present invention can contain additives as long as the object of the present invention is not impaired.
- additives include light stabilizers, ultraviolet absorbers, antioxidants, antistatic agents, lubricants, flame retardants, colorants (dyes, pigments), fluorescent brighteners, selective wavelength absorbers, plasticizers, and the like. Can do.
- the antioxidant and the light stabilizer the compounds described above that can be added to the crosslinked resin fine particles (Y) can be used.
- the light diffusing resin composition of the present invention can be produced by melt-kneading a raw material containing transparent resin (X) and crosslinked resin fine particles (Y).
- the production apparatus include a melt extruder, a kneader, a mill, and the like.
- the temperature is equal to or higher than the melting temperature of the transparent resin (X) and lower than the thermal decomposition temperature of the transparent resin (X) and the crosslinked resin fine particles (Y). Melt and knead.
- the whole amount of the transparent resin (X) and the whole amount of the crosslinked resin fine particles (Y) can be used. Further, a master batch having a high content ratio of the crosslinked resin fine particles (Y) is prepared in advance using a part of the transparent resin (X) and the total amount of the crosslinked resin fine particles (Y). The batch and the remaining transparent resin (X) may be kneaded.
- the preferred light diffusibility of the light diffusing resin composition of the present invention is shown below.
- the angle (hereinafter referred to as “dispersion degree (I)”) at which the emitted light has a luminance of 50% with respect to the emitted light at 0 degree is preferably 20 degrees or more, more preferably 23 degrees. That's it.
- the light diffusing resin composition of the present invention is also suitable as a molding material for members such as displays and lighting fixtures.
- the degree of dispersion is adjusted by balancing the difference in refractive index ( ⁇ n) between the transparent resin (X) and the crosslinked resin fine particles (Y), the particle diameter of the crosslinked resin fine particles (Y), the particle size distribution, and the amount added. Is done.
- the angle (hereinafter referred to as “dispersion degree (II)”) at which the emitted light has a luminance of 50% with respect to the emitted light at 0 degree when the light is incident on the surface in the vertical direction using a goniometer is preferable. Is 22 degrees or more, more preferably 23 degrees or more. If the degree of dispersion (II) is 22 degrees or more, it is preferable because light diffusion is excellent.
- a goniometer (variable photometer) was used to irradiate parallel light in the thickness direction perpendicular to one surface of a 1.5 mm thick sheet. It is obtained by measuring the light distribution of transmitted light on the other surface side.
- B ⁇ I ⁇ / cos ⁇ (1)
- the method for forming the sheet is not particularly limited, and can be obtained, for example, by subjecting the light diffusing resin composition to compression molding using a compression molding machine or the like. Moreover, since the value obtained by dispersion
- a molded article can be produced by various molding methods conventionally employed for molding resin compositions such as polycarbonate resins.
- the molding method for producing the molded body is appropriately selected according to the purpose of use and application, and is not particularly limited.
- extrusion molding, injection molding, compression molding, extrusion blow molding, injection blow molding, flow Examples include melt molding such as rolling, calendar molding, and casting.
- the molded body obtained by melt molding may be subjected to secondary molding processing such as bending, vacuum molding, blow molding, press molding, or the like, if necessary, to obtain a target molded body.
- secondary molding processing such as bending, vacuum molding, blow molding, press molding, or the like, if necessary, to obtain a target molded body.
- a processing method in which a lens shape and an embossed shape are formed on the surface of the molded body can be performed according to the purpose of use and application to adjust the optical characteristics.
- the molded body comprising the light diffusing resin composition of the present invention can be effectively used for optical applications such as a light diffusing plate, a Fresnel lens, a lenticular lens, a lighting fixture, and an electric signboard in a liquid crystal display device.
- the polymer is dissolved in tetrahydrofuran (THF) to prepare a 0.2% concentration solution, and 100 ⁇ L of the solution is injected into the column.
- THF tetrahydrofuran
- the eluent is THF
- the column temperature is 40 ° C.
- the eluent (THF) flow rate is 1. Measurement was performed at 0 mL / min.
- volume average particle diameter (dv) Methanol was added to the slurry containing the crosslinked resin fine particles obtained in Production Examples 1 to 13 shown in Table 1 to adjust the concentration of the fine particles to 5%, and the mixture was sufficiently shaken and dispersed uniformly.
- the dispersion was irradiated with ultrasonic waves for 10 minutes, and then particle size distribution measurement was performed using a laser diffraction scattering type particle size distribution analyzer “MT-3000” manufactured by Nikkiso Co., Ltd. Ion exchange water or acetone was used as a circulating dispersion medium at the time of measurement.
- the crosslinked resin fine particles of the commercial products 1 to 3 were put into acetone so that the concentration of the dry powder was 5%, and were sufficiently shaken to be uniformly dispersed. This dispersion was irradiated with ultrasonic waves for 10 minutes, and then particle size distribution measurement was performed. The median diameter ( ⁇ m) was calculated from the volume-based particle size distribution obtained by the particle size distribution measurement, and was defined as the volume average particle size (dv).
- the number average particle diameter (dn) for obtaining the coefficient of variation (CV) and the standard deviation ( ⁇ ) is the particle diameter (di) obtained by the SEM observation and the number of particles having the particle diameter (Ni). It was calculated from the following formula (4).
- dn ( ⁇ Nidi / ⁇ Ni) (4)
- homopolymers were synthesized by solution polymerization or photopolymerization, and measured with an Abbe refractometer “DR-M2” manufactured by Atago Co., Ltd., at a temperature of 25 ° C. and with a wavelength of 589 nm. .
- Td 50 Thermal decomposition temperature
- TG-DTA differential thermothermal gravimetric simultaneous measurement apparatus
- Total light transmittance of molded body Using the light diffusable resin composition, a sheet having a thickness of 1.5 mm was prepared, and this was cut into an appropriate size to obtain a measurement sample. The total light transmittance (Tt) was measured using a Nippon Denshoku haze meter “Haze meter NDH2000” (model name).
- Dispersion of molded product The same sheet as the total light transmittance was used as a measurement sample. As shown in FIG. 1, as a device including a light source 2, a variable angle photometer “GP-200” manufactured by Murakami Color Research Laboratory Co., Ltd. is used to irradiate a light beam perpendicularly to the surface of the sheet 1. The distribution of transmitted light (emitted light) was measured on the side to determine the degree of dispersion.
- GP-200 manufactured by Murakami Color Research Laboratory Co., Ltd.
- the angle ⁇ when the luminance of the light becomes 50 was calculated, and this ⁇ was defined as the degree of dispersion.
- B ⁇ I ⁇ / cos ⁇ (6)
- Synthesis Example 1 (Production of Macromonomer MM-1) 200 parts of ion-exchanged water was charged into a glass reaction vessel equipped with a stirrer, a reflux condenser, a thermometer, a nitrogen gas introduction pipe, and a liquid feed pipe connecting part. Next, the water temperature in the reaction vessel was adjusted to 80 ° C. while stirring and introducing nitrogen gas.
- MMA methyl methacrylate
- IBMA isobutyl methacrylate
- MAA methacrylic acid
- OTG 2-ethylhexyl thioglycolate
- the initiator aqueous solution dissolved in the part was added and stirred. Then, 5 minutes later, the supply of the monomer mixture was started from the glass container connected to the glass reaction container via the liquid feeding pipe connecting part using a metering pump. The monomer mixture was supplied at a constant rate over 240 minutes. After completing the supply of the monomer mixture, the temperature inside the reaction vessel was raised to 90 ° C. over 30 minutes. And it maintained at 90 degreeC for 4.5 hours, and obtained the dispersion liquid of the prepolymer. When a part of the dispersion was sampled and the prepolymer after removing the medium by drying was subjected to GPC measurement, Mn in terms of polystyrene was 2,700 and Mw was 4,600.
- Synthesis Example 2 (Production of macromonomer MM-2) A 500 ml pressurized stirred tank reactor equipped with a hot oil heating device was filled with ethyl 3-ethoxypropionate. The reactor was then warmed to about 250 ° C. Meanwhile, 20 parts of MMA, 55 parts of cyclohexyl acrylate (hereinafter “CHA”), 25 parts of acrylic acid (hereinafter “AA”) and 0.1 part of di-tert-butyl peroxide (hereinafter “DTBP”) are mixed. Then, a monomer mixed solution was prepared and stored in a raw material tank.
- CHA cyclohexyl acrylate
- AA acrylic acid
- DTBP di-tert-butyl peroxide
- the monomer mixed solution is continuously supplied from the raw material tank to the reactor while keeping the pressure in the reactor constant by the pressure regulator above the vapor pressure of ethyl 3-ethoxypropionate. Polymerization was carried out at 0 ° C. At this time, the feed rate was set so that the average residence time of the monomer mixture in the reactor was 12 minutes. A reaction solution corresponding to the supply amount of the monomer mixture was continuously taken out from the outlet of the reactor. The temperature in the reactor was maintained at 230 ° C. ⁇ 2 ° C. while supplying the monomer mixture.
- the reaction liquid taken out from the outlet of the reactor is introduced into a thin film evaporator to remove volatile components such as unreacted monomers in the reaction liquid, Monomer MM-2 was obtained.
- the macromonomer MM-2 was collected for 60 minutes and then cooled to obtain a solid macromonomer MM-2.
- Mn in terms of polystyrene was 3,100 and Mw was 10,600.
- concentration of terminal ethylenically unsaturated bonds contained in the macromonomer MM-2 was measured by nuclear magnetic resonance spectrum (hereinafter referred to as 1 H-NMR).
- the terminal ethylenically unsaturated bond introduction rate (hereinafter referred to as F value) of the macromonomer MM-2 calculated from the number average molecular weight and the concentration of the terminal ethylenically unsaturated bond was 98%.
- 100 parts of pulverized solid macromonomer MM-2, 260 parts of water and 22.5 parts of 25% aqueous ammonia were charged into a glass flask with a condenser tube, and a warm bath was used. The internal temperature was 90 ° C. Then, stirring was performed to make the macromonomer MM-2 water-soluble. After confirming that the macromonomer MM-2 was dissolved, water was added so that the solid content was 25% to obtain an aqueous solution of the macromonomer MM-2.
- crosslinked resin fine particles The crosslinked resin fine particles used in the production of the light diffusing resin composition are a synthetic product and a commercial product, and are shown below.
- Production Example 1 (Production of crosslinked resin fine particles A1)
- a glass reaction vessel equipped with a stirrer, a reflux condenser, a thermometer, a nitrogen gas introduction pipe and a liquid feed pipe connection part 100.4 parts of ion exchange water, 475.6 parts of methanol, 0.12 part of 25% ammonia water
- 5.86 parts of a dispersion containing the macromonomer MM-1 obtained in Synthesis Example 1 15.0 parts of MMA, 50.0 parts of IBMA, and 10.0 parts of 2-ethylhexyl acrylate (hereinafter “HA”) were charged. It is.
- the internal temperature of the reaction vessel was adjusted to 55 ° C. while stirring and introducing nitrogen gas.
- TMOS-PMA trimethoxysilylpropyl methacrylate
- the internal temperature was maintained at 55 ° C., and after 6 hours, the polymerization was terminated to obtain a dispersion of polymer fine particles having hydrolyzable silyl groups.
- 32.8 parts of 25% aqueous ammonia was added to the dispersion as a basic catalyst for crosslinking hydrolyzable silyl groups, the internal temperature was 62 ° C., and the mixture was held for 3 hours with stirring. As a result, fine particles having a crosslinked structure were formed.
- 1.0 part of an antioxidant (trade name “Irganox 245” manufactured by BASF Corporation) was added.
- Production Examples 2 to 6 and 9 to 13 (Production of crosslinked resin fine particles A2 to A6 and A9 and B1 to B4) The same procedure as in Production Example 1 was carried out except that the types and amounts of monomers used in the presence of the macromonomer, and the amounts of ion-exchanged water and methanol used were changed as shown in Table 1. Fine particles A2 to A6, A9 and B1 to B4 were obtained. Table 1 shows the physical properties of the obtained crosslinked resin fine particles.
- Production Example 7 (Production of crosslinked resin fine particles A7)
- the types and amounts of monomers used in the presence of the macromonomer, and the amounts of ion-exchanged water and methanol used are as shown in Table 1, and 9/10 of the monomers used are initially charged, and the rest was added in 10 minutes after adding the polymerization initiator, and the same operation as in Production Example 1 was performed to obtain crosslinked resin fine particles A7.
- the physical properties of the obtained A7 are shown in Table 1.
- crosslinked resin fine particles A8 were obtained by preparing seed particles SD-1 made of resin fine particles and then polymerizing a vinyl monomer containing a crosslinkable monomer in the presence of the seed particles SD-1. Fine particles.
- the obtained dispersion of seed particles SD-1 was subjected to centrifugal separation, and the supernatant was removed.
- the volume average particle diameter (dv) of the collected fine particles was measured with a laser diffraction / scattering particle size distribution analyzer. .65 ⁇ m.
- an emulsifier aqueous solution in which 1.5 parts of sodium lauryl sulfate as an emulsifier (trade name “Emar 2F-30”) as an emulsifier is dissolved in 100 parts of ion-exchanged water is added to the obtained mixture, followed by emulsification.
- the mixture was emulsified using a vessel to prepare an emulsion of vinyl monomer.
- the vinyl monomer emulsion prepared above is added to the reaction vessel containing the seed particles SD-1, and 2,2′-azobis (2,4-dimethylvalero) as a polymerization initiator is further added.
