BR112019012903B1 - MOLDED BODY AND ITS PRODUCTION METHOD - Google Patents

Abstract

The present invention relates to a molded body with excellent impact resistance, obtained by mixing an impact-resistant resin containing a polyamide resin and a polyolefin resin with a polyolefin resin, and to a method for producing it. The molded body includes: a continuous phase containing a first polyolefin resin and a second polyolefin resin; and a dispersed phase containing a polyamide resin and a modified elastomer, wherein the dispersed phase is composed of a melt-kneaded product of the polyamide resin and the modified elastomer, the elastomer is an elastomer with a reactive group that reacts with the polyamide resin. polyamide, the elastomer is an olefin-based thermoplastic elastomer, such as a skeleton, a copolymer of ethylene or propylene and an α-olefin with 3 to 8 carbon atoms, or a styrene-based thermoplastic elastomer with a styrene skeleton, when a total of the continuous phase and the dispersed phase is taken as 100% by mass, a content of the dispersed phase is 70% by mass or less, and when a total of the first polyolefin resin and the second polyolefin resin is taken as 100 % in large scale,(...).

Description

TECHNICAL FIELD OF THE INVENTION

[001] The present invention relates to a molded body and a method for its production. More specifically, the present invention relates to a molded body with excellent impact resistance and a method for producing it.

PREVIOUS TECHNIQUE

[002] Attempts have been made to date to mix different types of resins to obtain mixed resins that can offer characteristics superior to those offered by each of the resins individually. For example, in Patent Literatures 1 to 4 below, the present inventors have disclosed a technique in which a polyamide resin and a polyolefin resin are used in combination to obtain a mixed resin with improved characteristics.

LIST OF QUOTES PATENT LITERATURE

[003] Patent Literature 1: JP 2013-147645 A

[004] Patent Literature 2: JP 2013-147646 A

[005] Patent Literature 3: JP 2013-147647 A

[006] Patent Literature 4: JP 2013-147648 A

SUMMARY OF THE INVENTION TECHNICAL PROBLEMS

[007] Patent Literature 1 describes a polymer alloy (thermoplastic resin composition) of a polyamide resin and a polyolefin resin obtained using, as a compatibilizer, an elastomer modified with a reactive group capable of reacting with the polyamide resin .

[008] Patent Literature 2 describes that a plant-derived polyamide resin can be used as a polyamide resin contained in a polymer alloy of a polyamide resin and a polyolefin resin.

[009] Patent Literature 3 describes a polymer alloy containing a polyamide resin and a polyolefin resin, which has a resin phase-separated structure with a continuous phase, a dispersed phase in the continuous phase and a fine dispersed phase also dispersed in the dispersed phase.

[0010] Patent Literature 4 describes that a polymeric alloy with excellent impact resistance can be obtained, first, by melt mixing a polyamide resin and a compatibilizer to obtain a mixed resin and then mixing by fusion of mixed resin and a polyolefin resin.

[0011] However, according to Patent Literatures 1 to 4 above, the present inventors have studied the production and use of these polymer alloys alone, but have not studied the use of these polymer alloys together with other resins.

[0012] In light of the above circumstances, an object of the present invention is to provide a molded body with excellent impact resistance obtained by mixing an impact-resistant resin containing a polyamide resin and a polyolefin resin with a polyolefin resin, and to a method for its production

SOLUTION TO PROBLEMS

[0013] The present invention is as follows.

[0014] In order to achieve the above object, the present invention is directed to a molded body according to claim 1, obtained by molding a thermoplastic resin, including: a continuous phase (A) containing a first powder resin. lyolefin and a second polyolefin resin; and the dispersed phase (B) dispersed in the continuous phase (A) and containing a polyamide resin and a modified elastomer, wherein the dispersed phase (B) is composed of a kneaded product under fusion of the polyamide resin and the elastomer modified, the modified elastomer is an elastomer with a reactive group that reacts with the polyamide resin, the elastomer is an olefin-based thermoplastic elastomer having, as a skeleton, a copolymer of ethylene or propylene and an α- olefin with 3 to 8 carbon atoms or a styrene-based thermoplastic elastomer with a styrene skeleton, and when a total of the continuous phase (A) and the dispersed phase (B) is taken as 100% by mass, a content of Disperse phase (B) is 70% by mass or less, and when a total of the first polyolefin resin and the second polyolefin resin is taken as 100% by mass, a content of the second polyolefin resin is 80% by mass or less.

[0015] A molded body according to claim 2 is the molded body according to claim 1, wherein the thermoplastic resin is a mixture of an impact resistant resin containing the second polyolefin resin, the polyamide resin and the modified elastomer and the first polyolefin resin.

[0016] A molded body according to claim 3 is the molded body according to claim 1 or 2, wherein, when a total of the polyamide resin and the modified elastomer is taken as 100% by mass, a content of the Polyamide resin is 10% by mass or more, but 80% by mass or less.

[0017] A molded body according to claim 4 is the molded body according to any one of claims 1 to 3, wherein the dispersed phase (B) has a continuous phase (B1) containing the polyamide resin and a phase fine dispersed (B2) dispersed in the continuous phase (B1) and containing the modified elastomer.

[0018] A molded body according to claim 5 is the molded body according to any one of claims 1 to 4, wherein the polyamide resin is polyamide 6.

[0019] A molded body according to claim 6 is the molded body according to claim 5, wherein the second polyolefin resin has a number average molecular weight of 300,000 or more.

[0020] A molded body according to claim 7 is the molded body according to any one of claims 1 to 6, wherein the first polyolefin resin is a block copolymerized polyolefin resin having an ethylene block as a dispersed phase, and at least part of the ethylene block is aggregated at an interface between the continuous phase (A) and the dispersed phase (B).

[0021] A production method according to claim 8 is a method of producing the molded body according to claim 1, the method including: a step of preparing the raw material of the molded body, wherein a heat-resistant resin impacts obtained by melt-kneading the melt-kneaded product of the polyamide resin and the modified elastomer and the second polyolefin resin and the first polyolefin resin are mixed to obtain the raw material of a molded body; and a molding step in which the molded body raw material is molded to obtain the molded body.

[0022] A production method according to claim 9 is the molded body production method according to claim 8, wherein the impact resistant resin has a continuous phase (C) containing the second polyolefin resin and a dispersed phase (B) dispersed in the continuous phase (C) and containing the polyamide resin and the modified elastomer, and the dispersed phase (B) has a continuous phase (B1) containing the polyamide resin and a fine dispersed phase (B2) dispersed in the continuous phase (B1) and containing the modified elastomer.

[0023] A production method according to claim 10 is the method for producing the molded body according to claim 8 or 9, wherein the first polyolefin resin is a block copolymerized polyolefin resin having an ethylene block as a dispersed phase.

ADVANTAGEOUS EFFECTS OF THE INVENTION

[0024] The molded body according to the present invention can obtain excellent impact resistance characteristics.

[0025] When the thermoplastic resin is a mixture of the first polyolefin resin and an impact-resistant resin containing the second polyolefin resin, the polyamide resin and the modified elastomer, the molded body can achieve particularly excellent impact resistance characteristics.

[0026] When the total of the polyamide resin and the modified elastomer is taken as 100% by mass and the content of the polyamide resin is 10% by mass or more, but 80% by mass or less, a structure of specific phase can be obtained more stably and therefore the molded body can offer excellent impact resistance.

[0027] When the dispersed phase (B) has a continuous phase (B1) containing the polyamide resin and a fine dispersed phase (B2) dispersed in the continuous phase (B1) and containing the modified elastomer, a multi-phase structure is formed and therefore the molded body can have greater impact resistance.

[0028] When the polyamide resin is polyamide 6, the tensile modulus of elasticity derived from the first polyolefin resin can be maintained satisfactorily, and the molded body can have better impact resistance.

[0029] When the polyamide resin is polyamide 6 and the second polyolefin resin has a number average molecular weight of 300,000 or more, the molded body can achieve particularly excellent impact resistance characteristics.

[0030] When the first polyolefin resin is a block copolymerized polyolefin resin having an ethylene block as a dispersed phase, and at least part of the ethylene block is aggregated at the interface between the continuous phase (A) and the dispersed phase (B), a multi-phase structure is formed and therefore the molded body can have greater impact resistance.

[0031] According to the production method of the present invention, the molded body according to the present invention can be reliably obtained, which has a continuous phase (A) containing a first polyolefin resin and a second polyolefin resin. polyolefin and a dispersed phase (B) dispersed in the continuous phase (A) and containing a polyamide resin and a modified elastomer.

[0032] When the impact-resistant resin has a continuous phase (C) containing the second polyolefin resin and a dispersed phase (B) dispersed in the continuous phase (C) and containing the polyamide resin and the modified elastomer, and the dispersed phase (B) has a continuous phase (B1) containing the polyamide resin and a fine dispersed phase (B2) dispersed in the continuous phase (B1) and containing the modified elastomer, a molded body with a multi-phase structure and excellent strength impacts can be reliably obtained.

[0033] When the first polyolefin resin is a block copolymerized polyolefin resin having an ethylene block as a dispersed phase, a molded body having a multiphase structure can be reliably obtained, in which at least part of the ethylene block is aggregated at the interface between the continuous phase (A) and the dispersed phase (B). That is, a molded body having particularly excellent impact resistance can be obtained reliably.

BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 is a schematic diagram to explain the phase structure of a resin composition that constitutes the test samples for evaluating the Examples.

[0035] Figure 2 is a graph showing a correlation between the tensile modulus of elasticity and the amount of a reinforcing resin added to each of the test samples for evaluating the Examples [based on PA6 (no. 1) , based on PA6 (n° 2) and based on PA11].

DESCRIPTION OF MODALITIES

[0036] The particulars shown here are by way of example and for the purpose of illustrating the embodiments of the present invention only, and are presented with the intention of providing the description considered most useful and easily understood of the principles and conceptual aspects of the present invention. In this regard, while there is no attempt to show structural details of the present invention in more detail than is necessary for a fundamental understanding of the present invention, the description in conjunction with the drawings makes it apparent to those skilled in the art how the various forms of the present invention can be be incorporated into practice.