- Nitrile (trade name “V-65”, manufactured by Wako Pure Chemical Industries, Ltd.) 1 part was added, and the mixture was stirred at 20 ° C. for 12 hours to allow the seed monomer SD-1 to absorb the vinyl monomer and the polymerization initiator. . Thereafter, nitrogen gas was introduced into the gas phase portion in the reaction vessel through a nitrogen gas introduction pipe. And the vinyl monomer absorbed by the seed particle was polymerized by heating up internal temperature over 2 hours from 20 degreeC to 70 degreeC. After reaching 70 ° C., the mixture was further stirred for 2 hours while maintaining the temperature at 70 ° C.
- B5 Cross-linked polymethyl methacrylate fine particles “GM-0105” (trade name) manufactured by Ganz Kasei Co., Ltd.
- B6 Cross-linked polymethyl methacrylate fine particles “GM-0401S” (trade name) manufactured by Ganz Kasei Co., Ltd.
- B7 Silicone resin fine particle “Tospearl 120” (trade name) manufactured by Momentive Performance Materials.
- MMA Methyl methacrylate (refractive index 1.4900)
- IBMA Isobutyl methacrylate (refractive index: 1.4770)
- IBA Isobutyl acrylate (refractive index 1.4608)
- HA 2-ethylhexyl acrylate (refractive index: 1.4625)
- TMOS-PMA Trimethoxysilylpropyl methacrylate (refractive index 1.4800)
- TMPTA Trimethylolpropane triacrylate (refractive index 1.5135)
- St Styrene (refractive index 1.5900)
- Example 1 Production of Light Diffusing Resin Composition and Its Molded Product
- a composition containing a polycarbonate resin (trade name “Iupilon S-3000F”, refractive index 1.585) manufactured by Mitsubishi Engineering Plastics Co., Ltd.) and a crosslinked resin fine particle A1 are carried out. It was. After mixing 0.3 g of the crosslinked resin fine particles A1, 59.64 g of the polycarbonate resin, and 0.06 g of an antioxidant (trade name “Irganox B225” manufactured by BASF Corp.), Laboplast mill (manufactured by Toyo Seiki Co., Ltd., LABO PLASTOMILL) was melt-kneaded for 9 minutes at 250 ° C.
- a polycarbonate resin trade name “Iupilon S-3000F”, refractive index 1.585
- an antioxidant trade name “Irganox B225” manufactured by BASF Corp.
- Laboplast mill manufactured by Toyo Seiki Co., Ltd., LABO PLASTOMILL
- the light diffusing resin composition was compression-molded at 4 MPa with a compression molding machine (“SFA-37” manufactured by Shinto Metal Industries Co., Ltd.) using a mold having a cavity having a predetermined shape and size.
- a flat plate molded product 120 mm long ⁇ 120 mm wide ⁇ 1.5 mm thick was produced. Thereafter, the thickness of the flat plate was measured using a micrometer and confirmed to be in the range of 1.50 mm ⁇ 0.05 mm.
- the light-diffusing resin composition was prepared in the same manner as described above except that the blending amounts of the crosslinked resin fine particles A1 and the polycarbonate resin were changed as shown in (1), (2) or (4) of Table 2. And a flat plate molded article was manufactured. About each molded article obtained by the above, total light transmittance and dispersion degree were measured. The results are shown in Table 2. The absolute value ⁇ n of the refractive index difference between the transparent resin and the crosslinked resin fine particles is also shown.
- Example 2 Example 1 except that a GP polystyrene resin (manufactured by Dongbu Chemicals, trade name “SOLARENE GPPS G-116HV”, refractive index 1.590) was used instead of the polycarbonate resin, and the kneading temperature was 200 ° C.
- the light diffusing resin composition and the flat plate molded product were obtained. Separately, two types of compositions in which the content ratios of the polystyrene resin and the crosslinked resin fine particles A1 were changed were produced. About each obtained molded article, the total light transmittance and dispersion degree were measured. The results are shown in Table 2.
- Examples 3 to 10 A light diffusing resin composition and a flat molded article were obtained in the same manner as in Example 1 using the polycarbonate resin and the crosslinked resin fine particles A2 to A9 with the formulation shown in Table 2. About each obtained molded article, the total light transmittance and dispersion degree were measured. The results are shown in Table 2.
- Comparative Examples 1-7 A light diffusing resin composition and a flat molded product were obtained in the same manner as in Example 1 using the polycarbonate resin and the crosslinked resin fine particles B1 to B7 with the formulation shown in Table 3. About each obtained molded article, the total light transmittance and dispersion degree were measured. The results are shown in Table 3.
- the addition amount of the crosslinked resin fine particles (light diffusing agent) necessary for obtaining a degree of dispersion (light diffusibility) of about 20 degrees is as small as 0.5% or less.
- a result showing good diffusion efficiency was obtained.
- it can be confirmed that good diffusibility is exhibited in a wide total light transmittance region of approximately 60 to 90% within a range of the addition amount of the crosslinked resin fine particles up to 2.0%. It was. Focusing on the average volume particle diameter (dv), in Examples 1 to 9 using crosslinked resin fine particles having a dv of 1.8 ⁇ m or more, the degree of dispersion at a total light transmittance of about 85% is 20 degrees or more.
- Comparative Example 1 in which the refractive index difference ⁇ n between the transparent resin and the crosslinked resin fine particles is small, Comparative Example 3 in which the volume average particle size (dv) of the crosslinked resin fine particles is large, Comparative Example 5 in which the particle size distribution is wide, and Large particle size
- the dispersion degree is less than 20 degrees when the addition amount of the crosslinked resin fine particles (light diffusing agent) is 0.5%, and the diffusion efficiency is inferior. there were. Further, from the result of Comparative Example 1, it is estimated that the region exhibiting diffusibility with a degree of dispersion of 20 degrees or more is about 70 to 90% or so in the range of the addition amount of the crosslinked resin fine particles up to 2.0%.
- Example 1 the total light transmittance region showing good diffusibility compared with Example 1 was narrow.
- Comparative Example 2 in which the volume average particle diameter (dv) of the crosslinked resin fine particles is small and in Comparative Example 7 in which the silicone-based crosslinked resin fine particles are used, the dispersion in a high total light transmittance region having a total light transmittance of about 85%. It has been found that the total light transmittance region that can be applied is limited.
- Comparative Example 4 in which the monomer components constituting the crosslinkable fine particles are all methacrylic acid ester monomers has a high thermal decomposition rate, and when the crosslinked resin fine particles are used for a light diffusion plate or the like, The result of concern about heat resistance was obtained.
- the present invention it is possible to obtain a light diffusing resin composition having good light diffusibility and showing a high degree of dispersion in a wide range of total light transmittance. Moreover, the molded object excellent also in heat resistance etc. can be obtained. For this reason, the light diffusing resin composition of the present invention is used for applications such as light diffusing plates, transmissive screens, liquid crystal panels, and electric signboards for displays that require sufficient luminance and light diffusibility, and a wide range of total light transmission. It is useful for applications such as a cover of a lighting fixture that requires light diffusibility in the rate region.
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Abstract
Description
一方、透明樹脂と屈折率が異なり、架橋構造を有する高分子微粒子を有機系光拡散剤として用いる方法も知られている。有機系光拡散剤としては、例えば、架橋アクリル系粒子、架橋シリコーン系粒子及び架橋スチレン系粒子等が知られている。
有機系光拡散剤は、無機系光拡散剤と比較して成形品の表面平滑性に優れており、光拡散性も良好であることから、幅広く光拡散剤として用いられている。しかしながら、その添加量が多い場合には耐衝撃性や難燃性が低下するという問題があり、逆にコストを考慮して添加量を少なくした場合には光拡散性が不十分となることが知られている。 In a luminaire cover or a liquid crystal display device, a diffusion plate in which a light diffusing agent is dispersed in a matrix made of a transparent resin such as polymethyl methacrylate, polystyrene, and polycarbonate in order to uniformly diffuse light from a light source. It is used. Conventionally, inorganic particles such as crystalline silica, amorphous silica, calcium carbonate, barium sulfate, aluminum hydroxide, and titanium oxide, or inorganic fibers such as glass fibers have been used as the light diffusing agent. However, when a light diffusing agent made of inorganic particles or inorganic fibers is used, there are problems such as a decrease in impact resistance and a problem that light transmittance in the diffusion plate is lowered due to the high reflectance of the light diffusing agent. there were.
On the other hand, a method using polymer fine particles having a refractive index different from that of a transparent resin and having a crosslinked structure as an organic light diffusing agent is also known. As the organic light diffusing agent, for example, crosslinked acrylic particles, crosslinked silicone particles, and crosslinked styrene particles are known.
Organic light diffusing agents are widely used as light diffusing agents because they are superior in surface smoothness of molded articles and have good light diffusibility compared to inorganic light diffusing agents. However, when the addition amount is large, there is a problem that impact resistance and flame retardancy are lowered, and conversely, when the addition amount is reduced considering the cost, the light diffusibility may be insufficient. Are known.
特許文献3には、光拡散剤として平均粒子径が1~4μmであり、特定の粒子径分布を有するアクリル樹脂系微粒子が、ポリカーボネート樹脂中に分散された組成物が開示されている。更に、特許文献4には、ポリカーボネート樹脂と屈折率が異なり、その平均粒子径が0.5~100μmの範囲にある架橋ポリマー微粒子を含有する組成物が開示されている。
特許文献5には、屈折率が1.495~1.504の範囲である高分子微粒子が、ポリカーボネート樹脂中に分散された組成物が開示されている。
また、特許文献6には、体積平均粒子径が0.7~2.5μmであり、粒子径分布の狭い特定の(メタ)アクリル酸エステル系樹脂からなる架橋樹脂微粒子を含有する組成物が開示されている。 Technologies using organic light diffusing agents have been proposed.
Patent Document 3 discloses a composition in which acrylic resin-based fine particles having an average particle size of 1 to 4 μm as a light diffusing agent and having a specific particle size distribution are dispersed in a polycarbonate resin. Further, Patent Document 4 discloses a composition containing crosslinked polymer fine particles having a refractive index different from that of polycarbonate resin and having an average particle diameter in the range of 0.5 to 100 μm.
Patent Document 5 discloses a composition in which polymer fine particles having a refractive index in the range of 1.495 to 1.504 are dispersed in a polycarbonate resin.
Patent Document 6 discloses a composition containing crosslinked resin fine particles comprising a specific (meth) acrylate ester resin having a volume average particle size of 0.7 to 2.5 μm and a narrow particle size distribution. Has been.
透明な樹脂に光拡散剤粒子を配合した樹脂組成物及びそれからなる成形体の光拡散性は、樹脂と光拡散剤粒子との屈折率差、光拡散剤粒子の粒子径、及び光拡散剤粒子の含有量等に依存することが知られており、樹脂と光拡散剤粒子との屈折率差が大きいほど、また光拡散剤粒子の粒子径が大きいほど、1個の光拡散剤粒子による光拡散係数は大きくなる。しかし、光拡散剤粒子の粒子径が大きいと、光拡散剤粒子の質量が大きくなるため、樹脂中での光拡散剤粒子の質量割合を一定にした場合には、樹脂に含有される大粒子径の光拡散剤粒子の個数が少なくなり、個々の光拡散剤粒子の光拡散係数と、樹脂中に含有されている光拡散剤粒子の個数との積に基づく全体の光拡散性は必ずしも高くならない。一方、透明な樹脂中に含有させる光拡散剤粒子の粒子径が小さ過ぎると、光拡散係数が指数関数的に減少するため、十分な光拡散性が得られない。 However, with the recent increase in performance of lighting fixtures and displays, there has been an increasing demand for components relating to light diffusion, such as lighting fixture covers and display diffusion plates. In particular, regarding a cover for a lighting fixture, there is a demand for a molding material that exhibits good light diffusibility in a wide range of total light transmittance. Furthermore, there is a demand for a molding material containing a light diffusing agent that can achieve a target light diffusibility (dispersion degree) with a small amount of addition. Here, “dispersion degree” means the amount of transmitted light (emitted light) at θ = 0 (degrees) when a light beam is emitted perpendicularly from the
The light diffusibility of a resin composition in which a light diffusing agent particle is blended with a transparent resin and a molded product made from the resin composition are the refractive index difference between the resin and the light diffusing agent particle, the particle size of the light diffusing agent particle, and the light diffusing agent particle. As the refractive index difference between the resin and the light diffusing agent particle is larger, and the particle size of the light diffusing agent particle is larger, the light from one light diffusing agent particle is known. The diffusion coefficient increases. However, if the particle size of the light diffusing agent particles is large, the mass of the light diffusing agent particles becomes large. Therefore, when the mass ratio of the light diffusing agent particles in the resin is constant, the large particles contained in the resin The number of light diffusing agent particles having a smaller diameter is reduced, and the overall light diffusibility based on the product of the light diffusion coefficient of each light diffusing agent particle and the number of light diffusing agent particles contained in the resin is not necessarily high. Don't be. On the other hand, if the particle size of the light diffusing agent particles contained in the transparent resin is too small, the light diffusion coefficient decreases exponentially, so that sufficient light diffusibility cannot be obtained.
更に、光拡散板の成形は、300℃を超えるような高い温度条件下で行われることもあるため、光拡散剤には係る高温条件下においても分解等が起こりにくいというような優れた耐熱性も要求されている。 Moreover, if the difference between the refractive index of the transparent resin and the refractive index of the light diffusing agent particles becomes too large, the amount of reflected light from the molded body increases. Then, the total light transmittance is reduced, and for example, sufficient brightness cannot be obtained in a light diffusing plate of a display, a transmissive screen, a cover of a lighting fixture, an electric signboard, and the like.
Furthermore, since the light diffusing plate may be molded under a high temperature condition exceeding 300 ° C., the light diffusing agent has excellent heat resistance such that decomposition or the like hardly occurs even under a high temperature condition. Is also required.
特許文献1の技術は、拡散板の成形において、比較的多量の光拡散剤を必要とするため、実用性に乏しかった。特許文献2に記載の技術では、比較的少量の光拡散剤により、良好な光拡散性を示すが、全光線透過率が70%以上の領域における光拡散性が十分ではない。このため、照明器具のカバー等の、高い光透過が必要な用途には使用できない。また、特許文献3~5に記載の光拡散剤は、全光線透過率80%未満程度の領域では良好な光拡散性を得るために添加量を多くする必要があり、耐衝撃性及びコストの面から問題があった。
特許文献6に記載の技術では、少量の光拡散剤により、幅広い全光線透過率領域において良好な光拡散性を発現することが可能であるものの、耐熱性の点では改善の余地があった。 However, conventionally, a light diffusing resin composition that satisfies all of the above requirements has not been obtained.
The technique disclosed in
In the technique described in Patent Document 6, although it is possible to express good light diffusibility in a wide range of total light transmittance with a small amount of light diffusing agent, there is room for improvement in terms of heat resistance.
1.透明樹脂(X)及び架橋樹脂微粒子(Y)を含み、上記透明樹脂(X)の屈折率と、上記架橋樹脂微粒子(Y)の屈折率との差の絶対値(以下、「Δn」という)が0.095~0.115であり、上記架橋樹脂微粒子(Y)の体積平均粒子径が1.5~3.3μmであり、上記架橋樹脂微粒子(Y)の粒子径の変動係数が20%以下であり、上記架橋樹脂微粒子(Y)を、窒素ガス雰囲気下、昇温速度10℃/分の条件で熱分解させた場合に、質量が半分となる温度が320℃以上であることを特徴とする光拡散性樹脂組成物。
2.上記架橋樹脂微粒子(Y)が(メタ)アクリル酸エステルに由来する構造単位を含む上記1に記載の光拡散性樹脂組成物。
3.上記光拡散性樹脂組成物を用いて作製した厚さ1.5mmのシートであって、白色光の全光線透過率が85%である該シートの表面に、ゴニオメーターを用いて垂直方向に光を入射した場合に、0度の出射光に対して50%の輝度の出射光となる角度が20度以上である上記1又は2に記載の光拡散性樹脂組成物。
4.上記透明樹脂(X)及び上記架橋樹脂微粒子(Y)の質量割合がそれぞれ100質量部及び0.5質量部である光散乱性樹脂組成物を用いて作製した厚さ1.5mmのシートの表面に、ゴニオメーターを用いて垂直方向に光を入射した場合に、0度の出射光に対して50%の輝度の出射光となる角度が22度以上である上記1又は2に記載の光拡散性樹脂組成物。
5.上記透明樹脂(X)がポリカーボネート樹脂である上記1~4のいずれかに記載の光拡散性樹脂組成物。
6.上記透明樹脂(X)100重量部に対して上記架橋樹脂微粒子(Y)を0.1~2.0質量部含んでなる上記1~5のいずれかに記載の光拡散性樹脂組成物。
7.上記架橋樹脂微粒子(Y)が、分散重合により製造されたものである上記1~6いずれかに記載の光拡散性樹脂組成物。
8.上記架橋樹脂微粒子(Y)が、加水分解性シリル基を有する(メタ)アクリル酸エステル系樹脂をシラン架橋して得られる架橋樹脂微粒子である上記1~7のいずれかに記載の光拡散性樹脂組成物。
9.上記1から8のいずれかに記載の光拡散性樹脂組成物からなる成形品。
10.上記成形品が照明器具又は表示器具に配設される上記9に記載の成形品。 The present invention is as follows.
1. An absolute value of a difference between the refractive index of the transparent resin (X) and the refractive index of the crosslinked resin fine particles (Y) (hereinafter referred to as “Δn”) including the transparent resin (X) and the crosslinked resin fine particles (Y). 0.095 to 0.115, the volume average particle diameter of the crosslinked resin fine particles (Y) is 1.5 to 3.3 μm, and the coefficient of variation of the particle diameter of the crosslinked resin fine particles (Y) is 20%. The cross-linked resin fine particles (Y) are characterized in that the temperature at which the mass is halved is 320 ° C. or higher when pyrolyzed in a nitrogen gas atmosphere at a temperature rising rate of 10 ° C./min. A light diffusing resin composition.
2. 2. The light diffusing resin composition as described in 1 above, wherein the crosslinked resin fine particles (Y) contain a structural unit derived from a (meth) acrylic acid ester.
3. A sheet of 1.5 mm thickness produced using the light diffusing resin composition, which has a total light transmittance of 85% for white light, is irradiated with light in a vertical direction using a goniometer. 3. The light diffusing resin composition according to 1 or 2 above, wherein an angle at which the emitted light having a luminance of 50% with respect to the emitted light at 0 degree is 20 degrees or more when the incident light is incident.
4). The surface of a 1.5 mm thick sheet prepared using a light-scattering resin composition in which the mass ratio of the transparent resin (X) and the crosslinked resin fine particles (Y) is 100 parts by mass and 0.5 parts by mass, respectively. The light diffusion according to 1 or 2 above, wherein, when light is incident in a vertical direction using a goniometer, the angle at which the emitted light having a luminance of 50% with respect to the emitted light at 0 degree is 22 degrees or more Resin composition.
5. 5. The light diffusing resin composition as described in any one of 1 to 4 above, wherein the transparent resin (X) is a polycarbonate resin.
6). 6. The light diffusing resin composition according to any one of 1 to 5, comprising 0.1 to 2.0 parts by mass of the crosslinked resin fine particles (Y) with respect to 100 parts by weight of the transparent resin (X).
7). 7. The light diffusing resin composition as described in any one of 1 to 6 above, wherein the crosslinked resin fine particles (Y) are produced by dispersion polymerization.
8). 8. The light diffusing resin according to any one of 1 to 7 above, wherein the crosslinked resin fine particles (Y) are crosslinked resin fine particles obtained by silane-crosslinking a (meth) acrylic acid ester-based resin having a hydrolyzable silyl group. Composition.
9. A molded article comprising the light diffusing resin composition according to any one of 1 to 8 above.
10. 10. The molded product according to 9 above, wherein the molded product is disposed in a lighting device or a display device.
以下、本発明について詳しく説明する。 The light diffusing resin composition of the present invention comprises crosslinked resin fine particles (Y) having a specific particle size, particle size distribution, refractive index, composition and the like as a light diffusing agent, and a transparent resin (X). The present invention relates to a light diffusing resin composition that exhibits good light diffusivity and diffusion efficiency and is excellent in heat resistance and the like, and a molded body using the same. In the light diffusing resin composition of the present invention, the crosslinked resin fine particles (Y) have an action as a light diffusing agent.
The present invention will be described in detail below.
これらのうち、スチレンが、スチレン系樹脂の入手容易性、コスト、重合性等の点から好ましい。 Examples of the styrene monomer forming the styrene resin include styrene, α-methyl styrene, p-methyl styrene, o-methyl styrene, m-methyl styrene, vinyl toluene, p-ethyl styrene, p-tert. -Butyl-styrene, pn-butylstyrene, pn-hexylstyrene, p-octylstyrene, 2,4-dimethylstyrene, p-methoxystyrene, p-phenylstyrene, o-chlorostyrene, m-chlorostyrene , P-chlorostyrene, 2,4-dichlorostyrene and the like. The styrenic resin may contain only one type of structural unit derived from these styrenic monomers, or may contain two or more types.
Of these, styrene is preferable from the viewpoint of availability of styrene-based resin, cost, polymerizability, and the like.
上記スチレン系樹脂の分子量分布(Mw/Mn)は、1.5~3.5であることが、得られる成形体の強度等の点から好ましい。 The molecular weight of the styrene resin is not particularly limited. The weight average molecular weight (Mw) in terms of polystyrene measured by gel permeation chromatography (GPC) is 50,000 to 1 in terms of the moldability of the composition, particularly melt moldability, and the strength of the resulting molded product. It is preferably 1,000,000, more preferably 100,000 to 500,000.
The molecular weight distribution (Mw / Mn) of the styrenic resin is preferably 1.5 to 3.5 from the viewpoint of the strength of the obtained molded article.
上記ポリカーボネート樹脂は、界面重合及び溶融エステル交換のいずれの方法により得られたポリカーボネート樹脂であってもよい。 Specific examples of the divalent phenol include 2,2- (4-hydroxyphenyl) propane (bisphenol A), 2,2- (4-hydroxyphenyl) butane, and 2,2- (4-hydroxyphenyl). Examples include pentane, 4,4′-biphenol, hydroquinone, resorcinol and the like. Of these, 2,2- (4-hydroxyphenyl) propane (bisphenol A) is preferred because of its good impact resistance and the like.
The polycarbonate resin may be a polycarbonate resin obtained by any method of interfacial polymerization and melt transesterification.
(i)分散重合により製造した樹脂微粒子よりなるシード粒子に、架橋性単量体を含むビニル系単量体(m2)を吸収させた後、このビニル系単量体(m2)を重合させる方法。
(ii)分散重合により加水分解性シリル基を有する樹脂微粒子を得た後、加水分解性シリル基どうしによる架橋反応を行う方法。
本発明では、上記(i)及び(ii)等の方法により得られた架橋樹脂微粒子を単独で用いても良いし、組み合せて用いても良い。 The method for producing the crosslinked resin fine particles (Y) used in the present invention is not particularly limited, but the following methods can be exemplified.
(I) A method in which a vinyl monomer (m2) containing a crosslinkable monomer is absorbed in seed particles made of resin fine particles produced by dispersion polymerization, and then the vinyl monomer (m2) is polymerized. .
(Ii) A method of carrying out a crosslinking reaction between hydrolyzable silyl groups after obtaining resin fine particles having hydrolyzable silyl groups by dispersion polymerization.
In the present invention, the crosslinked resin fine particles obtained by the above methods (i) and (ii) may be used alone or in combination.
カルボキシル基含有マクロモノマーは、分子の末端又は側鎖にラジカル重合性不飽和結合を有するものであれば、特に限定されない。このラジカル重合性不飽和結合としては、末端ビニリデン基、末端(メタ)アクリロイル基、側鎖(メタ)アクリロイル基、末端スチリル基等が挙げられる。 In the case of the above method (i), the seed particle is preferably a (meth) acrylic acid ester resin and is produced by subjecting the vinyl monomer (m1) to dispersion polymerization in a water / alcohol polar solvent. can do. At this time, when a carboxyl group-containing macromonomer is used as a dispersion stabilizer, dispersion polymerization proceeds more smoothly.
The carboxyl group-containing macromonomer is not particularly limited as long as it has a radical polymerizable unsaturated bond at the molecular end or side chain. Examples of the radical polymerizable unsaturated bond include a terminal vinylidene group, a terminal (meth) acryloyl group, a side chain (meth) acryloyl group, and a terminal styryl group.
上記シード粒子の形成に用いられる(メタ)アクリル酸エステルの使用量は、ビニル系単量体(m1)の全質量に対して、好ましくは50~100質量%、より好ましくは80~100質量%である。
また、上記シード粒子は、シード粒子を構成する構造単位の全量100質量%に対し、好ましくは60質量%以上、更に好ましくは65質量%以上、特に好ましくは70~100質量%が、メタクリル酸メチルに由来する構造単位及び/又はメタクリル酸イソブチルに由来する構造単位からなるメタクリル酸エステル系樹脂であることが、粒子の耐熱ブロッキング性、耐候性及び屈折率の点から好ましい。 Examples of the vinyl monomer (m1) forming the seed particles include (meth) acrylic acid esters and aromatic vinyl compounds. Specific monomers include methyl (meth) acrylate, (meta ) Ethyl acrylate, propyl (meth) acrylate, n-butyl (meth) acrylate, isobutyl (meth) acrylate, tert-butyl (meth) acrylate, pentyl (meth) acrylate, (meth) acrylic acid 2 -Alkyl esters of (meth) acrylic acid such as ethylhexyl, lauryl (meth) acrylate and stearyl (meth) acrylate; alicyclics of (meth) acrylic acid such as cyclohexyl (meth) acrylate and isobornyl (meth) acrylate Group-containing ester; (meth) such as glycidyl (meth) acrylate and tetrahydrofurfuryl (meth) acrylate Heterocyclic group-containing esters of crylic acid; 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, 3-hydroxypropyl (meth) acrylate, 4-hydroxybutyl (meth) acrylate, etc. Examples include hydroxyalkyl esters of (meth) acrylic acid; alkoxyalkyl esters of (meth) acrylic acid such as 2-methoxyethyl (meth) acrylate. These compounds may be used alone or in combination of two or more. The vinyl monomer (m1) preferably contains a (meth) acrylic acid ester, and methyl methacrylate and isobutyl methacrylate are particularly preferable.
The amount of the (meth) acrylic acid ester used for the formation of the seed particles is preferably 50 to 100% by mass, more preferably 80 to 100% by mass, based on the total mass of the vinyl monomer (m1). It is.
The seed particles are preferably 60% by mass or more, more preferably 65% by mass or more, and particularly preferably 70 to 100% by mass based on 100% by mass of the total amount of structural units constituting the seed particles. It is preferable from the point of the heat-resistant blocking property of a particle | grain, a weather resistance, and a refractive index that it is a methacrylic ester resin which consists of a structural unit derived from (2) and / or a structural unit derived from isobutyl methacrylate.