[0037] A molded body according to the present invention is a molded body obtained by molding a thermoplastic resin, the molded body including: a continuous phase (A) containing a first polyolefin resin and a second polyolefin resin; and the dispersed phase (B) dispersed in the continuous phase (A) and containing a polyamide resin and a modified elastomer, wherein the dispersed phase (B) is composed of a product kneaded under fusion of the polyamide resin and the modified elastomer, the modified elastomer is an elastomer with a reactive group that reacts with the polyamide resin, the elastomer is an olefin-based thermoplastic elastomer having, as a skeleton, a copolymer of ethylene or propylene and an α-olefin with 3 to 8 carbon atoms or a styrene-based thermoplastic elastomer with a styrene skeleton, and when a total of the continuous phase (A) and the dispersed phase (B) is taken as 100% by mass, a content of the dispersed phase (B) is 70% by mass or less, and when a total of the first polyolefin resin and the second polyolefin resin is taken as 100% by mass, a content of the second polyolefin resin is 80% by mass or less . [1] COMPONENTS

(1) FIRST POLYOLEFINE RESIN

[0038] The "first polyolefin resin" (hereinafter also simply referred to as "first polyolefin") is an olefin homopolymer and/or an olefin copolymer. In the molded body, this first polyolefin resin is contained in the continuous phase (A) together with the second polyolefin resin.

[0039] An olefin that constitutes the first polyolefin is not particularly limited, but its examples include ethylene, propylene, 1-butene, 3-methyl-1-butene, 1-pentene, 3-methyl-1-pentene, 4-methyl -1- pentene, 1-hexene and 1-octene. These olefins can be used separately or in combination of two or more of them.

[0040] Specific examples of the polyolefin resin include a polyethylene resin, a polypropylene resin, poly-1-butene, poly-1-hexene, poly-4-methyl-1-pentene. These polymers can be used separately or in combination with two or more of them. That is, polyolefin resin can be a mixture of the above polymers.

[0041] Examples of polyethylene resin include an ethylene homopolymer and a copolymer of ethylene and another olefin. Examples of the latter include an ethylene-1-butene copolymer, an ethylene-1-hexene copolymer, an ethylene-1-octene copolymer and ethylene-4-methyl-1-pentene copolymer (the content of a structural unit derived of ethylene is 50% or more of the total structural units).

[0042] Examples of polypropylene resin include a propylene homopolymer and a copolymer of propylene and another olefin.

[0043] Examples of the other olefin that constitutes the copolymer of propylene and another olefin include the various olefins mentioned above (with the exception of propylene). Among them, for example, ethylene and 1-butene are preferred. That is, the copolymer of propylene and another olefin is preferably a propylene-ethylene copolymer or a propylene-1-butene copolymer.

[0044] The copolymer of propylene and another olefin can be either a random copolymer or a block copolymer. Among them, a block copolymer is preferred with regard to excellent impact resistance. Particularly, a propylene-ethylene block copolymer having ethylene as another olefin is preferred. This propylene-ethylene block copolymer is a block copolymerized polypropylene having an ethylene block as a dispersed phase. More specifically, the propylene-ethylene block copolymer is a polypropylene resin having a continuous phase composed of homopolypropylene and a dispersed phase present in the continuous phase and containing polyethylene. A block copolymerized polypropylene having an ethylene block as a dispersed phase is also called, for example, an impact copolymer, a polypropylene impact copolymer, a heterophasic polypropylene or a heterophasic block polypropylene. This block copolymerized polypropylene is preferred for excellent impact resistance.

[0045] It is worth noting that the content of a propylene-derived unit from the copolymer of propylene and another olefin is 50% or more of the total structural units.

[0046] The number average molecular weight of the first polyolefin resin is not particularly limited, and may be, for example, 10,000 or more, but 500,000 or less, and is preferably 100,000 or more, but preferably 450,000 or less, more preferably 200,000 or more, but 400,000 or less.

[0047] For example, when the number average molecular weight of the second polyolefin resin that will be described later is 300,000 or more, the number average molecular weight of the first polyolefin resin may be 150,000 or more, but less than 300,000. When the number average molecular weight of the second polyolefin resin is 350,000 or more, the number average molecular weight of the first polyolefin resin may be 150,000 or more, but less than 350,000.

[0048] It should be noted that the number average molecular weight of the first polyolefin resin is determined by gel permeation chromatography (GPC) based on polystyrene standards. When the first polyolefin resin used in the present invention is a homopolymer, the numerical ranges above the number average molecular weight can be respectively considered as the numerical ranges of a number average molecular weight.

[0049] The first polyolefin resin is a polyolefin that does not have affinity with the polyamide resin that will be described later, and which also does not have a reactive group capable of reacting with the polyamide resin. At this point, the second polyolefin resin is different from an olefin-based component, as is the modified elastomer that will be described later.

(1) SECOND POLYOLEFINE RESIN

[0050] The "second polyolefin resin" (hereinafter also simply referred to as "second polyolefin") is an olefin homopolymer and/or an olefin copolymer. In the molded body, this second polyolefin resin is contained in the continuous phase (A) together with the first polyolefin resin.

[0051] An olefin that constitutes the second polyolefin is not particularly limited, and examples thereof include the olefins mentioned above with reference to the first polyolefin.

[0052] The first polyolefin and the second polyolefin may be the same resin or different resins.

[0053] When the first polyolefin and the second polyolefin are different resins, for example, one of the first polyolefin and the second polyolefin is a block copolymerized polyolefin resin (for example, a block copolymerized polypropylene resin) having a block of ethylene as a dispersed phase, and the other is a non-block copolymerized polyolefin resin.

[0054] In this case, in relation to impact resistance, it is preferable that the first polyolefin is a block copolymerized polypropylene resin having an ethylene block as a dispersed phase, and the second polyolefin is a non-copolymerized polyolefin resin. - block merized. Furthermore, the non-block copolymerized polyolefin resin is preferably a homopolypropylene resin.

[0055] It is worth noting that non-block copolymerized polyolefin resin in this document refers to a copolymerized polyolefin resin that does not have an ethylene block as a dispersed phase. Therefore, in this disclosure, a block copolymerized polyolefin resin that does not have an ethylene block as a dispersed phase is included in the non-block copolymerized polyolefin resin.

[0056] In the case described above, in which the first polyolefin is a block copolymerized polypropylene resin having an ethylene block as a dispersed phase and the second polyolefin is a non-block copolymerized polypropylene resin, the molded body has a phase continuous (A) formed from homopolypropylene constituting the first polypropylene resin and the second polypropylene resin, a dispersed phase (B) dispersed in the continuous phase (A) and containing the polyamide resin and the modified elastomer, and a dispersed phase (B') composed of the ethylene block constituting the first polypropylene resin. Furthermore, at least part of the ethylene block is aggregated at the interface between the continuous phase (A) and the dispersed phase (B). This allows the thermoplastic resin composition and molded body to offer particularly excellent impact resistance.

[0057] The number average molecular weight of the second polyolefin resin is not particularly limited, and may be, for example, 10,000 or more (normally 700,000 or less), but is preferably 100,000 or more, more preferably 200,000 or more.

[0058] It should be noted that the number average molecular weight of the second polyolefin resin is determined by gel permeation chromatography (GPC) based on polystyrene standards. When the second polyolefin resin used in the present invention is a homopolymer, the numerical ranges above the number average molecular weight can be respectively considered as the numerical ranges of a number average molecular weight.

[0059] When the polyamide that will be described later is polyamide 6, the number average molecular weight of the second polyolefin resin may be 300,000 or more (normally 700,000 or less), but is preferably 310,000 or more, of preferably 350,000 or more, even more preferably 370,000 or more, even more preferably 400,000 or more, especially preferably 450,000 or more, more particularly preferably 470,000 or more, even more particularly preferably 500,000 or more.

[0060] In this case, the molded body can have greater impact resistance, while maintaining the elastic modulus in the traction of the first polyolefin resin.

[0061] It should be noted that the upper limit of the numerical average molecular weight may be, for example, 700,000 or less, as described above, but may still be 650,000 or less and may still be 600,000 or less.

[0062] The MFR (flow index) of the second polyolefin resin is not particularly limited. The molecular weight (including the number average molecular weight) of a polyolefin resin generally has a proportional relationship with the MFR. The MFR of the second polyolefin resin is preferably, for example, 25 g/10 min or less. The lower limit of the MFR is not particularly limited, but may be, for example, 1 g/10 min or more. The MFR is preferably 22 g/10 min or less, more preferably 19 g/10 min or less, even more preferably 16 g/10 min or less, even more preferably 13 g/10 min or less, especially preferably 10 g/ 10 min or less, even more particularly preferably 9 g/10 min or less, even more particularly preferably 8 g/10 min or less.

[0063] The MFR of the second polyolefin resin is measured in accordance with JIS K 7210, under conditions of temperature of 230°C and load of 21.18 N (2.16 kgf).

[0064] It should be noted that the second polyolefin resin is a polyolefin that does not have affinity with the polyamide resin that will be described later, and that also does not have a reactive group capable of reacting with the polyamide resin. At this point, the second polyolefin resin is different from an olefin-based component, as is the modified elastomer that will be described later.

(3) POLYAMIDE RESIN

[0065] "Polyamide resin" is a polymer with a chain-like skeleton formed by the polymerization of a plurality of monomers through amide bonds (-NH-CO-). In the molded body, this polyolefin resin is contained in the dispersed phase (B) together with the modified elastomer.

[0066] Examples of a monomer that forms polyamide resin include amino acids, such as 6-aminocaproic acid, 11-aminoundecanoic acid, 12-aminododecanoic acid and para-aminomethyl benzoic acid, and lactams such as ε-caprolactam, undecane lac- tama and w-lauryl lactam. These olefins can be used separately or in combination of two or more of them.

[0067] Furthermore, polyamide resin can be obtained by copolymerization of a diamine and a dicarboxylic acid. In this case, examples of diamine as a monomer include: aliphatic diamines such as ethylene diamine, 1,3-diaminopropane, 1,4-diaminobutane, 1,6-diaminohexane, 1,7-diaminoeptane, 1,8-diamino- octane, 1,9-diaminononane, 1,10-diaminodecane, 1,11-diaminoundecane, 1,12-diaminododecane, 1,13-diaminotridecane, 1,14-diaminotetradecane, 1,15-diaminopentadecane, 1,16-diaminohexadecane, 1,17-diaminoheptadecane, 1,18-diaminooctadecane, 1,19-diaminononadecane, 1-20-diaminoeicosane, 2-methyl-1,5-diaminopentane and 2-methyl-1,8-diaminooctane; alicyclic diamines such as diamino cyclohexane and bis-(4-aminocyclohexyl)methane; and aromatic diamines such as xylylene diamines (e.g. p-phenylenediamine and m-phenylenediamine). These olefins can be used separately or in combination of two or more of them.