これらのうち、エチレングリコールジ(メタ)アクリレート及びトリメチロールプロパントリ(メタ)アクリレートが、(メタ)アクリル酸エステル系樹脂からなるシード粒子への吸収が容易であること、架橋密度を高くすることが可能であること、及び重合安定性に優れる等の点から好ましく用いられる。 In addition, the vinyl monomer (m2) to be polymerized after being absorbed in the seed particles obtained by dispersion polymerization contains a polyfunctional vinyl monomer in order to form the crosslinked resin fine particles (Y). As this polyfunctional vinyl monomer, a polyfunctional (meth) acrylate compound excellent in polymerizability is preferably used. Specific examples include ethylene glycol di (meth) acrylate, propylene glycol di (meth) acrylate, 1,6-hexanediol di (meth) acrylate, polyethylene glycol di (meth) acrylate, polypropylene glycol di (meth) acrylate and the like. Di (meth) acrylate of dihydric alcohol; trimethylolpropane tri (meth) acrylate, trimethylolpropane ethylene oxide modified tri (meth) acrylate, glycerol tri (meth) acrylate, pentaerythritol tri (meth) acrylate, pentaerythritol Examples include tri (meth) acrylates of trihydric or higher polyhydric alcohols such as tetra (meth) acrylate and poly (meth) acrylates such as tetra (meth) acrylate. Only 1 type may be used for a polyfunctional (meth) acrylate compound, and 2 or more types can be used for it.
Among these, ethylene glycol di (meth) acrylate and trimethylolpropane tri (meth) acrylate can be easily absorbed into seed particles made of (meth) acrylic ester resin, and can increase the crosslinking density. It is preferably used in terms of being possible and excellent in polymerization stability.
尚、多官能ビニル単量体の使用量は、ビニル系単量体(m2)の全質量に対して、好ましくは3~95質量%、特に好ましくは5~75質量%である。 The ratio of the preferred amount of seed particles and vinyl monomer (m2) used in the production of the crosslinked resin fine particles (Y) is not particularly limited, but the crosslinking structure is imparted to the particles and the monomer is absorbed into the seed particles. From the point of view, it is shown below. The vinyl monomer (m2) is preferably 0.5 to 10 parts by mass and more preferably 0.7 to 5 parts by mass with respect to 1 part by mass of the seed particles.
The amount of the polyfunctional vinyl monomer used is preferably 3 to 95% by mass, particularly preferably 5 to 75% by mass, based on the total mass of the vinyl monomer (m2).
これらのうち、加水分解性シリル基を有するビニル系単量体としては、加水分解性シリル基含有アクリル酸エステル、及び、加水分解性シリル基含有メタクリル酸エステルが好ましい。これらの単量体は、(メタ)アクリル酸エステル等との共重合性に優れ、耐熱性及び耐候性に優れた微粒子が得られることから好ましい。上記ビニル系単量体としては、(メタ)アクリル酸エステルとの共重合性、分散重合時の安定性及び架橋性に優れることから、メタクリル酸トリメトキシシリルプロピル(別称:トリメトキシシリルプロピルメタクリレート)が特に好ましく用いられる。 Any vinyl compound having at least one hydrolyzable silyl group can be used as the vinyl monomer having a hydrolyzable silyl group. For example, vinyl silane such as vinyltrimethoxysilane, vinyltriethoxysilane, vinylmethyldimethoxysilane, vinyldimethylmethoxysilane, etc .; hydrolysis of trimethoxysilylpropyl acrylate, triethoxysilylpropyl acrylate, methyldimethoxysilylpropyl acrylate, etc. Hydrolyzable silyl group-containing acrylic acid ester; hydrolyzable silyl group-containing methacrylate ester such as trimethoxysilylpropyl methacrylate, triethoxysilylpropyl methacrylate, methyldimethoxysilylpropyl methacrylate, dimethylmethoxysilylpropyl methacrylate; Hydrolyzable silyl group-containing vinyl ethers such as propyl vinyl ether; Hydrolyzable silyl group-containing vinyl ethers such as vinyl trimethoxysilylundecanoate Mention may be made of the ether and the like. These vinyl monomers may be used alone or in combination of two or more.
Among these, as the vinyl monomer having a hydrolyzable silyl group, a hydrolyzable silyl group-containing acrylate ester and a hydrolyzable silyl group-containing methacrylate ester are preferable. These monomers are preferable because they are excellent in copolymerizability with (meth) acrylic acid esters and the like, and fine particles excellent in heat resistance and weather resistance are obtained. As the vinyl monomer, trimethoxysilylpropyl methacrylate (also known as trimethoxysilylpropyl methacrylate) is excellent in copolymerization with (meth) acrylic acid ester, stability during dispersion polymerization, and crosslinkability. Is particularly preferably used.
(メタ)アクリロイル基は、ポリマー鎖の末端及び側鎖のいずれの位置に結合していてもよい。特に、(メタ)アクリロイル基が側鎖に結合したマクロモノマー型分散安定剤は、より少量の使用で、目的とする加水分解性シリル基を有する(メタ)アクリル酸エステル系樹脂微粒子を安定に製造できる点から好ましい。
側鎖に(メタ)アクリロイル基を有し且つカルボキシル基を有するマクロモノマー型分散安定剤の製造方法としては、乳化重合によりカルボキシル基含有プレポリマーを合成し、その後、このプレポリマーのカルボキシル基と、(メタ)アクリル酸グリシジル等のエポキシ基含有(メタ)アクリレートにおけるエポキシ基とを反応させて、(メタ)アクリロイル基を付与する方法が挙げられる。このとき、プレポリマーのカルボキシル基の一部が残存してもよい。この方法であれば、簡便に高性能のマクロモノマーを製造することができる。エポキシ基含有(メタ)アクリレートを用いる場合には、ポリマー鎖1本当たりに0.6~2.0個付加させることで、より粒子径分布が狭く、粒子径の揃った微粒子を製造でき、好ましい。 In addition, in the dispersion polymerization for producing resin fine particles having a hydrolyzable silyl group, it is preferable to use a macromonomer type dispersion stabilizer having a (meth) acryloyl group. When a macromonomer type dispersion stabilizer having a (meth) acryloyl group is used, a (meth) acrylic acid ester system having a target particle size and a hydrolyzable silyl group having a narrow particle size distribution with a small amount of use. Resin fine particles can be obtained smoothly. Furthermore, the macromonomer type dispersion stabilizer more preferably has a carboxyl group.
The (meth) acryloyl group may be bonded to any position of the end of the polymer chain and the side chain. In particular, a macromonomer type dispersion stabilizer with a (meth) acryloyl group bonded to the side chain stably produces (meth) acrylic ester resin fine particles having the desired hydrolyzable silyl group with a smaller amount of use. It is preferable from the point which can be performed.
As a method for producing a macromonomer type dispersion stabilizer having a (meth) acryloyl group in the side chain and having a carboxyl group, a carboxyl group-containing prepolymer is synthesized by emulsion polymerization, and then the carboxyl group of this prepolymer, A method of reacting with an epoxy group in an epoxy group-containing (meth) acrylate such as glycidyl (meth) acrylate to give a (meth) acryloyl group can be mentioned. At this time, a part of the carboxyl group of the prepolymer may remain. With this method, a high-performance macromonomer can be easily produced. In the case of using an epoxy group-containing (meth) acrylate, it is preferable to add 0.6 to 2.0 per polymer chain, whereby fine particles having a narrower particle size distribution and a uniform particle size can be produced. .
架橋反応は、加水分解性シリル基を有する(メタ)アクリル酸エステル系樹脂微粒子を含む分散液に、架橋用触媒を添加することにより行うことができる。架橋用触媒により、加水分解性シリル基どうしを縮合反応させてシロキサン結合を形成することができる。架橋用触媒としては、アルカリ材料が好ましく、特に、架橋反応後、除去が容易なアンモニアや、低沸点アミンが好ましく用いられる。
アルカリ材料の使用量は、シリル架橋度が高くなる点から、加水分解性シリル基を有する樹脂微粒子中のシリル基に対して3倍当量以上であることが好ましく、6倍当量以上であることがより好ましい。 Thereafter, the hydrolyzable silyl groups in the (meth) acrylic acid ester resin fine particles having hydrolyzable silyl groups obtained above are subjected to a crosslinking reaction to produce crosslinked resin fine particles (Y).
The cross-linking reaction can be performed by adding a cross-linking catalyst to a dispersion containing (meth) acrylic ester resin fine particles having a hydrolyzable silyl group. With the crosslinking catalyst, a hydrolyzable silyl group can be subjected to a condensation reaction to form a siloxane bond. As the crosslinking catalyst, an alkaline material is preferable, and in particular, ammonia that can be easily removed after the crosslinking reaction or a low-boiling amine is preferably used.
The amount of the alkali material used is preferably 3 times equivalent or more and 6 times equivalent or more with respect to the silyl group in the resin fine particles having a hydrolyzable silyl group from the viewpoint of increasing the degree of silyl crosslinking. More preferred.
酸化防止剤としては、リン系酸化防止剤、フェノール系酸化防止剤、イオウ系酸化防止剤等が挙げられる。
このうち、リン系酸化防止剤としては、亜リン酸エステル化合物等が挙げられる。 In addition, the light diffusable resin composition of this invention can contain an additive so that it may mention later. In the present invention, the crosslinked resin fine particles (Y) may be particles containing an antioxidant, a light stabilizer and the like. A light diffusing resin composition containing these additives is a preferable embodiment because it is particularly excellent in heat decomposition stability and weather resistance.
Examples of the antioxidant include phosphorus antioxidants, phenolic antioxidants, sulfur antioxidants, and the like.
Of these, examples of phosphorus antioxidants include phosphite compounds.
上記酸化防止剤は、1種又は2種以上を組み合せて使用することができる。 Examples of sulfur-based antioxidants include pentaerythritol tetrakis (3-mercaptopropionate), pentaerythritol tetrakis (3-laurylthiopropionate), and glycerol-3-stearylthiopropionate. .
The said antioxidant can be used 1 type or in combination of 2 or more types.
上記光安定剤は、1種又は2種以上を組み合せて使用することができる。 Examples of the light stabilizer include bis (2,2,6,6-tetramethyl-4-piperidyl) sebacate, bis (1,2,2,6,6-pentamethyl-4-piperidyl) sebacate, tetrakis (2 , 2,6,6-tetramethyl-4-piperidyl) -1,2,3,4-butanetetracarboxylate, tetrakis (1,2,2,6,6-pentamethyl-4-piperidyl) -1,2 , 3,4-Butanetetracarboxylate, poly {[6- (1,1,3,3-tetramethylbutyl) amino-1,3,5-triazine-2,4-diyl] [(2,2, 6,6-tetramethylpiperidyl) imino] hexamethylene [(2,2,6,6-tetramethylpiperidyl) imino]}, polymethylpropyl 3-oxy- [4- (2,2,6,6-tetra Methyl) piperi Sulfonyl] hindered amine compounds such siloxanes, and the like.
The said light stabilizer can be used 1 type or in combination of 2 or more types.
体積平均粒子径(dv)が1.5μm未満の場合、粒子1個当たりの拡散光の割合が少なくなるため拡散せずに透過する正透過光の割合が多くなり、全光線透過率が高い領域で拡散性(分散度)が低下するため好ましくない。一方、体積平均粒子径(dv)が3.3μmを超える場合、同質量における粒子数が少なくなり、同じ全光線透過率を得るために必要な添加量が多くなるため好ましくない。また、架橋樹脂微粒子(Y)の粒子が大きい場合には、拡散透過光がより直進性を増すために好ましくない。 The volume average particle diameter (dv) of the crosslinked resin fine particles (Y) according to the present invention is 1.5 to 3.3 μm, preferably 1.8 to 2.8 μm, more preferably 2.1 to 2.5 μm. It is.
When the volume average particle diameter (dv) is less than 1.5 μm, the ratio of diffuse light per particle decreases, so the ratio of regular transmitted light that does not diffuse increases, and the total light transmittance is high. This is not preferable because the diffusibility (dispersion degree) decreases. On the other hand, when the volume average particle diameter (dv) exceeds 3.3 μm, the number of particles at the same mass decreases, and the amount added to obtain the same total light transmittance increases, which is not preferable. Moreover, when the particle | grains of crosslinked resin microparticles | fine-particles (Y) are large, since diffused transmission light increases more straightness, it is not preferable.
尚、変動係数(CV)の値を粒子径分布の広がりを表す指標として用いることができる。変動係数(CV)が小さいほど粒子径分布が狭いことを表し、20%以下であれば、その分布幅は非常に狭いものであるということができる。全粒子が同一粒子径且つ真球状粒子である場合には、変動係数(CV)が0となるが、現実に得られるものとしては2%程度が下限と考えられる。 In the particle size distribution of the crosslinked resin fine particles (Y), the coefficient of variation (CV) is 20% or less, preferably 10% or less. When the CV value exceeds 20%, the degree of dispersion in the high transmittance region tends to decrease.
Note that the coefficient of variation (CV) can be used as an index representing the spread of the particle size distribution. The smaller the coefficient of variation (CV), the narrower the particle size distribution. If it is 20% or less, it can be said that the distribution width is very narrow. When all the particles have the same particle size and a true spherical particle, the coefficient of variation (CV) is 0, but about 2% is considered to be the lower limit as what is actually obtained.
一般に、メタクリル系ポリマーは、他のポリマー材料と比較すると、加熱した際の分解速度が大きいことが知られており、メタクリル系単量体のみからなる架橋樹脂微粒子のTd50は、低くなる。しかしながら、アクリル系単量体及びスチレン系単量体等を、数質量%程度共重合させることにより、加熱時の分解速度が低減されるため、Td50の値を高めることができる。 Further, in the present invention, when the crosslinked resin fine particles (Y) are thermally decomposed under a nitrogen gas atmosphere at a temperature rising rate of 10 ° C./min, the temperature at which the mass becomes half, that is, 50% by weight. The temperature reduction (Td 50 ) is 320 ° C. or higher, preferably 350 ° C. or higher. The upper limit temperature is 400 ° C. for general acrylic fine particles. When Td 50 is less than 320 ° C., the crosslinked resin fine particles are decomposed by heat applied at the time of kneading, which may cause problems such as change in particle diameter, generation of gas, and coloring. Td 50 can be measured, for example, using a thermogravimetric / differential thermal analyzer.
In general, methacrylic polymers are known to have a higher decomposition rate when heated compared to other polymer materials, and the Td 50 of crosslinked resin fine particles consisting only of methacrylic monomers is low. However, the copolymerization of acrylic monomer, styrene monomer, etc. by about several mass% reduces the decomposition rate at the time of heating, so that the value of Td 50 can be increased.
Δnが大きい場合には、光拡散剤粒子1個当たりの散乱光の割合が多くなり、必要な拡散剤添加量が少なくなるため基本的には好ましい。しかし、Δnが大き過ぎると、反射光の割合が多くなるので好ましくない。また、必要な光拡散剤添加量が少なすぎると、樹脂組成物中で粒子に当たらず透過してしまう正透過光が多くなり、拡散透過光が少なくなるため好ましくない。このような場合には全光線透過率が高い領域において分散度が低下する傾向があり、Δnが0.115を超えるとこれらの不具合が生じることがある。
また、Δnが0.095未満の場合には、粒子1個当たりの拡散光の割合が少なくなるため光拡散剤の添加量を増やす必要があり、好ましくない。 The light diffusing resin composition of the present invention includes the transparent resin (X) and the crosslinked resin fine particles (Y), and the refractive index of the transparent resin (X) and the refractive index of the crosslinked resin fine particles (Y) The absolute value (Δn) of the difference is 0.095 to 0.115, preferably 0.100 to 0.110.
When Δn is large, the ratio of scattered light per light diffusing agent particle is increased, and the necessary amount of diffusing agent added is reduced, which is basically preferable. However, if Δn is too large, the ratio of reflected light increases, which is not preferable. In addition, if the amount of the light diffusing agent added is too small, it is not preferable because the regular transmitted light that does not hit the particles in the resin composition and is transmitted increases and the diffuse transmitted light decreases. In such a case, the degree of dispersion tends to decrease in a region where the total light transmittance is high. If Δn exceeds 0.115, these problems may occur.
On the other hand, when Δn is less than 0.095, the ratio of the diffused light per particle is reduced, so that it is necessary to increase the amount of the light diffusing agent, which is not preferable.
ここで、酸化防止剤及び光安定剤は、架橋樹脂微粒子(Y)に添加可能なものとして既述した化合物を用いることができる。 The light diffusing resin composition of the present invention can contain additives as long as the object of the present invention is not impaired. Examples of additives include light stabilizers, ultraviolet absorbers, antioxidants, antistatic agents, lubricants, flame retardants, colorants (dyes, pigments), fluorescent brighteners, selective wavelength absorbers, plasticizers, and the like. Can do.
Here, as the antioxidant and the light stabilizer, the compounds described above that can be added to the crosslinked resin fine particles (Y) can be used.
この性質は、全光線透過率が高い領域で一定水準以上の分散度を示す光拡散性樹脂組成物は、光拡散性が良好であることを示し、分散度(I)が20度以上であることにより十分な明るさと良好な光拡散性が両立されることとなる。そのため、本発明の光拡散性樹脂組成物は、ディスプレイや照明器具等の部材用の成形材料としても好適となる。分散度は、透明樹脂(X)及び架橋樹脂微粒子(Y)との屈折率差(Δn)、架橋樹脂微粒子(Y)の粒子径、粒子径分布及びその添加量等をバランス化させることにより調整される。 The preferred light diffusibility of the light diffusing resin composition of the present invention is shown below. A sheet having a thickness of 1.5 mm and produced using the light diffusing resin composition of the present invention, wherein the total light transmittance of white light is 85%, and a vertical direction using a goniometer When light is incident on the light, the angle (hereinafter referred to as “dispersion degree (I)”) at which the emitted light has a luminance of 50% with respect to the emitted light at 0 degree is preferably 20 degrees or more, more preferably 23 degrees. That's it.
This property indicates that the light diffusing resin composition exhibiting a degree of dispersion of a certain level or higher in a region where the total light transmittance is high indicates that the light diffusibility is good, and the degree of dispersion (I) is 20 degrees or more. As a result, sufficient brightness and good light diffusibility can be achieved at the same time. Therefore, the light diffusing resin composition of the present invention is also suitable as a molding material for members such as displays and lighting fixtures. The degree of dispersion is adjusted by balancing the difference in refractive index (Δn) between the transparent resin (X) and the crosslinked resin fine particles (Y), the particle diameter of the crosslinked resin fine particles (Y), the particle size distribution, and the amount added. Is done.
上記分散度(II)が22度以上であれば、光拡散に優れるため好ましい。 In the present invention, a 1.5 mm thick sheet prepared using a light diffusing resin composition in which the transparent resin (X) and the crosslinked resin fine particles (Y) are 100 parts by mass and 0.5 parts by mass, respectively. The angle (hereinafter referred to as “dispersion degree (II)”) at which the emitted light has a luminance of 50% with respect to the emitted light at 0 degree when the light is incident on the surface in the vertical direction using a goniometer is preferable. Is 22 degrees or more, more preferably 23 degrees or more.
If the degree of dispersion (II) is 22 degrees or more, it is preferable because light diffusion is excellent.
Bθ=Iθ/cosθ (1) For the dispersities (I) and (II), a goniometer (variable photometer) was used to irradiate parallel light in the thickness direction perpendicular to one surface of a 1.5 mm thick sheet. It is obtained by measuring the light distribution of transmitted light on the other surface side. Specifically, the luminance Bθ is obtained from the following equation (1) using the luminous intensity Iθ at each emission angle θ, and the angle at which the luminance becomes 50% with respect to the luminance B 0 when θ = 0 ° is set as the degree of dispersion. It was.
Bθ = Iθ / cos θ (1)
マクロモノマー、架橋樹脂微粒子(Y)、並びに光拡散性樹脂組成物から製造した成形体等に対して実施した評価方法は、以下の通りである。 1. Evaluation Method of Physical Properties Evaluation methods carried out on the macromonomer, the crosslinked resin fine particles (Y), a molded product produced from the light diffusing resin composition, and the like are as follows.
マクロモノマー又はその製造原料であるプレポリマーを、ゲルパーミエーションクロマトグラフィー(GPC)に供して、分子量が既知のポリスチレンを基準物質として用いて予め作成しておいた検量線から、数平均分子量(以下、「Mn」)及び重量平均分子量(以下、「Mw」)を算出した。
GPC装置として、東ソー社製「HLC-8220GPC」を使用し、カラムとして東ソー社製「TSK-GEL MULTIPORE HXL-M」(4本)を使用して測定した。重合体をテトラヒドロフラン(THF)に溶解して濃度0.2%の溶液を調製した後、溶液100μLを、カラムに注入し、溶離液にTHF、カラム温度40℃、溶離液(THF)の流速1.0mL/分にて測定を行った。 (1) Number average molecular weight (Mn) and weight average molecular weight (Mw)
From a calibration curve prepared in advance using a polystyrene having a known molecular weight as a reference substance, a macromonomer or a prepolymer that is a raw material for production thereof is subjected to gel permeation chromatography (GPC). , “Mn”) and weight average molecular weight (hereinafter “Mw”).
Measurement was performed using “HLC-8220GPC” manufactured by Tosoh Corporation as the GPC apparatus and “TSK-GEL MULTIPIORE HXL-M” (four) manufactured by Tosoh Corporation as the column. The polymer is dissolved in tetrahydrofuran (THF) to prepare a 0.2% concentration solution, and 100 μL of the solution is injected into the column. The eluent is THF, the column temperature is 40 ° C., and the eluent (THF) flow rate is 1. Measurement was performed at 0 mL / min.
表1に示した製造例1~13で得られた架橋樹脂微粒子を含むスラリーにメタノールを加えて、微粒子の濃度が5%となるよう調整し、十分に振り混ぜて、均一分散させた。この分散液に、超音波を10分間照射した後、日機装社製レーザー回折散乱式粒度分布計「MT-3000」を用いて、粒子径分布測定を行った。測定時の循環分散媒として、イオン交換水若しくはアセトンを使用した。また、市販品1~3の架橋樹脂微粒子は、その乾燥粉末の濃度が5%となるようにアセトン中に投入し、十分に振り混ぜて、均一分散させた。この分散液に、超音波を10分間照射した後、粒子径分布測定を行った。粒子径分布測定により得られた体積基準での粒子径分布よりメジアン径(μm)を計算し、体積平均粒子径(dv)とした。 (2) Volume average particle diameter (dv)
Methanol was added to the slurry containing the crosslinked resin fine particles obtained in Production Examples 1 to 13 shown in Table 1 to adjust the concentration of the fine particles to 5%, and the mixture was sufficiently shaken and dispersed uniformly. The dispersion was irradiated with ultrasonic waves for 10 minutes, and then particle size distribution measurement was performed using a laser diffraction scattering type particle size distribution analyzer “MT-3000” manufactured by Nikkiso Co., Ltd. Ion exchange water or acetone was used as a circulating dispersion medium at the time of measurement. Further, the crosslinked resin fine particles of the
表1に示した架橋樹脂微粒子(A1)~(A9)及び(B1)~(B7)を、日本電子社製電界放射走査型電子顕微鏡(FE-SEM)「JSM-6330F」にて観察した。1枚に50~100個程度の粒子が観察できる倍率で撮影した後、粒子像を明確に確認できる0.2μm以上の架橋樹脂微粒子(200個以上)について、粒子径(di)(円相当直径)を測定した。次いで、下記式(3)により標準偏差(σ)を算出し、これを用いて下記式(2)により変動係数(CV)を算出した。
CV(%)=100×(σ/dn) (2)
σ=(Σ(di-dn)2/ΣNi)1/2 (3)
ここで変動係数(CV)及び標準偏差(σ)を求めるための数平均粒子径(dn)は上記SEM観察で得られた粒子径(di)及び粒子径を有する粒子数(Ni)を用いて、下記式(4)から算出した。
dn=(ΣNidi/ΣNi) (4) (3) Coefficient of variation (CV)
The crosslinked resin fine particles (A1) to (A9) and (B1) to (B7) shown in Table 1 were observed with a field emission scanning electron microscope (FE-SEM) “JSM-6330F” manufactured by JEOL. After photographing at a magnification at which about 50 to 100 particles can be observed on one sheet, the particle diameter (di) (equivalent circle diameter) of 0.2 μm or more crosslinked resin fine particles (200 or more) that can clearly confirm the particle image ) Was measured. Next, the standard deviation (σ) was calculated by the following formula (3), and the coefficient of variation (CV) was calculated by the following formula (2) using this.
CV (%) = 100 × (σ / dn) (2)
σ = (Σ (di-dn) 2 / ΣNi) 1/2 (3)
Here, the number average particle diameter (dn) for obtaining the coefficient of variation (CV) and the standard deviation (σ) is the particle diameter (di) obtained by the SEM observation and the number of particles having the particle diameter (Ni). It was calculated from the following formula (4).
dn = (ΣNidi / ΣNi) (4)
架橋樹脂微粒子の屈折率は、架橋樹脂を構成する各構造単位のホモポリマーの屈折率(ni)、及び、架橋樹脂を構成する構造単位の全量に対する各構造単位の質量割合(wi)を用いて、下記式(5)より算出した。
n=Σniwi (5)
尚、各ホモポリマーの屈折率は「POLYMER HANDBOOK 第4版」(John Wiley & Sons,Inc.発行)に記載された値を用いた。文献に屈折率記載のないポリマーについては、溶液重合若しくは光重合によりホモポリマーを合成し、アタゴ社製アッベ屈折計「DR-M2」を用いて、温度25℃で、波長589nmの光で測定した。 (4) Refractive index (n)
The refractive index of the crosslinked resin fine particles is determined by using the refractive index (ni) of the homopolymer of each structural unit constituting the crosslinked resin and the mass ratio (wi) of each structural unit to the total amount of the structural units constituting the crosslinked resin. It was calculated from the following formula (5).
n = Σniwi (5)
In addition, the refractive index of each homopolymer used the value described in "POLYMER HANDBOOK 4th edition" (John Wiley & Sons, Inc. issue). For polymers whose refractive index is not described in the literature, homopolymers were synthesized by solution polymerization or photopolymerization, and measured with an Abbe refractometer “DR-M2” manufactured by Atago Co., Ltd., at a temperature of 25 ° C. and with a wavelength of 589 nm. .
架橋性微粒子の熱分解温度を、エスアイアイ・ナノテクノロジー社製示差熱熱重量同時測定装置(TG-DTA)「SII EXSTAR6000」にて測定した。窒素ガス雰囲気下、昇温速度10℃/分で25℃から500℃まで昇温し、重量変化を測定した。測定前の質量が半減したときの温度を測定し、これをTd50とした。 (5) Thermal decomposition temperature (Td 50 )
The thermal decomposition temperature of the crosslinkable fine particles was measured with a differential thermothermal gravimetric simultaneous measurement apparatus (TG-DTA) “SII EXSTAR6000” manufactured by SII Nanotechnology. Under a nitrogen gas atmosphere, the temperature was increased from 25 ° C. to 500 ° C. at a temperature increase rate of 10 ° C./min, and the weight change was measured. The temperature at which the measurement before the mass was halved was measured, which was used as Td 50.