[0068] Examples of dicarboxylic acid as a monomer include: aliphatic dicarboxylic acids, such as oxalic acid, malonic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, acid undecanedioic acid, dodecanedioic acid, brasilic acid, tetradecanedioic acid, pentadecanedioic acid and octadecanedioic acid; alicyclic dicarboxylic acids such as cyclohexanedicarboxylic acid; and aromatic dicarboxylic acids, such as phthalic acid, terephthalic acid, isophthalic acid and naphthalenedicarboxylic acid. These olefins can be used separately or in combination of two or more of them.

[0069] Specific examples of polyamide resin include polyamide 6, polyamide 66, polyamide 11, polyamide 610, polyamide 612, polyamide 614, polyamide 12, polyamide 6T, polyamide 6I, polyamide 9T, polyamide M5T, polyamide 1010, polyamide 1012, polyamide 10T, polyamide MXD6, polyamide 6T/66, polyamide 6T/6I, polyamide 6T/6I/66, polyamide 6T/2M-5T and polyamide 9T/2M-8T. These polyamides can be used separately or in combination with two or more of them.

[0070] In the present invention, among the various polyamide resins mentioned above, plant-derived polyamide resins can be used. Plant-derived polyamide resins are preferable from an environmental protection standpoint (particularly from a carbon neutral standpoint) because they are resins that use monomers derived from plant-derived components such as vegetable oils.

[0071] Examples of plant-derived polyamide resins include polyamide 11 (hereinafter also simply referred to as "PA11"), polyamide 610 (hereinafter also simply referred to as "PA610"), polyamide 612 (hereinafter also simply referred to as " PA612"), polyamide 614 (hereinafter also simply referred to as "PA614"), polyamide 1010 (hereinafter also simply referred to as "PA1010"), polyamide 1012 (hereinafter also simply referred to as "PA1012") and polyamide 10T (the hereafter also simply referred to as "PA10T"). These olefins can be used separately or in combination of two or more of them.

[0072] Among the above-mentioned polyamide resins, PA11 has a structure in which monomers with 11 carbon atoms are linked through amide bonds. PA11 can be obtained using aminoundecanoic acid, derived from castor oil as a monomer. The content of a structural unit derived from the monomer with 11 carbon atoms in PA11 is preferably 50% or more, or may be 100% of all structural units of PA11.

[0073] PA610 has a structure in which monomers with 6 carbon atoms and monomers with 10 carbon atoms are linked through amide bonds. PA610 can be obtained using sebacic acid derived from castor oil as a monomer. The total content of a structural unit derived from the monomer having 6 carbon atoms and a structural unit derived from the monomer having 10 carbon atoms in PA610 is preferably 50% or more, or may be 100% of all structural units of PA610.

[0074] PA1010 has a structure in which a diamine with 10 carbon atoms and a dicarboxylic acid with 10 carbon atoms are copolymerized. PA1010 can be obtained using 1,10-decanediamine (decamethylene diamine) and sebacic acid, which are derived from castor oil, as monomers. The total content of a diamine-derived structural unit of 10 carbon atoms and a dicarboxylic acid-derived structural unit of 10 carbon atoms in PA1010 is preferably 50% or more, or may be 100% of all structural units of PA1010 .

[0075] PA614 has a structure in which a monomer with 6 carbon atoms and a monomer with 14 carbon atoms are linked through amide bonds. PA614 can be obtained by using a plant-derived dicarboxylic acid with 14 carbon atoms as a monomer. The total content of a structural unit derived from a monomer with 6 carbon atoms and a structural unit derived from a monomer with 14 carbon atoms in PA614 is preferably 50% or more, but may be 100% of all units. structures of PA614.

[0076] PA10T has a structure in which a diamine with 10 carbon atoms and terephthalic acid are linked through amide bonds. PA10T can be obtained using 1,10-decanediamine (decamethylene diamine) derived from castor oil as a monomer. The total content of a diamine-derived structural unit with 10 carbon atoms and a terephthalic acid-derived structural unit in PA10T is preferably 50% or more, or may be 100% of all structural units in PA10T.

[0077] Among the above five plant-derived polyamide resins, PA11 is superior to the other four plant-derived polyamide resins in terms of low water absorption capacity, low specific gravity and high degree of biomass.

[0078] Polyamide 610 is inferior to PA11 in water absorption rate, chemical resistance and impact resistance, but it is excellent in heat resistance (melting point) and rigidity (strength). Furthermore, polyamide 610 has lower water absorption capacity and is superior to polyamide 6 or polyamide 66 in size stability and therefore can be used as an alternative to polyamide 6 or polyamide 66.

[0079] Polyamide 1010 is superior to PA11 in heat resistance and stiffness. Furthermore, the biomass grade of polyamide 1010 is comparable to that of PA11 and therefore polyamide 1010 can be used for parts that need to have greater durability.

[0080] Polyamide 10T has an aromatic ring in its molecular skeleton and therefore has a higher melting point and greater rigidity than polyamide 1010. Therefore, polyamide 10T can be used in harsh environments (such as parts that need have heat resistance or parts on which a force will be exerted).

[0081] In the present invention, among the various polyamide resins mentioned above, polyamide 6 can be used.

[0082] In this case, the tensile modulus of elasticity derived from the first polyolefin resin can be maintained satisfactorily, and the molded body can have better impact resistance. Furthermore, compared to a case where another polyamide, such as the above-described polyamide 11, is used, the molded body can achieve comparable or superior performance (especially the tensile modulus of elasticity), even when the polyamide content is relatively low. smaller, which is advantageous in terms of costs.

(4) MODIFIED ELASTOMER

[0083] The "modified elastomer" is an elastomer with a reactive group that reacts with the polyamide resin. That is, the modified elastomer is an elastomer that is given a reactive group that can react with the polyamide resin. In the molded body, this modified elastomer is contained in the dispersed phase (B) together with the polyamide resin.

[0084] The modified elastomer is preferably a component with an affinity for the second polyolefin resin. More specifically, the modified elastomer is preferably a component with a compatibilizing effect on the polyamide resin and the second polyolefin resin. In other words, the modified elastomer is preferably a compatibilizer for the polyamide resin and the second polyolefin resin.

[0085] The elastomer (i.e., a skeletal resin that forms the skeleton of the modified elastomer) is an olefin-based thermoplastic elastomer that has, as a skeleton, an ethylene or propylene copolymer and an α-olefin with 3 to 8 carbon atoms (i.e. a copolymer of ethylene and an α-olefin with 3 to 8 carbon atoms or a copolymer of propylene and an α-olefin with 4 to 8 carbon atoms) or a thermoplastic elastomer based on stretch it with a styrene skeleton. These elastomers can be used individually or in combination of two or more of them.

[0086] Examples of α-olefin with 3 to 8 carbon atoms include propylene, 1-butene, 3-methyl-1-butene, 1-pentene, 3-methyl-1-pentene, 4-methyl-1-pentene , 1-hexene and 1-octene.

[0087] Examples of the copolymer of ethylene and an α-olefin with 3 to 8 carbon atoms include an ethylene-propylene copolymer (EPR), an ethylene-1-butene copolymer (EBR), an ethylene-1- pentene and an ethylene-1-octene copolymer (EOR).

[0088] Examples of the copolymer of propylene and an α-olefin with 4 to 8 carbon atoms include a propylene-1-butene (PBR) copolymer, a propylene-1-pentene copolymer and a propylene-1-octene copolymer (PER). These olefins can be used individually or in combination of two or more of them.

[0089] Examples of styrene-based thermoplastic elastomer include a block copolymer of a styrene-based compound and a conjugated diene compound and a hydrogenated product thereof.

[0090] Examples of the styrene-based compound include styrene, alkyl styrenes, such as α-methyl styrene, p-methyl styrene and p-t-butyl styrene, p-methoxy styrene and vinyl naphthalene. These olefins can be used individually or in combination of two or more of them.

[0091] Examples of the conjugated diene compound include butadiene, isoprene, piperylene, methyl pentadiene, phenyl butadiene, 3,4-dimethyl-1,3-hexadiene and 4,5-diethyl-1,3-octadiene. These olefins can be used individually or in combination of two or more of them.

[0092] Specific examples of the styrene-based thermoplastic elastomer include a styrene-butadiene-styrene (SBS) copolymer, a styrene-isoprene-styrene (SIS) copolymer, a styrene-ethylene/butylene-styrene copolymer ( SEBS) and a styrene-ethylene/propylene-styrene copolymer (SEPS). These olefins can be used individually or in combination of two or more of them. Among them, SEBS is preferred.

[0093] Examples of the reactive group that reacts with the polyamide resin (the reactive group given to the elastomer) include an acid anhydride group (-CO-O-OC-), a carboxyl group (-COOH), an epoxy group {-C2O (a three-membered ring structure composed of two carbon atoms and one oxygen atom)}, an oxazoline group (-C3H4N) and an isocyanate group (-NCO). These reactive groups can be given individually or in combination of two or more of them.

[0094] It should be noted that the amount of modification of the modified elastomer is not limited, and the modified elastomer only needs to have one or more reactive groups per molecule. Furthermore, the modified elastomer preferably has 1 or more but 50 or fewer reactive groups, more preferably 3 or more but 30 or fewer reactive groups, particularly preferably 5 or more but 20 or fewer reactive groups per molecule.

[0095] Examples of the modified elastomer include: a polymer that uses any monomer capable of introducing a reactive group as a starting monomer (a modified elastomer obtained by polymerization using monomers capable of introducing a reactive group as part of starting monomers); a product of oxidative degradation of a polymer containing a skeletal resin (an elastomer modified with a reactive group formed by oxidative degradation); and a graft polymer obtained by graft polymerization of an organic acid on a skeletal resin (an elastomer modified with a reactive group introduced by graft polymerization of an organic acid). These olefins can be used individually or in combination of two or more of them.

[0096] Examples of the monomer capable of introducing a reactive group include a monomer with a polymerizable unsaturated bond and an acid anhydride group, a monomer with a polymerizable unsaturated bond and a carboxyl group, and a monomer with a polymerizable unsaturated bond and a epoxy.

[0097] Specific examples of the monomer capable of introducing a reactive group include: acid anhydrides such as maleic anhydride, itaconic anhydride, succinic anhydride, glutaric anhydride, adipic anhydride, citraconic anhydride, tetrahydrophthalic anhydride and buphenyl succinic anhydride; and carboxylic acids such as maleic acid, itaconic acid, fumaric acid, acrylic acid and methacrylic acid. These monomers can be used individually or in combination of two or more of them. Among these compounds, acid anhydrides are preferred; Maleic anhydride and itaconic anhydride are more preferred, and maleic anhydride is particularly preferred.

[0098] The molecular weight of the modified elastomer is not particularly limited, but the number average molecular weight of the modified elastomer is preferably 10,000 or more, but 500,000 or less, more preferably 35,000 or more, but 500,000 or less , particularly preferably 35,000 or more, but 300,000 or less. It should be noted that the number average molecular weight is measured by GPC (based on polystyrene standards).

(5) OTHER COMPONENTS

[0099] The molded body may contain, in addition to the first polyolefin resin, the second polyolefin resin, the polyamide resin and the modified elastomer, various additives such as another thermoplastic resin, a flame retardant, a flame retardant auxiliary, a filler, a coloring agent, an antimicrobial agent and an antistatic agent. These olefins can be used individually or in combination of two or more of them.

[00100] Examples of other thermoplastic resin include polyester-based resins (polybutylene terephthalate, polyethylene terephthalate, polycarbonate, polybutylene succinate, polyethylene succinate and polylactic acid). These olefins can be used individually or in combination of two or more of them.

[00101] Examples of the flame retardant include halogen-based flame retardants (halogenated aromatic compounds), phosphorus-based flame retardants (e.g., nitrogen-containing phosphate compounds and phosphoric acid esters), phosphoric acid-based flame retardants nitrogen (e.g. guanidine, triazine, melamine and their derivatives), inorganic flame retardants (e.g. metal hydroxides), boron-based flame retardants, silicone-based flame retardants, flame retardants sulfur-based and red phosphorus-based flame retardants. These olefins can be used individually or in combination of two or more of them.

[00102] Examples of the flame retardant auxiliary include various antimony compounds, zinc-containing metal compounds, bismuth-containing metal compounds, magnesium hydroxide and clay silicate. These olefins can be used individually or in combination of two or more of them.

[00103] Examples of the filler include: glass components (e.g., glass fibers, glass beads and glass flakes); silica; inorganic fibers (glass fibers, alumina fibers and carbon fibers), graphite, silicate compounds (e.g. calcium silicate, aluminum silicate, kaolin, talc and clay), metal oxides (e.g. of iron, titanium oxide, zinc oxide, antimony oxide and alumina), carbonates and sulfates of metals such as calcium, magnesium and zinc, and organic fibers (e.g. aromatic polyester fibers, aromatic polyamide fibers, fluororesin, polyimide fibers and vegetable fibers). These olefins can be used individually or in combination of two or more of them.

[00104] Examples of the coloring agent include pigments and dyes. These olefins can be used individually or in combination of two or more of them.

(6) PHASE STRUCTURE

[00105] In the molded body, the first polyolefin resin and the second polyolefin resin form the continuous phase (A). Furthermore, the polyamide resin and the modified elastomer form the dispersed phase (B). The dispersed phase (B) is dispersed in the continuous phase (A). This phase structure can be obtained by molding a thermoplastic resin that is a mixture of the first polyolefin resin and an impact-resistant resin containing the second polyolefin resin, the polyamide resin and the modified elastomer.

[00106] Furthermore, in the molded body, the polyamide resin that constitutes the dispersed phase (B), which is composed of the polyamide resin and the modified elastomer, forms a continuous phase (B1) in the dispersed phase (B), and at least the modified elastomer outside the polyamide resin and the modified elastomer can form a fine dispersed phase (B2) in the dispersed phase (B). By having such a multi-phase structure, in which the fine dispersed phase (B2) is still contained in the dispersed phase (B), the molded body can have greater impact resistance.

[00107] Furthermore, in the molded body, when the first polyolefin resin is a block copolymerized polyolefin resin with an ethylene block as a dispersed phase, at least part of the ethylene block that forms the block copolymerized polyolefin resin they can be aggregated at the interface between the continuous phase (A) and the dispersed phase (B). Also by having such a phase structure, the molded body can have greater impact resistance.

[00108] The size of the dispersed phase (B) contained in the continuous phase (A) of the molded body is not particularly limited, but the average diameter (average particle diameter) of the dispersed phase (B) is preferably 10000 nm, plus or minus , more preferably 50 nm or more, but 8000 nm or less, even more preferably 100 nm or more, but 4000 nm or less. The average diameter of the dispersed phase (B) is the average value (nm) of the maximum lengths of 50 randomly selected dispersed phase particles (B) in an image obtained using an electron microscope.

[00109] The size of the fine dispersed phase (B2) contained in the dispersed phase (A) of the molded body is not particularly limited, but the average diameter (average particle diameter) of the fine dispersed phase (B2) is preferably 5 nm or more , but 1000 nm or less, more preferably 5 nm or more, but 600 nm or less, even more preferably 10 nm or more, but 400 nm or less, particularly preferably 15 nm or more, but 350 nm or less. The average diameter of the fine dispersed phase (B2) is the average value (nm) of the maximum lengths of 100 randomly selected fine dispersed phase (B2) particles in an image obtained using an electron microscope.

(7) MIXING RATIO

[00110] When the total of the continuous phase (A) and the dispersed phase (B) in the molded body is taken as 100% by mass, the content of the dispersed phase (B) is 70% by mass or less. More specifically, when the total amount of the first polyolefin resin and the second polyolefin resin is defined as WA, the total amount of the polyamide resin and the modified elastomer is defined as WB, and the total of the WA and WB is taken as 100 % by mass, the WB ratio is generally 70% by mass or less. When the WB ratio is within the above range, excellent impact resistance and excellent balance between stiffness and formability can be achieved. The WB ratio is preferably 0.5% by mass or more, but 50% by mass or less, preferably 2% by mass or more, but 48% by mass or less, particularly preferably 4% by mass or more , but 45% by mass or less.

[00111] The content of each of the first polyolefin resin and the second polyolefin resin is not particularly limited, but when the total of the first polyolefin resin and the second polyolefin resin is taken as 100% by mass , the content of the second polyolefin resin is 80% by mass or less. The content of the second polyolefin resin may still be 1 mass % or more, but 70 mass % or less, may still be 1 mass % or more, but 60 mass % or less, may still be 3 % by mass or more, but 40% by mass or less, may still be 5% by mass or more, but 30% by mass or less, may still be 10% by mass or more, but 25% by mass or any less.

[00112] Furthermore, when the total of the polyamide resin and the modified elastomer is taken as 100% by mass, the content of the polyamide resin may be 10% by mass or more, but 80% by mass or less. When the polyamide resin content is within the above range, the molded body can have excellent impact resistance characteristics and excellent rigidity. The content of the polyolefin resin is preferably 12% by mass or more, but 78% by mass or less, more preferably 14% by mass or more, but 75% by mass or less, even more preferably 25% by mass or more , but 73% by mass or less, even more preferably 30% by mass or more, but 71% by mass or less, particularly preferably 34% by mass or more, but 68% by mass or less, more particularly preferably 40% by mass mass or less, but 64% by mass or less. When the polyamide resin content is within the above range, the polyamide resin and modified elastomer can be dispersed as smaller particles from the dispersed phase (B) into the continuous phase (A) . Furthermore, the amount of polyamide resin, which has a large specific gravity, to be used can be reduced to reduce the specific gravity of the molded body. This allows the molded body to have excellent impact resistance and rigidity while being lightweight.

[00113] Furthermore, since the polyamide resin content can be reduced, while these mechanical characteristics are maintained satisfactorily, the molded body can have a uniform appearance with low surface gloss. Therefore, the thermoplastic resin composition and molded body can be applied to external and internal materials, which are directly visually recognized, and can provide excellent design flexibility.

[00114] When the polyamide is polyamide 6 and the total of the polyamide resin and the modified elastomer is taken as 100% by mass, the content of the polyamide resin may be 10% by mass or more, but 80% by mass or less, but is preferably 12% by mass or more, but 68% by mass or less, more preferably 14% by mass or more, but 65% by mass or less, even more preferably 16% by mass or more, but 63% by mass or less, even more preferably 18% by mass or more, but 61% by mass or less, particularly preferably 20% by mass or more, but 58% by mass or less, more particularly preferably 25% by mass or less more, but 54% by mass or less.

[00115] When the polyamide resin content is within the above range, the molded body can have excellent impact resistance characteristics and excellent rigidity. Furthermore, the polyamide resin and modified elastomer can be dispersed as smaller particles from the dispersed phase (B) in the continuous phase (A). Furthermore, the amount of polyamide resin, which has a large specific gravity, to be used can be reduced to reduce the specific gravity of the molded body. This allows the molded body to have excellent impact resistance and rigidity while being lightweight. Furthermore, the tensile modulus of elasticity derived from the first polyolefin resin can be maintained satisfactorily, and the molded body can have better impact resistance. Furthermore, compared to a case where another polyamide is used, such as polyamide 11 described above, the molded body can achieve excellent impact resistance while satisfactorily maintaining the tensile modulus of elasticity derived from the first polyamide resin. polyolefin, even when the polyamide content is relatively lower.

[00116] When the total of the first polyolefin resin, the second polyolefin resin, the polyamide resin and the modified elastomer is taken as 100% by mass, the content of the polyamide resin may be 0.5% by mass or more, but 30% by mass or less. The content of the polyamide resin is preferably 1% by mass or more, but 22% by mass or less, preferably 2% by mass or more, but 15% by mass or less.

[00117] When the total of the first polyolefin resin, the second polyolefin resin, the polyamide resin and the modified elastomer is taken as 100% by mass, the content of the modified elastomer may be 0.5% by mass or more , but 30% by mass or less. When the polyamide resin content is within the above range, the molded body can have excellent impact resistance characteristics and excellent rigidity. The content of the polyamide resin is preferably 1% by mass or more, but 22% by mass or less, preferably 2% by mass or more, but 15% by mass or less.

[00118] The specific gravity of the molded body is not particularly limited, but can generally be 1.05 or less. When the molded body has a polyamide content of 1% by mass or more but 40% by mass or less, a polypropylene resin content of 50% by mass or more but 75% by mass or less, and a maleic anhydride modified olefin-based thermoplastic elastomer content of 5% by mass or more, but 30% by mass or less, the specific gravity may particularly be 0.89 or more, but 1.05 or less, and more particularly it may be 0.92 or more, but 0.98 or less. That is, even when it has a specific gravity equivalent to that of a polyethylene resin and a polypropylene resin, the molded body can offer impact resistance and rigidity far superior to those resins.