光拡散性樹脂組成物を用いて、厚さ1.5mmのシートを作製し、これを適当な大きさに切りだして測定試料とした。日本電色社製ヘイズメーター「ヘイズメーターNDH2000」(型式名)を使用して、全光線透過率(T.t.)を測定した。 (6) Total light transmittance of molded body Using the light diffusable resin composition, a sheet having a thickness of 1.5 mm was prepared, and this was cut into an appropriate size to obtain a measurement sample. The total light transmittance (Tt) was measured using a Nippon Denshoku haze meter “Haze meter NDH2000” (model name).
全光線透過率と同じシートを測定試料とした。図1に示すように、光源2を備える装置として、村上色彩技術研究所社製変角光度計「GP-200」を用いて、シート1の表面に対して垂直に、光線を照射し、裏面側で透過光(出射光)の配光分布を測定して分散度を求めた。具体的には、各透過光(出射光)の出射角度θでの光度Iθを測定した後、下記式(6)より輝度Bθを求め、θ=0のときの輝度B0を100とした場合の輝度が50になるときの角度θを算出し、このθを分散度とした。
Bθ=Iθ/cosθ (6) (7) Dispersion of molded product The same sheet as the total light transmittance was used as a measurement sample. As shown in FIG. 1, as a device including a
Bθ = Iθ / cos θ (6)
はじめに、架橋樹脂微粒子を製造するために、マクロモノマーMM-1及びMM-2を製造した。 2. Synthesis of Macromonomer First, macromonomers MM-1 and MM-2 were produced in order to produce crosslinked resin fine particles.
攪拌機、還流冷却器、温度計、窒素ガス導入管及び送液配管連結部を備えたガラス製反応容器に、イオン交換水200部を仕込んだ。次いで、攪拌、及び窒素ガスの導入を行いながら、反応容器内の水温を80℃に調整した。一方、送液配管を取り付けたガラス製容器に、メタクリル酸メチル(以下、「MMA」)36.35部、メタクリル酸イソブチル(以下、「IBMA」)36.35部、メタクリル酸(以下、「MAA」)20部及びチオグリコール酸2-エチルヘキシル(以下、「OTG」)7.3部を仕込み、攪拌して単量体混合液(100部)を調製した。ガラス製反応容器内の水温が80℃で安定したことを確認した後、ガラス製反応容器に、重合開始剤である過硫酸アンモニウム(以下、「APS」)0.8部をイオン交換水3.0部に溶解した開始剤水溶液を添加し、撹拌した。そして、その5分後に、送液配管連結部を介してガラス製反応容器に接続されたガラス製容器から、定量ポンプを用いて、単量体混合液の供給を開始した。単量体混合液の供給は、一定速度で240分かけて行った。単量体混合液の供給完了後、反応容器内温を30分かけて90℃に昇温した。そして、90℃で4.5時間維持してプレポリマーの分散液を得た。分散液の一部をサンプリングし、乾燥により媒体を除いた後のプレポリマーを、GPC測定に供したところ、ポリスチレン換算のMnは2,700であり、Mwは4,600であった。
上記で得られたプレポリマー分散液の温度を30分かけて80℃に降温した後、導入ガスを、窒素ガスから空気に変更し、直ちにメトキシハイドロキノン0.03部を添加した。メトキシハイドロキノンを添加して5分後に、トリエチルアミン9.4部を一定速度で30分かけて反応容器に供給した。その15分後にメタクリル酸グリシジル(以下、「GMA」)6.1部を一定速度で30分かけて反応容器に供給し、温80℃で3時間加熱した。これにより、プレポリマーのカルボキシル基と、GMAに含まれるグリシジル基とを反応させ、GMAに由来するメタクリロイル基を有するマクロモノマーMM-1を含む分散液を得た(NV34%)。 Synthesis Example 1 (Production of Macromonomer MM-1)
200 parts of ion-exchanged water was charged into a glass reaction vessel equipped with a stirrer, a reflux condenser, a thermometer, a nitrogen gas introduction pipe, and a liquid feed pipe connecting part. Next, the water temperature in the reaction vessel was adjusted to 80 ° C. while stirring and introducing nitrogen gas. Meanwhile, 36.35 parts of methyl methacrylate (hereinafter referred to as “MMA”), 36.35 parts of isobutyl methacrylate (hereinafter referred to as “IBMA”), methacrylic acid (hereinafter referred to as “MAA”) ”) And 20 parts of 2-ethylhexyl thioglycolate (hereinafter“ OTG ”) were charged and stirred to prepare a monomer mixture (100 parts). After confirming that the water temperature in the glass reaction vessel was stabilized at 80 ° C., 0.8 parts of ammonium persulfate (hereinafter referred to as “APS”), which is a polymerization initiator, was added to the ion exchange water 3.0 in the glass reaction vessel. The initiator aqueous solution dissolved in the part was added and stirred. Then, 5 minutes later, the supply of the monomer mixture was started from the glass container connected to the glass reaction container via the liquid feeding pipe connecting part using a metering pump. The monomer mixture was supplied at a constant rate over 240 minutes. After completing the supply of the monomer mixture, the temperature inside the reaction vessel was raised to 90 ° C. over 30 minutes. And it maintained at 90 degreeC for 4.5 hours, and obtained the dispersion liquid of the prepolymer. When a part of the dispersion was sampled and the prepolymer after removing the medium by drying was subjected to GPC measurement, Mn in terms of polystyrene was 2,700 and Mw was 4,600.
After the temperature of the prepolymer dispersion obtained above was lowered to 80 ° C. over 30 minutes, the introduced gas was changed from nitrogen gas to air, and 0.03 part of methoxyhydroquinone was immediately added. Five minutes after adding methoxyhydroquinone, 9.4 parts of triethylamine was supplied to the reaction vessel at a constant rate over 30 minutes. After 15 minutes, 6.1 parts of glycidyl methacrylate (hereinafter, “GMA”) was supplied to the reaction vessel at a constant rate over 30 minutes and heated at a temperature of 80 ° C. for 3 hours. As a result, the carboxyl group of the prepolymer and the glycidyl group contained in GMA were reacted to obtain a dispersion containing macromonomer MM-1 having a methacryloyl group derived from GMA (NV 34%).
ホットオイルによる加熱装置を備えた容量500mlの加圧式攪拌槽型反応器を、3-エトキシプロピオン酸エチルで満たした。その後、反応器を約250℃に加温した。一方、MMA20部、アクリル酸シクロヘキシル(以下、「CHA」)55部、アクリル酸(以下、「AA」)25部及びジ-tert-ブチルパーオキサイド(以下、「DTBP」)0.1部を混合して、単量体混合液を調製し、それを原料タンクに収容した。
次いで、上記反応器内の圧力を、圧力調節器により3-エトキシプロピオン酸エチルの蒸気圧以上で一定に保ちながら、上記単量体混合液を原料タンクから反応器に連続的に供給し、230℃で重合を行った。このとき、単量体混合液の反応器内での平均滞留時間が12分となるように供給速度を設定した。単量体混合液の供給量に相当する反応液を反応器の出口から連続的に取り出した。尚、単量体混合液を供給している間、反応器内の温度を230℃±2℃に維持した。
単量体混合液の供給開始から90分後、反応器の出口から取り出した反応液を薄膜蒸発器に導入して、反応液中の未反応単量体等の揮発性成分を除去し、マクロモノマーMM-2を得た。マクロモノマーMM-2の採取を60分間行い、その後、冷却することにより、固体のマクロモノマーMM-2を得た。そして、マクロモノマーMM-2をGPC測定に供したところ、ポリスチレン換算によるMnは3,100であり、Mwは10,600であった。また、核磁気共鳴スペクトル(以下、1H-NMRという。)により、マクロモノマーMM-2に含まれる末端エチレン性不飽和結合の濃度を測定した。数平均分子量及び末端エチレン性不飽和結合の濃度から算出されるマクロモノマーMM-2の末端エチレン性不飽和結合導入率(以下、F値という。)は98%であった。
次に、固体のマクロモノマーMM-2を粉砕してフレーク状としたもの100部、水260部及び25%アンモニア水22.5部を、冷却管付ガラス製フラスコに仕込み、温浴を用いて、内温を90℃とした。そして、攪拌を行い、マクロモノマーMM-2を水溶化させた。マクロモノマーMM-2が溶解したことを確認した後、固形分が25%となるように水を加え、マクロモノマーMM-2の水溶液を得た。 Synthesis Example 2 (Production of macromonomer MM-2)
A 500 ml pressurized stirred tank reactor equipped with a hot oil heating device was filled with ethyl 3-ethoxypropionate. The reactor was then warmed to about 250 ° C. Meanwhile, 20 parts of MMA, 55 parts of cyclohexyl acrylate (hereinafter “CHA”), 25 parts of acrylic acid (hereinafter “AA”) and 0.1 part of di-tert-butyl peroxide (hereinafter “DTBP”) are mixed. Then, a monomer mixed solution was prepared and stored in a raw material tank.
Next, the monomer mixed solution is continuously supplied from the raw material tank to the reactor while keeping the pressure in the reactor constant by the pressure regulator above the vapor pressure of ethyl 3-ethoxypropionate. Polymerization was carried out at 0 ° C. At this time, the feed rate was set so that the average residence time of the monomer mixture in the reactor was 12 minutes. A reaction solution corresponding to the supply amount of the monomer mixture was continuously taken out from the outlet of the reactor. The temperature in the reactor was maintained at 230 ° C. ± 2 ° C. while supplying the monomer mixture.
After 90 minutes from the start of supplying the monomer mixture, the reaction liquid taken out from the outlet of the reactor is introduced into a thin film evaporator to remove volatile components such as unreacted monomers in the reaction liquid, Monomer MM-2 was obtained. The macromonomer MM-2 was collected for 60 minutes and then cooled to obtain a solid macromonomer MM-2. When the macromonomer MM-2 was subjected to GPC measurement, Mn in terms of polystyrene was 3,100 and Mw was 10,600. Further, the concentration of terminal ethylenically unsaturated bonds contained in the macromonomer MM-2 was measured by nuclear magnetic resonance spectrum (hereinafter referred to as 1 H-NMR). The terminal ethylenically unsaturated bond introduction rate (hereinafter referred to as F value) of the macromonomer MM-2 calculated from the number average molecular weight and the concentration of the terminal ethylenically unsaturated bond was 98%.
Next, 100 parts of pulverized solid macromonomer MM-2, 260 parts of water and 22.5 parts of 25% aqueous ammonia were charged into a glass flask with a condenser tube, and a warm bath was used. The internal temperature was 90 ° C. Then, stirring was performed to make the macromonomer MM-2 water-soluble. After confirming that the macromonomer MM-2 was dissolved, water was added so that the solid content was 25% to obtain an aqueous solution of the macromonomer MM-2.
光拡散性樹脂組成物の製造に用いた架橋樹脂微粒子は、合成品及び市販品であり、以下に示される。 3. Crosslinked resin fine particles The crosslinked resin fine particles used in the production of the light diffusing resin composition are a synthetic product and a commercial product, and are shown below.
攪拌機、還流冷却器、温度計、窒素ガス導入管及び送液配管連結部を備えたガラス製反応容器に、イオン交換水100.4部、メタノール475.6部、25%アンモニア水0.12部、合成例1で得られたマクロモノマーMM-1を含む分散液5.86部、MMA15.0部、IBMA50.0部及びアクリル酸2-エチルヘキシル(以下、「HA」)10.0部を仕込んだ。次いで、攪拌、及び窒素ガスの導入を行いながら、反応容器の内温を55℃に調整した。
内温が55℃で安定したことを確認した後、トリメトキシシリルプロピルメタクリレート(以下、「TMOS-PMA」)25.0部を反応容器に供給した。更に、その10分後、重合開始剤としてtert-ブチルパーオキシピバレートの70%溶液(日本油脂社製、商品名「パーブチルPV」)2.4部を添加して重合を開始した。この重合開始剤を添加すると、直ちに反応液に濁りが生じ、徐々に白化して乳白色となった。即ち、重合体微粒子が生成していることが確認された。重合開始剤の添加開始から、内温を55℃に保持して、6時間後、重合を終了し、加水分解性シリル基を有する重合体微粒子の分散液を得た。
次に、加水分解性シリル基を架橋させるための塩基性触媒として、25%アンモニア水32.8部を、上記分散液に添加し、内温を62℃として、攪拌下、3時間保持した。これにより、架橋構造を有する微粒子を形成させた。尚、アンモニア水の添加から2.5時間経過した時点で、酸化防止剤(BASF社製、商品名「Irganox245」)1.0部を添加した。
反応液を冷却後、200目ポリネットでろ過を行い、濾液(架橋樹脂微粒子の分散液)を回収した。そして、この分散液を、155℃で30分間加熱した場合の不揮発分が98%以上になるまで60℃で乾燥した。乾燥後、解砕を行い、粉末の架橋樹脂微粒子A1を得た。その後、上記の方法により、dv、CV、屈折率及びTd50を得た(表1参照)。 Production Example 1 (Production of crosslinked resin fine particles A1)
In a glass reaction vessel equipped with a stirrer, a reflux condenser, a thermometer, a nitrogen gas introduction pipe and a liquid feed pipe connection part, 100.4 parts of ion exchange water, 475.6 parts of methanol, 0.12 part of 25% ammonia water Then, 5.86 parts of a dispersion containing the macromonomer MM-1 obtained in Synthesis Example 1, 15.0 parts of MMA, 50.0 parts of IBMA, and 10.0 parts of 2-ethylhexyl acrylate (hereinafter “HA”) were charged. It is. Next, the internal temperature of the reaction vessel was adjusted to 55 ° C. while stirring and introducing nitrogen gas.