(8) TYPES OF MOLDED BODIES

[00119] The shape, size, thickness, etc. of the molded body are not particularly limited, and the application of the molded body is also not particularly limited.

[00120] The molded body is used as various articles for use in vehicles such as automobiles, railway vehicles (railway vehicles in general), aircraft fuselages (fuselages in general), boats and ships/hulls (hulls in general) and bicycles (bicycles in general).

[00121] Among them, examples of articles for use in automobiles include external parts, internal parts, engine parts and electrical parts. Specific examples of automobile exterior parts include roof rails, fenders, fender liners, trim, bumpers, door panels, roof panels, hood panels, trunk lids, fuel caps, rear view mirrors, spoilers, hood ventilation grilles, wheel covers, hubcaps, grill apron cover frames, lamp frames, door handles, door moldings, rear trims, wipers, engine protectors, floor protectors, lower external moldings (rocker moldings), hood grilles and grilles (motorcycles).

[00122] Examples of automobile interior parts include: trim parts such as door trim base materials (FR, RR, BACK), pockets, armrests, switch bases, decorative panels, trim panels, EA materials , speaker grilles and quarter trim base materials; column fittings; hood side trims (side hood trims); seat parts such as protectors, back plates, dynamic shock absorbers and side airbag peripheral parts; instrument panel parts, such as central clusters, registers, central boxes (doors), glove boxes, cup holders and airbag peripheral parts; center consoles; overhead consoles; solar visors; floor plates (luggage plates) and bottom trays; packaging trays; covers for elevated brake lamps; CRS coverage; seat side trims; foot plates; indoor lamps; auxiliary handles, parts for seat belts; recording slides; levers for washing; window regulator handles; window regulator handles; and passing light levers.

[00123] Examples of automobile engine parts include alternator terminals, alternator connectors, IC regulators, potentiometric bases for light regulators, exhaust gas valves, fuel pipes, coolant pipes, brake pipes, window wipers , exhaust pipes, intake pipes, hoses, tubes, air intake nozzles, intake manifolds, fuel pumps, engine cooling water gaskets, carburetor main parts, carburetor spacers, exhaust gas sensors, cooling water sensors, oil temperature sensors, brake pad wear sensors, throttle position sensors, crankshaft position sensor, air flow meters, brake pad wear sensors, brake pistons , solenoid coils, engine oil filters, igniter housings and torque control levers.

[00124] Examples of automobile electrical parts include battery peripheral parts, air conditioning thermostats, hot air flow control valves, brush holders for radiator motors, water pump impellers, turbine fins, engine-related parts. wiper motor, distributors, starter switches, starter relays, transmission cable harnesses, window washer nozzles, air conditioning panel switch plates, fuel-related electromagnetic valve coils, various connectors such as harness connectors wire connectors, SMJ connectors, PCB connectors, door grommet connectors and fusible connectors, horn terminals, electrical component insulation boards, stepper motor rotors, lamp sockets, lamp reflectors, lamp housings, wiper housings , filter boxes and powertrains.

[00125] Furthermore, the molded body is used as various articles also in other applications other than vehicles in addition to the above vehicles. Specific examples include: industrial materials, such as ropes, spunbonded fabrics, polishing brushes, industrial brushes, filters, transport containers, trays, transport carts and other general materials; electronic parts, such as connectors, coils, sensors, lamps LED, sockets, resistors, relay holders, miniature switches, spiral coils, capacitors, variable capacitor holders, optical pickups, resonators, various terminal boards, transformers, plugs, printed circuit boards, tuners, speakers, microphones, headphones, compact motors, compact transmission gears, magnetic head bases, power modules, semiconductors, liquid crystals, FDD carts, FDD chassis, motor brush holders, satellite dishes and computer related parts; electrical devices such as power generators, electric motors, electrical transformers, current transformers, voltage regulators, rectifiers, inverters, relays, power contacts, switches, circuit breakers, knife switches, various rods and enclosures for electrical parts; industrial robot bodies, bodies nurse robots and drones (flying objects operated by remote control, flying objects capable of flying autonomously); household appliances and office equipment, such as VTR parts, television parts, irons, hair dryers, electric cooker parts, microwave parts, acoustic parts, audio/LD parts, CD/DVD parts, lighting, refrigerator parts, washing machine parts, air conditioning parts, typewriter/word processor parts, office computer parts, PCs, gaming machines, tablet terminals, mobile phones, smartphones, telephones and related parts, fax machine parts, copier parts, cleaning/washing devices and engine parts; optical and precision instruments such as cameras, watches, microscopes, binoculars, telescopes and glasses; everyday items and household items such as storage cases (e.g. food trays, storage boxes, storage trays, briefcases, suitcases, helmets, bottles and jars), hygiene products, writing tools, writing materials stationery, from razors, skin care tools, utensils, crockery, laundry utensils, cleaning tools, hangers, food containers and lids (e.g., lids for glass bottles); entertainment articles such as toys; machine tools / general machinery / machine parts such as bodies and covers for cutting machines, bodies and covers for power tools and different clamps; sporting goods such as tennis racket strings, ski plates/boards, protectors (baseball, football, motor sports), shoes, shoe soles (shoe soles, athletic shoe soles), and climbing/outdoor tools free; items related to furniture, such as wardrobes, tables, chairs, shoe boxes, kitchen utensils, shower stall items and bathroom items; civil and housing engineering related articles such as internal and external walls/ceilings, thermal insulation materials, doors/door related parts, window materials related parts, flooring, floor materials related parts, damping parts, seismic insulation , shutters, gutters, parts related to water supply and sewage (lifeline related parts), car parks, parts related to gas and power supply (lifeline related parts), civil engineering related parts, signs traffic, highway signs, poles, central poles, guardrails (protection wires) and equipment for construction works; medical supplies such as respirators, medical equipment and medication containers; clothing items, such as shoes; and items related to agriculture, forestry, fishing, such as agricultural machinery, agricultural tools, flower pots (planters), fishing material, tools related to marine culture and tools for the forestry industry.

[00126] Other examples of the molded body include pellets of various shapes.

[2] PRODUCTION METHOD

[00127] A method for producing a molded body according to the present invention is a method for producing the molded body described above, and includes a step of preparing the molded body raw material and a molding step.

[00128] According to this method, a required impact-resistant resin is formed in advance, and a mixture of the impact-resistant resin and the first polyolefin resin is molded, which makes it possible to reduce the heat history of the first polyolefin resin . More specifically, the molded body can be obtained by applying a thermal load to the first polyolefin resin only once during molding, while the heat histories of the polyamide resin, the modified elastomer and the second polyolefin resin are accumulated in proportion to the number of times of kneading under melting. The above molded body having a continuous phase (A) and a dispersed phase (B) can also be obtained by a production method.

[00129] The "molded body raw material preparation step" is a step in which the first polyolefin resin and an impact-resistant resin, which is obtained by kneading under fusion of the second polyolefin resin and a product kneaded under fusion of polyamide resin and modified elastomer are mixed to obtain raw material for a molded body.

[00130] In this method, the raw material for a molded body is obtained by first obtaining an impact-resistant resin and mixing the impact-resistant resin with the first polyolefin resin. More specifically, the raw material of a molded body can be obtained, for example, by dry mixing pellets made from a previously obtained impact-resistant resin and pellets made from the first polyolefin resin.

[00131] The above "melt kneaded product" is a thermoplastic resin composition obtained by melt kneading the polyamide resin and the modified elastomer. Examples of each of the polyamide resin and modified elastomer that can be used at this time are the same as those mentioned above.

[00132] The melt-kneaded product can be obtained by melt-kneading the polyamide resin and the modified elastomer, so that when the total of both the polyamide resin and the modified elastomer is taken as 100% in mass, the mixing ratio of polyamide resin is 10% by mass or more, but 80% by mass or less. This makes it possible, when the melt-kneaded product and the second polyolefin resin are mixed, to obtain an impact-resistant resin in which the polyamide resin is dispersed in the second polyolefin resin. More specifically, the impact resistant resin may have a phase structure in which a continuous phase (C) containing the second polyolefin resin is formed, and a dispersed phase (B) containing the polyamide resin and the modified elastomer is dispersed in the continuous phase (C). Furthermore, a multi-phase structure can be obtained, in which the dispersed phase (B) has a continuous phase (B1) containing the polyamide resin and a fine dispersed phase (B2) dispersed in the continuous phase (B1) and containing the modified elastomer.

[00133] The polyolefin resin content is preferably 12% by mass or more, but 78% by mass or less, more preferably 14% by mass or more, but 75% by mass or less, even more preferably 25% by mass mass or more, but 73 mass% or less, even more preferably 30 mass% or more, but 71 mass% or less, particularly preferably 34 mass% or more, but 68 mass% or less, more particularly preferably 40% by mass or less, but 64% by mass or less. When the mixing ratio of the polyamide resin is within the above range, an impact-resistant resin can be obtained, in which the polyamide resin is dispersed as smaller particles in the second polyolefin resin.

[00134] It should be noted that, from the point of view of obtaining an impact-resistant resin of the type rich in polyamide resin, the polyamide resin content of which is 50% by mass or more, the polyamide resin content may be 50% by mass or more, but 80% by mass or less, when the total of the polyamide resin and the elastomer is taken as 100% by mass.

[00135] When the polyamide is polyamide 6 and the total of the polyamide resin and the modified elastomer is taken as 100% by mass, the mixing ratio of the resin in the melt-kneaded product may be 10% by mass or more, but 80% by mass or less. The ratio of polyolefin resin is preferably 12% by mass or more, but 68% by mass or less, more preferably 14% by mass or more, but 65% by mass or less, even more preferably 16% by mass or more , but 63% by mass or less, even more preferably 18% by mass or more, but 61% by mass or less, particularly preferably 20% by mass or more, but 58% by mass or less, more particularly preferably 25% by mass mass or less, but 54% by mass or less. When the mixing ratio of the polyamide resin is within the above range, an impact-resistant resin can be obtained, in which the polyamide resin is dispersed as smaller particles in the second polyolefin resin.

[00136] There is no specific limitation on the kneading method used to obtain the melt-kneaded product. The kneaded product can be obtained, for example, using a kneading device such as an extruder (e.g., a single-screw extruder or a twin-screw extruder), a kneader or a mixer (e.g., a high-flow mixer). speed, a paddle mixer or a ribbon mixer). These devices can be used individually or in combination with two or more of them. When two or more devices are used, they can be operated continuously or in batch mode. Furthermore, all components of the melt-kneaded product can be mixed at once or can be mixed by adding them in several batches (multi-phase addition).

[00137] The kneading temperature at which the melt-kneaded product is obtained is not particularly limited, as long as melt-kneading can be carried out, and the kneading temperature can be adjusted appropriately according to the type of each of the components . In particular, it is preferred that all resins are kneaded into a molten state. More specifically, the kneading temperature may be 190 to 350°C, but is preferably 200 to 330°C, more preferably 205 to 310°C.

[00138] The impact-resistant resin described above is a thermoplastic resin composition obtained by melt-kneading the second polyolefin resin and the melt-kneaded product described above. Examples of the second polyolefin resin that can be used at this time are the same as those described above.

[00139] The impact-resistant resin can be obtained by melt-kneading both the second polyamide resin and the melt-kneaded product, so that when the total of the second polyolefin resin and the melt-kneaded product is taken as 100% by mass, the mixing ratio of the second polyamide resin is 20% by mass or more, but 75% by mass or less. This makes it possible to disperse the polyamide resin in the second polyolefin resin. More specifically, the impact resistant resin may have a phase structure in which a continuous phase (C) containing the second polyolefin resin is formed, and a dispersed phase (B) containing the polyamide resin and the modified elastomer is dispersed in the continuous phase (C). Furthermore, a multi-phase structure can be obtained, in which the dispersed phase (B) has a continuous phase (B1) containing the polyamide resin and a fine dispersed phase (B2) dispersed in the continuous phase (B1) and containing the modified elastomer.

[00140] The mixing ratio of the second polyamide resin is preferably 25% by mass or more, but 70% by mass or less, preferably 35% by mass or more, but 65% by mass or less. When the mixing ratio of the polyamide resin is within the above range, an impact-resistant resin can be obtained, in which the polyamide resin is dispersed as smaller particles in the second polyolefin resin.

[00141] A kneading method used to obtain the impact-resistant resin is not particularly limited, and the same device, mode of operation, kneading temperature described above can be used with reference to a case in which the product is obtained kneaded under melting.

[00142] When the total of the second polyamide resin and the polyamide resin is taken as 100% by mass, the content of the polyamide resin may be 60% by mass or less (usually 1% by mass or more). The content is preferably 5% by mass or more, but 55% by mass or less, more preferably 15% by mass or more, but 53% by mass or less, even more preferably 19% by mass or more, but 50 % by mass or less, even more preferably 21% by mass or more, but 48% by mass or less, particularly preferably 23% by mass or more, but 46% by mass or less, more particularly preferably 25% by mass or more , but 44% by mass or less, even more particularly preferably 28% by mass or less, but 43% by mass or less.

[00143] When the polyamide is polyamide 6 and the total of the second polyolefin resin and the polyamide resin is taken as 100% by mass, the polyamide resin content may be 60% by mass or less (usually 1% by mass or more), but is preferably 5% by mass or more, but 45% by mass or less, more preferably 7% by mass or more, but 43% by mass or less, even more preferably 9% by mass or more more, but 40% by mass or less, even more preferably 11% by mass or more, but 38% by mass or less, particularly preferably 13% by mass or more, but 36% by mass or less, more particularly preferably 15% by mass or more, but 34% by mass or less, even more particularly preferably 18% by mass or more, but 33% by mass or less.

[00144] Furthermore, when the total of the second polyolefin resin, the polyamide resin and the modified elastomer is taken as 100% by mass, the content of the polyamide resin may be 1% by mass or more, however 60% by mass or less. The content of the polyolefin resin is preferably 3% by mass or more, but 50% by mass or less, more preferably 5% by mass or more, but 45% by mass or less, even more preferably 7% by mass or more , but 40% by mass or less, even more preferably 9% by mass or more, but 35% by mass or less, more particularly preferably 12% by mass or more, but 30% by mass or less.

[00145] Furthermore, when the total of the second polyolefin resin, the polyamide resin and the modified elastomer is taken as 100% by mass, the content of the modified elastomer may be 1% by mass or more, but 70 % by mass or less. The content of the modified elastomer is preferably 2% by mass or more, but 65% by mass or less, more preferably 3% by mass or more, but 60% by mass or less, even more preferably 5% by mass or more, but 55% by mass or less, even more preferably 7% by mass or more, but 50% by mass or less, particularly preferably 13% by mass or more, but 47% by mass or less, more particularly preferably 17% by mass or more, but 45% by mass or less. The raw material for the molded body described above is a thermoplastic resin mixture obtained by mixing the first polyolefin resin and the impact resistant resin described above. Examples of the first polyolefin resin that can be used at this time are the same as those described above.

[00147] The raw material of the molded body can be obtained by mixing both the first polyolefin resin and the impact-resistant resin, so that when the total of the first polyolefin resin and the impact-resistant resin is taken as 100% by mass, the mixing ratio of the first polyolefin resin is 20% by mass or more, but 99.5% by mass or less. This makes it possible to obtain raw material from a molded body in which the heat history load of the first polyolefin resin has been reduced.

[00148] Particularly, the mixing ratio of the first polyolefin resin may be 30% by mass or more, but 99% by mass or less, may also be 40% by mass or more, but 98% by mass or less , can still be 45% by mass or more, but 97% by mass or less, can still be 52% by mass or more, but 96% by mass or less, and can still be 55% by mass or more , but 95% by mass or less.

[00149] Furthermore, as described above, the molded body obtained by this method may contain, in addition to the first polyolefin resin, the second polyolefin resin, the polyamide resin and the modified elastomer, various additives such as a flame retardant, a flame retardant auxiliary, a filler, a coloring agent, an antimicrobial agent and an antistatic agent. When these additives are added to the molded body, impact resistant resin can be used as a carrier that transports these additives.

[00150] The "molding step" described above is a step in which the molded body raw material obtained in the molded body raw material preparation step is molded to obtain a molded body.

[00151] There is no specific limitation on the molding method to be used in this molding step, and any molding method can be used. Examples of the molding method include injection molding, extrusion molding (sheet extrusion, profiled extrusion), T-die molding, blow molding, injection blow molding, blow molding, blow molding, vacuum molding, molding compression molding, pressure molding, stamping molding and transfer molding. These olefins can be used individually or in combination of two or more of them.

[00152] It should be noted that, according to this method, a molded body can be obtained by molding a thermoplastic resin, the molded body with a continuous phase (A) containing a first polyolefin resin and a second polyolefin resin and a dispersed phase (B) dispersed in the continuous phase (A) and containing a polyamide resin and a modified elastomer, wherein the dispersed phase (B) is composed of a product kneaded under fusion of the polyamide resin and the modified elastomer , the elastomer is an elastomer with a reactive group that reacts with the polyamide resin, the elastomer is an olefin-based thermoplastic elastomer having, as a skeleton, a copolymer of ethylene or propylene and an α-olefin with 3 to 8 atoms carbon or a styrene-based thermoplastic elastomer with a styrene skeleton, when a total of the continuous phase (A) and the dispersed phase (B) is taken as 100% by mass, a content of the dispersed phase is 70% by mass mass or less and, when a total of the first polyolefin resin and the second polyolefin resin is taken as 100% by mass, a content of the second polyolefin resin is 80% by mass or less.

[00153] This molded body obtained using the method described above can offer significantly excellent impact resistance, while maintaining the rigidity that the polyolefin originally has. Furthermore, when part of a polyolefin to be used is mixed as a first polyolefin resin, a molded body can be obtained in which the heat history of the first polyolefin resin has been reduced compared to a case in which all of the polyolefin is added from the beginning. That is, a molded body can be obtained by molding a resin of the first polyolefin resin and an impact-resistant resin containing the second polyolefin resin, the polyamide resin and the modified elastomer.

[00154] However, at the time of filing the present application, it is impossible to directly specify the property that the heat history of the first polyolefin resin is lower than that of the second polyolefin resin. Even if it were possible, it is time-consuming and costly to specify this property even with current analytical techniques, and therefore there are impractical circumstances in light of the need for speed, etc. due to the nature of the patent application.

EXAMPLES

[00155] Hereinafter, the present invention will be specifically described with reference to examples.

[1-1] Production of molded bodies for evaluation <1> IMPACT RESISTANT RESIN

[00156] An impact-resistant resin was prepared by the following procedure. The impact-resistant resin contained 55% by mass of a second polyolefin, 15% by mass of a polyamide resin, and 30% by mass of an elastomer modified by 100% of its total mass.

(1) PREPARATION OF THE MELTED MIXTURE

[00157] Pellets of the following polyamide resin and pellets of the following modified elastomer were dry mixed, then fed to a double screw melt kneading extruder (manufactured by TECHNOVEL CORPORATION, screw diameter: 15 mm, L/ D = 59), and sub-fusion kneaded under conditions of a kneading temperature of 210°C, and extrusion speed of 2.0 kg/h and a rotational speed of 200 rpm. The melt-kneaded product thus obtained was pelletized by a pellet machine to obtain pellets of the melt-kneaded product.

[00158] Polyamide resin: polyamide 6 (n°1), manufactured by BASF, product name: "Ultramid B3S", weight average molecular weight: 18,000, melting point: 220°C

[00159] Modified elastomer: ethylene-butene copolymer modified with maleic anhydride (modified EBR), manufactured by Mitsui Chemicals, Inc., product name: "TAFMER MH7020", MFR (230°C) = 1.5 g/10 min.

(2) PREPARATION OF IMPACT RESISTANT RESIN

[00160] The molten mixture pellets obtained in (1) above and the second polyolefin resin pellets below were dry mixed, then fed to a double screw melt kneading extruder (manufactured by TECHNOVEL CORPORATION, screw diameter : 15 mm, L/D = 59), and mixed under conditions of a kneading temperature of 210°C, an extrusion speed of 2.0 kg/hr and a rotation speed of 200 rpm, and the mixture thus obtained, it was pelletized by a pellet machine to obtain pellets of an impact-resistant resin.

[00161] Second polyolefin resin: polyprolylene resin (no. 1), homopolymer, manufactured by Prime Polymer Co., Ltd., product name: "Prime Polypro F113G", number average molecular weight: 520,000, melting point: 160°C, MFR: 3 g/10 min.