After confirming that the internal temperature was stable at 55 ° C., 25.0 parts of trimethoxysilylpropyl methacrylate (hereinafter “TMOS-PMA”) was supplied to the reaction vessel. Further, 10 minutes later, 2.4 parts of a 70% solution of tert-butyl peroxypivalate (trade name “Perbutyl PV” manufactured by NOF Corporation) was added as a polymerization initiator to initiate polymerization. As soon as this polymerization initiator was added, the reaction solution became turbid and gradually whitened to become milky white. That is, it was confirmed that polymer fine particles were generated. From the start of addition of the polymerization initiator, the internal temperature was maintained at 55 ° C., and after 6 hours, the polymerization was terminated to obtain a dispersion of polymer fine particles having hydrolyzable silyl groups.
Next, 32.8 parts of 25% aqueous ammonia was added to the dispersion as a basic catalyst for crosslinking hydrolyzable silyl groups, the internal temperature was 62 ° C., and the mixture was held for 3 hours with stirring. As a result, fine particles having a crosslinked structure were formed. When 2.5 hours had elapsed since the addition of the ammonia water, 1.0 part of an antioxidant (trade name “Irganox 245” manufactured by BASF Corporation) was added.
After cooling the reaction solution, it was filtered through a 200-mesh polynet to collect a filtrate (a dispersion of crosslinked resin fine particles). And this dispersion liquid was dried at 60 degreeC until the non volatile matter at the time of heating at 155 degreeC for 30 minutes became 98% or more. After drying, crushing was performed to obtain powdered crosslinked resin fine particles A1. Thereafter, dv, CV, refractive index and Td 50 were obtained by the above method (see Table 1).
マクロモノマーの存在下に使用する単量体の種類及び使用量、並びに、イオン交換水及びメタノールの使用量を表1に示すとおり変更した以外は、製造例1と同様の操作を行い、架橋樹脂微粒子A2~A6、A9及びB1~B4を得た。得られた架橋樹脂微粒子の物性を表1に示す。 Production Examples 2 to 6 and 9 to 13 (Production of crosslinked resin fine particles A2 to A6 and A9 and B1 to B4)
The same procedure as in Production Example 1 was carried out except that the types and amounts of monomers used in the presence of the macromonomer, and the amounts of ion-exchanged water and methanol used were changed as shown in Table 1. Fine particles A2 to A6, A9 and B1 to B4 were obtained. Table 1 shows the physical properties of the obtained crosslinked resin fine particles.
マクロモノマーの存在下に使用する単量体の種類及び使用量、並びに、イオン交換水及びメタノールの使用量を表1に示すとおりとし、使用する単量体の9/10を初期に仕込み、残りの1/10を、重合開始剤を添加してから10分後に添加した以外は、製造例1と同様の操作を行い、架橋樹脂微粒子A7を得た。得られたA7の物性を表1に示す。 Production Example 7 (Production of crosslinked resin fine particles A7)
The types and amounts of monomers used in the presence of the macromonomer, and the amounts of ion-exchanged water and methanol used are as shown in Table 1, and 9/10 of the monomers used are initially charged, and the rest Was added in 10 minutes after adding the polymerization initiator, and the same operation as in Production Example 1 was performed to obtain crosslinked resin fine particles A7. The physical properties of the obtained A7 are shown in Table 1.
架橋樹脂微粒子A8は、樹脂微粒子よりなるシード粒子SD-1を作製した後、このシード粒子SD-1の存在下に、架橋性単量体を含むビニル系単量体を重合させて得られた微粒子である。 Production Example 8 (Production of crosslinked resin fine particles A8)
The crosslinked resin fine particles A8 were obtained by preparing seed particles SD-1 made of resin fine particles and then polymerizing a vinyl monomer containing a crosslinkable monomer in the presence of the seed particles SD-1. Fine particles.
攪拌機、還流冷却器、温度計、窒素ガス導入管及び送液配管連結部を備えたガラス製反応容器に、イオン交換水250部、メタノール750部、MMA40部、IBMA50部、アクリル酸イソブチル(以下、「IBA」)10部、及び、上記で得られたマクロモノマー(MM-2)を含む水溶液40部を仕込んだ。次いで、攪拌、及び窒素ガスの導入を行いながら、反応容器内の混合液の温度を60℃に調整した。
混合液の温度が60℃で安定したことを確認した後、ガラス製反応容器に、重合開始剤「パーブチルPV」2.4部を添加し、攪拌下、重合を開始した。この重合開始剤を添加すると、直ちに反応液に濁りが生じ、徐々に白化して乳白色となった。即ち、重合体微粒子が生成していることが確認された。重合開始剤の添加開始から、内温を60℃に保持して、6時間後、50℃まで冷却した。その後、減圧下、メタノール及び水を留去して、固形分が35.0%となるように調整して、シード粒子SD-1を含む分散液を得た。
得られたシード粒子SD-1の分散液を遠心分離処理し、上澄み液を除去した後、回収した微粒子の体積平均粒子径(dv)を、レーザー回折散乱式粒度分布計により測定したところ、1.65μmであった。 (1) Production of seed particles SD-1 In a glass reaction vessel equipped with a stirrer, a reflux condenser, a thermometer, a nitrogen gas introduction pipe and a liquid feed pipe connection section, 250 parts of ion-exchanged water, 750 parts of methanol, 40 parts of MMA , 50 parts of IBMA, 10 parts of isobutyl acrylate (hereinafter “IBA”), and 40 parts of an aqueous solution containing the macromonomer (MM-2) obtained above. Subsequently, the temperature of the liquid mixture in the reaction vessel was adjusted to 60 ° C. while stirring and introducing nitrogen gas.
After confirming that the temperature of the mixed solution was stable at 60 ° C., 2.4 parts of a polymerization initiator “perbutyl PV” was added to a glass reaction vessel, and polymerization was started with stirring. As soon as this polymerization initiator was added, the reaction solution became turbid and gradually whitened to become milky white. That is, it was confirmed that polymer fine particles were generated. From the start of addition of the polymerization initiator, the internal temperature was kept at 60 ° C., and after 6 hours, it was cooled to 50 ° C. Thereafter, methanol and water were distilled off under reduced pressure to adjust the solid content to 35.0% to obtain a dispersion containing seed particles SD-1.
The obtained dispersion of seed particles SD-1 was subjected to centrifugal separation, and the supernatant was removed. The volume average particle diameter (dv) of the collected fine particles was measured with a laser diffraction / scattering particle size distribution analyzer. .65 μm.
一方、SUS製容器に、MMA40部、IBMA40部及びトリメチロールプロパントリアクリレート(東亞合成社製、商品名「アロニックスM-309」)20部を仕込み、攪拌混合した。その後、得られた混合物に、更にイオン交換水100部に、乳化剤であるラウリル硫酸ナトリウム(花王社製、商品名「エマール2F-30」)1.5部を溶解させた乳化剤水溶液を加え、乳化器を用いて乳化させ、ビニル単量体の乳化物を調製した。
次に、シード粒子SD-1が収容された上記反応容器に、上記で調整したビニル単量体の乳化液を加え、更に重合開始剤である2,2’-アゾビス(2,4-ジメチルバレロニトリル)(和光純薬社製、商品名「V-65」)1部を加え、20℃で、12時間攪拌を行い、シード粒子SD-1にビニル単量体及び重合開始剤を吸収させた。
その後、反応容器内の気相部に、窒素ガス導入管より窒素ガスを導入した。そして、内温を20℃から70℃まで2時間かけて昇温することでシード粒子に吸収されたビニル単量体を重合させた。70℃に到達した後、更に2時間、70℃に維持しつつ、撹拌を行った。次いで、酸化防止剤であるトリエチレングリコールビス[3-(3-tert-ブチル-4-ヒドロキシ-5-メチルフェニル)]プロピオネート(ADEKA社製、商品名「AO-70」)1部をメタノール19部に溶解した液を加え、攪拌下、70℃で更に30分保持した。その後、冷却して架橋樹脂微粒子A8を含む分散液を得た。
次に、上記分散液の遠心分離処理を行い、上澄みを除去して、架橋樹脂微粒子A8を含む沈降ケーキを得た。得られた沈降ケーキを、同質量のイオン交換水と混合して、再分散させた。その後、再度遠心分離処理を行い、上澄みを除去して沈降ケーキを得た。そして、得られた沈降ケーキを、155℃で30分間加熱した場合の、不揮発分が98%以上になるまで80℃で乾燥した。乾燥後、解砕を行い、粉末の架橋樹脂微粒子A8を得た。得られたA8の物性を表1に示す。 (2) Production of crosslinked resin fine particles A8 In a glass reaction vessel equipped with a stirrer, reflux condenser, thermometer and nitrogen gas introduction tube, 299 parts of ion-exchanged water, 3.0 parts of 10% KOH aqueous solution, and the above A dispersion of 285.7 parts of the produced seed particle SD-1 was charged. Then, the temperature in reaction container was adjusted to 20 degreeC, stirring these.
On the other hand, 40 parts of MMA, 40 parts of IBMA and 20 parts of trimethylolpropane triacrylate (manufactured by Toagosei Co., Ltd., trade name “Aronix M-309”) were charged into a SUS container and mixed with stirring. Thereafter, an emulsifier aqueous solution in which 1.5 parts of sodium lauryl sulfate as an emulsifier (trade name “Emar 2F-30”) as an emulsifier is dissolved in 100 parts of ion-exchanged water is added to the obtained mixture, followed by emulsification. The mixture was emulsified using a vessel to prepare an emulsion of vinyl monomer.
Next, the vinyl monomer emulsion prepared above is added to the reaction vessel containing the seed particles SD-1, and 2,2′-azobis (2,4-dimethylvalero) as a polymerization initiator is further added. Nitrile) (trade name “V-65”, manufactured by Wako Pure Chemical Industries, Ltd.) 1 part was added, and the mixture was stirred at 20 ° C. for 12 hours to allow the seed monomer SD-1 to absorb the vinyl monomer and the polymerization initiator. .
Thereafter, nitrogen gas was introduced into the gas phase portion in the reaction vessel through a nitrogen gas introduction pipe. And the vinyl monomer absorbed by the seed particle was polymerized by heating up internal temperature over 2 hours from 20 degreeC to 70 degreeC. After reaching 70 ° C., the mixture was further stirred for 2 hours while maintaining the temperature at 70 ° C. Next, 1 part of triethylene glycol bis [3- (3-tert-butyl-4-hydroxy-5-methylphenyl)] propionate (trade name “AO-70” manufactured by ADEKA) as an antioxidant is added to methanol 19. The liquid which melt | dissolved in the part was added and it hold | maintained for 30 minutes at 70 degreeC under stirring. Thereafter, the mixture was cooled to obtain a dispersion containing crosslinked resin fine particles A8.
Next, the dispersion was centrifuged and the supernatant was removed to obtain a precipitated cake containing crosslinked resin fine particles A8. The obtained precipitated cake was mixed with the same mass of ion-exchanged water and redispersed. Then, the centrifugation process was performed again, the supernatant was removed, and the sedimentation cake was obtained. The obtained precipitated cake was dried at 80 ° C. until the non-volatile content reached 98% or more when heated at 155 ° C. for 30 minutes. After drying, crushing was performed to obtain powdered crosslinked resin fine particles A8. Table 1 shows the physical properties of the obtained A8.
B5:ガンツ化成社製、架橋ポリメタクリル酸メチル微粒子「GM-0105」(商品名)。
B6:ガンツ化成社製、架橋ポリメタクリル酸メチル微粒子「GM-0401S」(商品名)。
B7:モメンティブ・パフォーマンス・マテリアルズ社製、シリコーン樹脂微粒子「トスパール120」(商品名)。 Commercially available crosslinked resin fine particles B5 to B7 are shown below. Table 1 shows the volume average particle diameter (dv), coefficient of variation (CV), refractive index, and thermal decomposition temperature (Td 50 ).
B5: Cross-linked polymethyl methacrylate fine particles “GM-0105” (trade name) manufactured by Ganz Kasei Co., Ltd.
B6: Cross-linked polymethyl methacrylate fine particles “GM-0401S” (trade name) manufactured by Ganz Kasei Co., Ltd.
B7: Silicone resin fine particle “Tospearl 120” (trade name) manufactured by Momentive Performance Materials.
MMA:メタクリル酸メチル(屈折率 1.4900)
IBMA:メタクリル酸イソブチル(屈折率 1.4770)
IBA:アクリル酸イソブチル(屈折率 1.4608)
HA:アクリル酸2-エチルヘキシル(屈折率 1.4625)
TMOS-PMA:トリメトキシシリルプロピルメタクリレート(屈折率 1.4800)
TMPTA:トリメチロールプロパントリアクリレート(屈折率 1.5135)
St:スチレン(屈折率 1.5900) The abbreviations of the compounds used in Table 1 and the refractive index values of the respective homopolymers used for calculating the refractive index of the obtained crosslinked resin fine particles are described below.