<2> PRODUCTION OF THE MOLDED BODIES OF EXAMPLES 1 TO 5

[00162] Each of a molded body containing 80% by mass of a first polyolefin and 20% by mass of an impact-resistant resin for 100% of its total mass (Example 1), a molded body containing 75% by mass of a first polyolefin and 25% by mass of an impact-resistant resin for 100% of its total mass (Example 2), a molded body containing 70% by mass of a first polyolefin resin and 30% by mass of an impact-resistant resin impacts for 100% of its total mass (Example 3), a molded body containing 60% by mass of a first polyolefin resin and 40% by mass of an impact resistant resin for 100% of its total mass (Example 4) and a molded body containing 40% by mass of a first polyolefin and 60% by mass of an impact resistant resin for 100% of its total mass (Example 5) was produced by the following procedure.

[00163] The pellets of the impact-resistant resin obtained in [1-1] (2) above and the pellets of the first polyolefin resin below were dry mixed to obtain raw material for a molded body. obtained molded body was fed to a hopper of an injection molding machine (manufactured by NISSEI PLASTIC INDUSTRIAL CO., LTD., 40 ton injection molding machine), and injection molded under injection conditions of a temperature set temperature of 210°C and a mold temperature of 60°C to obtain test samples for evaluation of physical properties.

[00164] First polyolefin resin: block copolymerized polyolefin resin having an ethylene block as a dispersed phase, manufactured by SunAllomer Ltd., product name: "YS559N", melting point: 165°C.

<3> PRODUCTION OF THE MOLDED BODIES OF COMPARATIVE EXAMPLES (1) PRODUCTION OF THE MOLDED BODY OF COMPARATIVE EXAMPLE 1

[00165] The following polyolefin resin (which was the same first polyolefin resin used for the molded bodies of the Examples) was fed into a hopper of an injection molding machine (manufactured by NISSEI PLASTIC INDUSTRIAL CO., LTD., 40 ton injection molding machine) and injection molded under injection conditions of a set temperature of 210°C and a mold temperature of 60°C to obtain test samples for evaluation of physical properties.

[00166] First polyolefin resin: block copolymerized polyolefin resin having an ethylene block as a dispersed phase, manufactured by SunAllomer Ltd., product name: "YS559N", melting point: 165°C.

(2) PRODUCTION OF THE MOLDED BODIES OF COMPARATIVE EXAMPLES 2 AND 3

[00167] Pellets of the following impact resistance imparting agent conventionally used to impart impact resistance and pellets of the following polyolefin resin were dry mixed to obtain the raw material of a molded body, and the raw material of molded body was fed into a hopper of an injection molding machine (manufactured by NISSEI PLASTIC INDUSTRIAL CO., LTD., 40 ton injection molding machine) and injection molded under injection conditions of a set temperature of 210° C and a mold temperature of 60°C to obtain test samples for evaluation of physical properties.

[00168] Polyolefin resin: block copolymerized polyolefin resin having an ethylene block as a dispersed phase, manufactured by SunAllomer Ltd., product name: "YS559N", melting point: 165°C

[00169] Impact resistance attribution agent: manufactured by Mitsui Chemicals, Inc., product name: "TAFMER DF810".

[1-2] EVALUATIONS OF MOLDED BODIES FOR EVALUATION (1) MEASUREMENT OF CHARPY IMPACT RESISTANCE

[00170] Charpy impact resistance measurement was carried out in accordance with JIS K7111-1 using each of the test samples for evaluation of Examples 1 to 5 and Comparative Examples 1 to 3 obtained in [1-1] above. The measurement results are shown in Table 1. It should be noted that in the Charpy impact resistance measurement, the impact resistance was measured at a temperature of 23°C by a longitudinal test method using a test sample with a notch ( type A).

(2) OBSERVATION OF MORPHOLOGY

[00171] A sample cut from each of the test samples of Examples 1 to 5 that were subjected to the Charpy impact resistance measurement described above in (1) was embedded in a resin. Then, the sample was trimmed and cut into a cross section using an ultramicrotome with a diamond knife and subjected to vapor dyeing with a metal oxide. An ultrathin section sample was taken from the cross section obtained after dyeing and observed through a transmission electron microscope (TEM, manufactured by Hitachi High-Technologies Corporation, Model "HT7700") to observe a phase structure. The measurement results are summarized in Table 1.

[00172] As a result, in Examples 1 to 5, as shown in the schematic diagram shown in figure 1, a continuous phase 1 [continuous phase (A)] containing the first polyolefin resin and the second polyolefin resin, a phase dispersed 2 [dispersed phase (B)] dispersed in the continuous phase (A) and containing the polyamide resin and the modified elastomer, a continuous phase 3 [continuous phase (B1)] containing the polyamide resin, a fine dispersed phase 4 [fine dispersed phase (B2)] dispersed in the continuous phase (B1) and containing the modified elastomer, and an aggregated phase 5 [aggregated phase (D)], in which an ethylene block of the first polyolefin resin is aggregated at the interface between the continuous phase (A) and the dispersed phase (B). It should be noted that the aggregate phase (D) contains not only the ethylene block of the first polyolefin resin, but also the modified elastomer.

[00173] The results relating to the phase structure are also shown in Table 1.

(3) MEASUREMENT OF THE MODULUS OF ELASTICITY IN TENSION

[00174] The measurement of the tensile modulus of elasticity was carried out in accordance with JIS K7161 using each of the test samples for evaluation of Examples 1 to 5 and Comparative Examples 1 to 3 obtained in [1-1] above. The measurement results are shown in Table 1. TABLE 1

[1-3] EFFECTS

[00175] From the results presented in Table 1, it was confirmed that the molded bodies of Examples 1 to 5 obtained using the impact resistant resin offered much greater Charpy impact resistance than the molded body of Comparative Example 1 formed from the first resin made of polyolefin and therefore had excellent impact resistance. Furthermore, it was confirmed that a reduction in the tensile modulus of elasticity caused by the addition of impact-resistant resin was extremely small, so that stiffness was maintained adequately.

[00176] Furthermore, the above effect obtained using the impact-resistant resin was also evident from the comparison with the results of Comparative Examples 2 and 3 using the conventional additive.

[00177] Furthermore, as described above, from the result shown in figure 1, it can be seen that a continuous phase 1 [continuous phase (A)] and a dispersed phase 2 [dispersed phase (B)] are formed in the body molded. Furthermore, it can be seen that a fine dispersed phase 4 [fine dispersed phase (B2)] is formed in the dispersed phase (B). Furthermore, it can be seen that when a polyolefin resin block copolymerized with an ethylene block as a dispersed phase is used as the first polyolefin resin, at least part of the ethylene block (EPR) is aggregated at the interface between the continuous phase (A) and the dispersed phase (B) (see aggregate phase 5). This aggregation is considered to lead to greater impact resistance.

[2-1] PRODUCTION OF MOLDED BODIES FOR EVALUATION (EXAMPLES 6 TO 9) <1> IMPACT RESISTANT RESIN

[00178] An impact-resistant resin for use in Examples 6 to 9 was prepared by the following procedure. The impact-resistant resin contained 55% by mass of a second polyolefin, 15% by mass of a polyamide resin and 30% by mass of an elastomer modified by 100% of its total mass.

(1) PREPARATION OF THE MELTED MIXTURE

[00179] Pellets of the following polyamide resin and pellets of the following modified elastomer were dry mixed, then fed to a double screw melt kneading extruder (manufactured by TECHNOVEL CORPORATION, screw diameter: 15 mm, L /D = 59), and sub-fusion kneaded under conditions of a kneading temperature of 210°C, and extrusion speed of 2.0 kg/h and a rotational speed of 200 rpm. The melt-kneaded product thus obtained was pelletized by a pellet machine to obtain pellets of the melt-kneaded product.

[00180] Polyamide resin: polyamide 6 (no. 2), manufactured by Ube Industries, Ltd., product name: "1010X1", weight average molecular weight: 20,000, melting point: 215°C

[00181] Modified elastomer: ethylene-butene copolymer modified with maleic anhydride (modified EBR), manufactured by Mitsui Chemicals, Inc., product name: "TAFMER MH7020", MFR (230°C) = 1.5 g/10 min.

(2) PREPARATION OF IMPACT RESISTANT RESIN

[00182] The molten mixture pellets obtained in (1) above and the second polyolefin resin pellets below were dry mixed, fed to a double screw melt kneading extruder (manufactured by TECHNOVEL CORPORATION, screw diameter: 15 mm, L/D = 59), and mixed under conditions of a kneading temperature of 210°C, an extrusion speed of 2.0 kg/h and a rotation speed of 200 rpm, and the mixture thus obtained was pelletized by a pellet mill to obtain an impact-resistant resin (such as pellets.

[00183] Second polyolefin resin: polyprolylene resin (no. 1), homopolymer, manufactured by Prime Polymer Co., Ltd., product name: "Prime Polypro F113G", number average molecular weight: 520,000, melting point: 160°C, MFR: 3 g/10 min

<2> PRODUCTION OF THE MOLDED BODIES OF EXAMPLES 6 TO 9

[00184] Each of a molded body containing 80% by mass of a first polyolefin and 20% by mass of an impact-resistant resin for 100% of its total mass (Example 6), a molded body containing 60% by mass of a first polyolefin and 40% by mass of an impact-resistant resin for 100% of its total mass (Example 7), a molded body containing 40% by mass of a first polyolefin and 60% by mass of an impact-resistant resin for 100% of its total mass (Example 8) and a molded body containing 20% by mass of a first polyolefin and 60% by mass of an impact resistant resin for 100% of its total mass (Example 9) was produced by the procedure a follow.

[00185] The impact-resistant resin obtained in [2-1] (2) above and the pellets of the first polyolefin resin below were dry mixed to obtain raw material for a molded body. The obtained molded body raw material was fed into a hopper of an injection molding machine (manufactured by NISSEI PLASTIC INDUSTRIAL CO., LTD., 40 ton injection molding machine), and injection molded under injection conditions of a set temperature of 210°C and a mold temperature of 60°C to obtain test samples for evaluation of physical properties.

[00186] First polyolefin resin: block copolymerized polyolefin resin having an ethylene block as a dispersed phase, manufactured by SunAllomer Ltd., product name: "YS559N", melting point: 165°C

[2-2] PRODUCTION OF MOLDED BODIES FOR EVALUATION (EXAMPLES 10 TO 13) <1> IMPACT RESISTANT RESIN

[00187] An impact resistant resin for use in Examples 10 to 13 was prepared by the following procedure. The impact resistant resin contained 55% by mass of a second polyolefin, 25% by mass of a polyamide resin and 20% by mass of an elastomer modified by 100% of its total mass.

(1) PREPARATION OF THE MELTED MIXTURE

[00188] Pellets of the following polyamide resin and pellets of the following modified elastomer were dry mixed, then fed to a double screw melt kneading extruder (manufactured by TECHNOVEL CORPORATION, screw diameter: 15 mm, L/ D = 59), and sub-fusion kneaded under conditions of a kneading temperature of 210°C, and extrusion speed of 2.0 kg/hr and a rotational speed of 200 rpm. The melt-kneaded product thus obtained was pelletized by a pellet machine to obtain pellets of the melt-kneaded product.

[00189] Polyamide resin: polyamide 11, manufactured by Arkema, product name: "Rilsan BMN O", weight average molecular weight: 18,000, melting point: 189°C.

[00190] Modified elastomer: ethylene-butene copolymer modified with maleic anhydride (modified EBR), manufactured by Mitsui Chemicals, Inc., product name: "TAFMER MH7020", MFR (230°C) = 1.5 g/10 min.

(2) PREPARATION OF IMPACT RESISTANT RESIN

[00191] The molten mixture pellets obtained in (1) above and the second polyolefin resin pellets below were dry mixed, fed to a double screw melt kneading extruder (manufactured by TECHNOVEL CORPORATION, screw diameter: 15 mm, L/D = 59), and mixed under conditions of a kneading temperature of 210°C, an extrusion speed of 2.0 kg/hr and a rotational speed of 200 rpm, and the mixture thus obtained was pelletized by a pellet mill to obtain an impact-resistant resin (like pellets).

[00192] Second polyolefin resin: polyprolylene resin (no. 2), homopolymer, manufactured by Japan Polypropylene Corporation, product name: "NOVATEC MA1B", number average molecular weight: 312,000, melting point: 165°C, MFR : 21 g/10 min

<2> PRODUCTION OF THE MOLDED BODIES OF EXAMPLES 10 TO 13

[00193] Each of a molded body containing 90% by mass of a first polyolefin and 10% by mass of an impact-resistant resin for 100% of its total mass (Example 10), a molded body containing 80% by mass of a first polyolefin and 20% by mass of an impact-resistant resin for 100% of its total mass (Example 11), a molded body containing 70% by mass of a first polyolefin and 30% by mass of an impact-resistant resin for 100% of its total mass (Example 12) and a molded body containing 60% by mass of a first polyolefin and 40% by mass of an impact resistant resin for 100% of its total mass (Example 13) was produced by the procedure a follow.

[00194] The impact-resistant resin obtained in [2-2] (2) above and the pellets of the first polyolefin resin below were dry mixed to obtain raw material for a molded body. The obtained molded body raw material was fed into a hopper of an injection molding machine (manufactured by NISSEI PLASTIC INDUSTRIAL CO., LTD., 40 ton injection molding machine), and injection molded under injection conditions of a set temperature of 210°C and a mold temperature of 60°C to obtain test samples for evaluation of physical properties.

[00195] First polyolefin resin: block copolymerized polyolefin resin having an ethylene block as a dispersed phase, manufactured by SunAllomer Ltd., product name: "YS559N", melting point: 165°C

[2-3] EVALUATIONS OF MOLDED BODIES FOR EVALUATION (1) MEASUREMENT OF THE MODULE OF ELASTICITY IN TENSION

[00196] The measurement of the tensile modulus of elasticity was carried out in accordance with JIS K7161 using each of the test samples for evaluation of Examples 6 to 13 obtained in [2-1] and [2-2] above. The measurement results are shown in Table 2.

[00197] Furthermore, the graph is shown in figure 2, which shows a correlation between the tensile modulus of elasticity and the amount of an impact-resistant resin added to each of the test samples for evaluating Examples 1 to 5 [ impact-resistant resin based on PA6 (no. 1)], Examples 6 to 9 [impact-resistant resin based on PA6 (no. 2)] and Examples 10 to 13 [impact-resistant resin based on PA11].

(2) OBSERVATION OF MORPHOLOGY

[00198] A sample cut from each of the test samples from Examples 6 to 13 that were subjected to measurement of the tensile modulus of elasticity described above in (1) was embedded in a resin. Then, the sample was trimmed and cut into a cross section using an ultramicrotome with a diamond knife and subjected to vapor dyeing with a metal oxide. An ultrathin section sample was taken from the cross section obtained after dyeing and observed through a transmission electron microscope (TEM, manufactured by Hitachi High-Technologies Corporation, Model "HT7700") to observe a phase structure. The measurement results are shown in Table 2. TABLE 2

[2-4] EFFECTS

[00199] From the results presented in Table 2, it was confirmed that also in the case of the molded bodies of Examples 6 to 13 obtained by adding the impact-resistant resin using a polyamide different from that used in Examples 1 to 5 above, a reduction in the tensile modulus of elasticity determined by comparison with Comparative Example 1 was extremely small, as in the case of Examples 1 to 5 above, and therefore the stiffness was maintained sufficiently.

[00200] Furthermore, from the results shown in Figure 2, it was also confirmed that the molded bodies obtained using the impact-resistant resin containing PA6 as a polyamide resin [based on PA6 (No. 1) (Examples 1 to 5), based on PA6 (no. 2) (Examples 6 to 9)] maintained greater rigidity than the molded bodies obtained using the impact resistant resin containing PA11 as a polyamide resin [based on PA11 (Examples 10 to 13)]. It should be noted that this trend was more significant when the amount of impact-resistant resin added was lower.

[00201] This result revealed that when polyamide 6 is used as the polyamide, the molded body can achieve excellent impact resistance while maintaining sufficient tensile modulus of elasticity derived from the first polyolefin resin, even when the polyamide content is relatively lower compared to a case where polyamide 11 is used.

[00202] It should be noted that the present invention is not limited to the specific examples described above, and various modifications can be made to the examples within the scope of the present invention, depending on the intended purpose or use.

[00203] More specifically, for example, in the above examples, molded bodies were obtained by molding molded body raw materials obtained by dry mixing pellets of the impact-resistant resin and pellets of the first polyolefin resin, but the pellets obtained by subfusion kneading of impact-resistant resin pellets and first polyolefin resin pellets can, of course, be used as raw material for a molded body.

[00204] The examples described above are for illustrative purposes only, and should not be interpreted as limiting the present invention. Although the present invention has been described with reference to exemplary embodiments, it is understood that the words used in the description and drawings of the present invention are illustrative and explanatory, and not restrictive. As described in detail herein, modifications may be made to the embodiments within the scope of the appended claims, without departing from the scope and spirit of the present invention. Although the present invention has been described in detail with reference to certain structures, materials and examples, the present invention is not to be limited to the particulars described herein, but the present invention extends to all functionally equivalent structures, methods and uses within the scope of the attached claims. LIST OF REFERENCE SIGNALS 1; continuous phase (A) 2; dispersed phase (B) 3; continuous phase (B1) 4; fine dispersed phase (B2) 5; aggregate phase (D)

Claims (7)

1. Molded body obtained by molding a thermoplastic resin, characterized by the fact that the molded body comprises: a continuous phase (A) containing a first polyolefin resin and a second polyolefin resin; and a dispersed phase (B) dispersed in the continuous phase (A) and containing a polyamide resin and a modified elastomer, wherein the number average molecular weight of the first polyolefin resin is 150,000 or more, but less than 350,000, and the number average molecular weight of the second polyolefin resin is 350,000 or more, the polyamide is polyamide 6, the dispersed phase (B) is composed of a melt-kneaded product of the polyamide resin and the modified elastomer, the modified elastomer is an elastomer with a reactive group that reacts with the polyamide resin, the elastomer is ethylene-butene copolymer, when a total of the continuous phase (A) and the dispersed phase (B) is taken as 100% by mass, a content of the dispersed phase (B) is 70% by mass or less, and when a total of the first polyolefin resin and the second polyolefin resin is taken as 100% by mass, a content of the second polyolefin resin is 80% by mass or less , wherein the first polyolefin resin is a block copolymerized polyolefin resin having an ethylene block as a dispersed phase, and at least part of the ethylene block is aggregated at an interface between the continuous phase (A) and the dispersed phase (B). 2. Molded body according to claim 1, characterized by the fact that the thermoplastic resin is a mixture of an impact-resistant resin containing the second polyolefin resin, the polyamide resin, and the modified elastomer and the first resin of polyolefin. 3. Molded body according to claim 1, characterized by the fact that, when a total of the polyamide resin and the modified elastomer is taken as 100% by mass, a content of the polyamide resin is 10% by mass or more, but 80% by mass or less. 4. Molded body according to claim 1, characterized by the fact that the dispersed phase (B) has a continuous phase (B1) containing the polyamide resin and a fine dispersed phase (B2) dispersed in the continuous phase (B1 ) and containing the modified elastomer. 5. Method of producing the molded body as defined in claim 1, characterized in that it comprises: dry mixing an impact-resistant resin and a first polyolefin resin to obtain a molded body raw material, wherein the resistant resin impact is obtained by melt kneading the second polyolefin resin and a melt kneading product formed from a polyamide resin and a modified elastomer; and molding the molded body raw material to obtain the molded body, wherein the molded body comprises: a continuous phase (A) containing a first polyolefin resin and a second polyolefin resin; and a dispersed phase (B) dispersed in the continuous phase (A) and containing a polyamide resin and a modified elastomer; wherein the number average molecular weight of the first polyolefin resin is 150,000 or more but less than 350,000, and the number average molecular weight of the second polyolefin resin is 350,000 or more, the polyamide is polyamide 6, the dispersed phase ( B) is composed of a product kneaded under the fusion of a polyamide resin and the modified elastomer; the modified elastomer is an elastomer having a reactive group that reacts with the polyamide resin, the elastomer is ethylene-butene copolymer, when a total of the continuous phase (A) and the dispersed phase (B) is taken as 100% by mass , a content of the dispersed phase (B) is 70% by mass or less, and when a total of the first polyolefin resin and the second polyolefin resin is taken as 100% by mass, a content of the second polyolefin resin is 80% by mass or less. 6. Method of producing the molded body according to claim 5, characterized in that the impact-resistant resin has a continuous phase (C) containing the second polyolefin resin and a dispersed phase (B) dispersed in the continuous phase ( C) and containing the polyamide resin and the modified elastomer, and the dispersed phase (B) has a continuous phase (B1) containing the polyamide resin and a fine dispersed phase (B2) dispersed in the continuous phase (B1) and containing the modified elastomer. 7. Method of producing the molded body as defined in claim 5, characterized in that the first polyolefin resin is a block copolymerized polyolefin resin having an ethylene block as a dispersed phase.