MMA: Methyl methacrylate (refractive index 1.4900)
IBMA: Isobutyl methacrylate (refractive index: 1.4770)
IBA: Isobutyl acrylate (refractive index 1.4608)
HA: 2-ethylhexyl acrylate (refractive index: 1.4625)
TMOS-PMA: Trimethoxysilylpropyl methacrylate (refractive index 1.4800)
TMPTA: Trimethylolpropane triacrylate (refractive index 1.5135)
St: Styrene (refractive index 1.5900)
実施例1
本例では、透明樹脂であるポリカーボネート樹脂(三菱エンジニアリングプラスチックス社製、商品名「ユーピロン S-3000F」、屈折率 1.585)と、架橋樹脂微粒子A1とを含む組成物の製造及び評価を行った。
架橋樹脂微粒子A1を0.3gと、ポリカーボネート樹脂59.64gと、酸化防止剤(BASF社製、商品名「Irganox B225」)0.06gとを混合した後、ラボプラストミル(東洋精機社製、LABO PLASTOMILL)を用いて、250℃、50rpmの条件にて9分間溶融混練し、架橋樹脂微粒子A1を0.5%含む光拡散性樹脂組成物を得た(表2の(3)参照)。
光拡散性樹脂組成物を、所定の形状及び大きさを有するキャビティを有する金型を用いて、圧縮成型機(神藤金属工業所社製、「SFA-37」)により4MPaにて圧縮成型し、平板成形品(縦120mm×横120mm×厚さ1.5mm)を製造した。その後、マイクロメーターを用いて平板の厚さを測定し、1.50mm±0.05mmの範囲にあることを確認した。
また、別途、架橋樹脂微粒子A1及びポリカーボネート樹脂の配合量を、表2の(1)、(2)又は(4)に記載の通りに変えて、上記と同様にして、光拡散性樹脂組成物及び平板成形品を製造した。
上記により得られた各成形品について、全光線透過率及び分散度を測定した。結果を表2に示す。また、透明樹脂及び架橋樹脂微粒子の屈折率差の絶対値Δnも併記した。 4). Example 1 Production of Light Diffusing Resin Composition and Its Molded Product
In this example, the production and evaluation of a composition containing a polycarbonate resin (trade name “Iupilon S-3000F”, refractive index 1.585) manufactured by Mitsubishi Engineering Plastics Co., Ltd.) and a crosslinked resin fine particle A1 are carried out. It was.
After mixing 0.3 g of the crosslinked resin fine particles A1, 59.64 g of the polycarbonate resin, and 0.06 g of an antioxidant (trade name “Irganox B225” manufactured by BASF Corp.), Laboplast mill (manufactured by Toyo Seiki Co., Ltd., LABO PLASTOMILL) was melt-kneaded for 9 minutes at 250 ° C. and 50 rpm to obtain a light diffusing resin composition containing 0.5% of crosslinked resin fine particles A1 (see (3) in Table 2).
The light diffusing resin composition was compression-molded at 4 MPa with a compression molding machine (“SFA-37” manufactured by Shinto Metal Industries Co., Ltd.) using a mold having a cavity having a predetermined shape and size. A flat plate molded product (120 mm long × 120 mm wide × 1.5 mm thick) was produced. Thereafter, the thickness of the flat plate was measured using a micrometer and confirmed to be in the range of 1.50 mm ± 0.05 mm.
Separately, the light-diffusing resin composition was prepared in the same manner as described above except that the blending amounts of the crosslinked resin fine particles A1 and the polycarbonate resin were changed as shown in (1), (2) or (4) of Table 2. And a flat plate molded article was manufactured.
About each molded article obtained by the above, total light transmittance and dispersion degree were measured. The results are shown in Table 2. The absolute value Δn of the refractive index difference between the transparent resin and the crosslinked resin fine particles is also shown.
ポリカーボネート樹脂に代えて、GPポリスチレン樹脂(Dongbu Hannong Chemicals社製、商品名「SOLARENE GPPS G-116HV」、屈折率 1.590)を用い、混練温度を200℃とした以外は、実施例1と同様の操作を行い、光拡散性樹脂組成物及び平板成形品を得た。また、別途、ポリスチレン樹脂及び架橋樹脂微粒子A1の含有割合を変更した2種の組成物を製造した。得られた各成形品について、全光線透過率及び分散度を測定した。結果を表2に示す。 Example 2
Example 1 except that a GP polystyrene resin (manufactured by Dongbu Chemicals, trade name “SOLARENE GPPS G-116HV”, refractive index 1.590) was used instead of the polycarbonate resin, and the kneading temperature was 200 ° C. The light diffusing resin composition and the flat plate molded product were obtained. Separately, two types of compositions in which the content ratios of the polystyrene resin and the crosslinked resin fine particles A1 were changed were produced. About each obtained molded article, the total light transmittance and dispersion degree were measured. The results are shown in Table 2.
表2に示す配合で、ポリカーボネート樹脂及び架橋樹脂微粒子A2~A9を用い、実施例1と同様にして、光拡散性樹脂組成物及び平板成形品を得た。得られた各成形品について、全光線透過率及び分散度を測定した。結果を表2に示す。 Examples 3 to 10
A light diffusing resin composition and a flat molded article were obtained in the same manner as in Example 1 using the polycarbonate resin and the crosslinked resin fine particles A2 to A9 with the formulation shown in Table 2. About each obtained molded article, the total light transmittance and dispersion degree were measured. The results are shown in Table 2.
表3に示す配合で、ポリカーボネート樹脂及び架橋樹脂微粒子B1~B7を用い、実施例1と同様にして、光拡散性樹脂組成物及び平板成形品を得た。得られた各成形品について、全光線透過率及び分散度を測定した。結果を表3に示す。 Comparative Examples 1-7
A light diffusing resin composition and a flat molded product were obtained in the same manner as in Example 1 using the polycarbonate resin and the crosslinked resin fine particles B1 to B7 with the formulation shown in Table 3. About each obtained molded article, the total light transmittance and dispersion degree were measured. The results are shown in Table 3.
平均体積粒子径(dv)に着目してみると、1.8μm以上のdvを有する架橋樹脂微粒子を用いた実施例1~9では、全光線透過率85%程度における分散度が20度以上と認められ、全光線透過率の高い領域においても良好な拡散性が発揮されることが判った。また、dvが2.8μm以下である実施例1~4、並びに6~10では、透明樹脂に対する架橋性樹脂微粒子の添加量を0.5%とした際の分散度が22度以上であり、拡散効率がより良好である結果が得られた。 As is clear from Examples 1 to 10, the addition amount of the crosslinked resin fine particles (light diffusing agent) necessary for obtaining a degree of dispersion (light diffusibility) of about 20 degrees is as small as 0.5% or less. Thus, a result showing good diffusion efficiency was obtained. In addition, from the results of Example 1, it can be confirmed that good diffusibility is exhibited in a wide total light transmittance region of approximately 60 to 90% within a range of the addition amount of the crosslinked resin fine particles up to 2.0%. It was.
Focusing on the average volume particle diameter (dv), in Examples 1 to 9 using crosslinked resin fine particles having a dv of 1.8 μm or more, the degree of dispersion at a total light transmittance of about 85% is 20 degrees or more. It was recognized that good diffusivity was exhibited even in a region having a high total light transmittance. In Examples 1 to 4 and 6 to 10 where dv is 2.8 μm or less, the degree of dispersion when the addition amount of the crosslinkable resin fine particles to the transparent resin is 0.5% is 22 degrees or more, Results with better diffusion efficiency were obtained.
その他、架橋樹脂微粒子の体積平均粒子径(dv)が小さい比較例2、並びにシリコーン系の架橋樹脂微粒子を用いた比較例7では、全光線透過率85%程度の高い全光線透過率領域における分散度が低く、適用可能な全光線透過率領域が限られるものであることが判った。
更に、架橋性微粒子を構成する単量体成分が全てメタクリル酸エステル系単量体からなる比較例4は、熱分解速度が速く、架橋樹脂微粒子を光拡散板等に用いた場合には、その耐熱性において懸念される結果が得られた。 On the other hand, Comparative Example 1 in which the refractive index difference Δn between the transparent resin and the crosslinked resin fine particles is small, Comparative Example 3 in which the volume average particle size (dv) of the crosslinked resin fine particles is large, Comparative Example 5 in which the particle size distribution is wide, and Large particle size In Comparative Example 6 having a wide particle size distribution, the dispersion degree is less than 20 degrees when the addition amount of the crosslinked resin fine particles (light diffusing agent) is 0.5%, and the diffusion efficiency is inferior. there were. Further, from the result of Comparative Example 1, it is estimated that the region exhibiting diffusibility with a degree of dispersion of 20 degrees or more is about 70 to 90% or so in the range of the addition amount of the crosslinked resin fine particles up to 2.0%. As a result, the total light transmittance region showing good diffusibility compared with Example 1 was narrow.
In addition, in Comparative Example 2 in which the volume average particle diameter (dv) of the crosslinked resin fine particles is small and in Comparative Example 7 in which the silicone-based crosslinked resin fine particles are used, the dispersion in a high total light transmittance region having a total light transmittance of about 85%. It has been found that the total light transmittance region that can be applied is limited.
Furthermore, Comparative Example 4 in which the monomer components constituting the crosslinkable fine particles are all methacrylic acid ester monomers has a high thermal decomposition rate, and when the crosslinked resin fine particles are used for a light diffusion plate or the like, The result of concern about heat resistance was obtained.
Claims (10)
- 透明樹脂(X)及び架橋樹脂微粒子(Y)を含み、前記透明樹脂(X)の屈折率と、前記架橋樹脂微粒子(Y)の屈折率との差の絶対値が0.095~0.115であり、前記架橋樹脂微粒子(Y)の体積平均粒子径が1.5~3.3μmであり、前記架橋樹脂微粒子(Y)の粒子径の変動係数が20%以下であり、前記架橋樹脂微粒子(Y)を、窒素ガス雰囲気下、昇温速度10℃/分の条件で熱分解させた場合に、質量が半分となる温度が320℃以上であることを特徴とする光拡散性樹脂組成物。 Including a transparent resin (X) and crosslinked resin fine particles (Y), the absolute value of the difference between the refractive index of the transparent resin (X) and the refractive index of the crosslinked resin fine particles (Y) is 0.095 to 0.115. The volume average particle diameter of the crosslinked resin fine particles (Y) is 1.5 to 3.3 μm, the coefficient of variation of the particle diameter of the crosslinked resin fine particles (Y) is 20% or less, and the crosslinked resin fine particles The light diffusing resin composition is characterized in that, when (Y) is thermally decomposed under a nitrogen gas atmosphere at a temperature rising rate of 10 ° C./min, the temperature at which the mass becomes half is 320 ° C. or higher. .
- 前記架橋樹脂微粒子(Y)が(メタ)アクリル酸エステルに由来する構造単位を含む請求項1に記載の光拡散性樹脂組成物。 The light diffusing resin composition according to claim 1, wherein the crosslinked resin fine particles (Y) include a structural unit derived from a (meth) acrylic acid ester.
- 前記光拡散性樹脂組成物を用いて作製した厚さ1.5mmのシートであって、白色光の全光線透過率が85%である該シートの表面に、ゴニオメーターを用いて垂直方向に光を入射した場合に、0度の出射光に対して50%の輝度の出射光となる角度が20度以上である請求項1又は2に記載の光拡散性樹脂組成物。 A sheet of 1.5 mm thickness produced using the light diffusing resin composition and having a total light transmittance of white light of 85%, a light is vertically applied using a goniometer. The light diffusing resin composition according to claim 1, wherein an angle at which the emitted light having a luminance of 50% with respect to the emitted light at 0 degree is 20 degrees or more when the incident light is incident.
- 前記透明樹脂(X)及び前記架橋樹脂微粒子(B)の質量割合がそれぞれ100質量部及び0.5質量部である光拡散性樹脂組成物を用いて作製した厚さ1.5mmのシートの表面に、ゴニオメーターを用いて垂直方向に光を入射した場合に、0度の出射光に対して50%の輝度の出射光となる角度が22度以上である請求項1又は2に記載の光拡散性樹脂組成物。 The surface of a 1.5 mm thick sheet produced using a light diffusing resin composition in which the mass ratio of the transparent resin (X) and the crosslinked resin fine particles (B) is 100 parts by mass and 0.5 parts by mass, respectively. The light according to claim 1 or 2, wherein when light is incident in a vertical direction using a goniometer, the angle at which the emitted light having a luminance of 50% with respect to the emitted light at 0 degree is 22 degrees or more. A diffusible resin composition.
- 前記透明樹脂(X)がポリカーボネート樹脂である請求項1~4のいずれかに記載の光拡散性樹脂組成物。 The light diffusing resin composition according to any one of claims 1 to 4, wherein the transparent resin (X) is a polycarbonate resin.
- 前記透明樹脂(X)100重量部に対して前記架橋樹脂微粒子(Y)を0.1~2.0質量部含んでなる請求項1~5のいずれかに記載の光拡散性樹脂組成物。 6. The light diffusing resin composition according to claim 1, comprising 0.1 to 2.0 parts by mass of the crosslinked resin fine particles (Y) with respect to 100 parts by weight of the transparent resin (X).
- 前記架橋樹脂微粒子(Y)が、分散重合法により製造されたものである請求項1~6のいずれかに記載の光拡散樹脂組成物。 The light diffusing resin composition according to any one of claims 1 to 6, wherein the crosslinked resin fine particles (Y) are produced by a dispersion polymerization method.
- 前記架橋樹脂微粒子(Y)が、加水分解性シリル基を有する(メタ)アクリル酸エステル系樹脂をシラン架橋して得られる架橋樹脂微粒子である請求項1~7のいずれかに記載の光拡散性樹脂組成物。 The light diffusibility according to any one of claims 1 to 7, wherein the crosslinked resin fine particles (Y) are crosslinked resin fine particles obtained by silane-crosslinking a (meth) acrylic acid ester-based resin having a hydrolyzable silyl group. Resin composition.
- 請求項1~8のいずれかに記載の光拡散性樹脂組成物からなる成形品。 A molded article comprising the light diffusing resin composition according to any one of claims 1 to 8.
- 上記成形品が照明器具又は表示器具に配設される請求項9に記載の成形品。 The molded product according to claim 9, wherein the molded product is disposed in a lighting device or a display device.
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CN107266807B (en) * | 2017-06-07 | 2019-04-30 | 潮州明园新材料有限公司 | A kind of photodiffusion material |
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