CN101611111B - 含有甲醛系聚合物的树脂材料的粘接方法以及结构体 - Google Patents

含有甲醛系聚合物的树脂材料的粘接方法以及结构体 Download PDF

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CN101611111B
CN101611111B CN2007800441411A CN200780044141A CN101611111B CN 101611111 B CN101611111 B CN 101611111B CN 2007800441411 A CN2007800441411 A CN 2007800441411A CN 200780044141 A CN200780044141 A CN 200780044141A CN 101611111 B CN101611111 B CN 101611111B
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resin material
based polymer
formaldehyde based
polymer composition
peak
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CN101611111A (zh
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冈村显
长井聪
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Mitsubishi Gas Chemical Co Inc
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Abstract

本发明提供了一种树脂材料的粘接方法，该方法为将含甲醛系聚合物A的树脂材料X与树脂材料Y粘接的树脂材料的粘接方法，其中，该方法包括将满足下述条件(1)和(2)的甲醛系聚合物组合物B作为所述树脂材料Y，或者将所述树脂材料X或其它种类的树脂材料作为所述树脂材料Y且使所述甲醛系聚合物组合物B介于该树脂材料Y和树脂材料X之间，并实施加热处理；(1)所述甲醛系聚合物组合物B的熔点比所述甲醛系聚合物A的熔点低，且它们的熔点差小于5℃；(2)由用DSC测定的表示甲醛系聚合物组合物B的熔融状态的峰求得的峰面积的50％以上，存在于比甲醛系聚合物A的峰温度低5℃以上的温度区域内。还提供了通过该粘接方法得到的结构体。

Description

含有甲醛系聚合物的树脂材料的粘接方法以及结构体
技术领域
本发明涉及为了使含有甲醛系聚合物的树脂材料之间粘接而使用具有特定的熔点和熔融峰型的甲醛系聚合物的树脂材料的粘接方法、以及通过该粘接方法而得到的结构体。
背景技术
近年来，对于全球范围内的环境问题，为了防止产业废弃物污染环境，焚烧处理时必要的热量和CO2产生量的减小引起了人们的关注。其结果，对材料的回收、循环越来越关心。
甲醛系聚合物为脂肪族醚型、或者以脂肪族醚为主要成分的聚合物，主要由作为不依赖于石油的原料的甲醇所衍生，被公认为环境负荷低的材料。刚性等的机械特性高，作为工程塑料，是现在广泛使用的良好的材料。
作为将含甲醛系聚合物的树脂材料之间粘接的方法，由于其表面化学活性差，因此公知的有：进行超声波熔接的方法；预先将甲醛聚合物表面粗糙化、或者利用电子射线或等离子体处理来进行改良后，再使用氰基丙烯酸酯系粘接剂、环氧系粘接剂的方法。前者的工序和设备复杂，而且可适用的对象也限于部分注塑成型体。另外，后者不仅得不到充分的粘接效果，而且在再循环性方面，甲醛系聚合物存在因使用别的成分而不优选的问题。因此，期望用同一种甲醛系聚合物材料将含甲醛系聚合物的树脂材料之间粘接的技术。
在甲醛系聚合物之间的粘接中，提出了适用的有：同系的非晶性共聚物(参照专利文献1)、低熔点的共聚物(参照专利文献2)。关于前者，其粘接强度不充分，而且非晶性共聚物的熔点低，粘接后的耐热性差，实用性不充分。另外，后者与前者相比，粘接强度得以大幅度改善，粘接成分的耐热性提高了，但是粘接后，在与以往的甲醛系聚合物相同的环境下使用时，耐热性还比较差。
另外，甲醛系聚合物为结晶性高的树脂，存在以下问题：在粘接含有甲醛系聚合物的注塑成型品、挤出成型品、或延伸材料时，为了粘接而经过在高温或长时间下的热过程，热收缩比预想的大，而且变得不能无视材料侧的熔融、因此不能制备准确地维持形状的结构体。
本发明人已经开发了共聚用单体的含量大的甲醛共聚物。其熔点比以往的甲醛聚合物适当地低，但是丝毫没有言及作为粘接剂的有效性(参照专利文献3)。
专利文献1：特开平1-132638号公报
专利文献2：特开平8-60125号公报
专利文献3：国际公开WO2002-077049号公报
发明内容
本发明的目的在于提供一种能够提高含甲醛系聚合物的树脂材料之间的粘接性、抑制结构体的热收缩或热变形的树脂材料的粘接方法、以及通过该粘接方法得到的结构体。
本发明的发明人为了解决上述问题进行了深入的研究，结果本发明人想出了本发明：在延伸材料之间的粘接之际，相对于一方的树脂材料中所含的甲醛系聚合物的熔点，使用含有具有特定的熔点差、且由DSC测定的熔融峰满足所规定的关系的甲醛系聚合物的树脂材料，(1)作为另一方的树脂材料，或者(2)作为粘接层，并进行加热处理。于是，由此发现不存在热收缩或热变形的问题，而且能够提高材料间的粘接性。
即，本发明涉及一种树脂材料的粘接方法，该方法为将含甲醛系聚合物A的树脂材料X与树脂材料Y粘接的树脂材料的粘接方法，其中，该方法包括将满足下述条件(1)和(2)的甲醛系聚合物组合物B作为所述树脂材料Y，或者将所述树脂材料X或其它种类的树脂材料作为所述树脂材料Y且使所述甲醛系聚合物组合物B介于该树脂材料Y和树脂材料X之间，并实施加热处理。
(1)所述甲醛系聚合物组合物B的熔点比所述甲醛系聚合物A的熔点低，且它们的熔点差小于5℃。
(2)由用DSC测定的表示甲醛系聚合物组合物B的熔融状态的峰求得的峰面积的50％以上，存在于比甲醛系聚合物A的峰温度低5℃以上的温度区域内。
另外，本发明涉及一种结构体，其中，该结构体是通过使用上述粘接方法而得到的。
根据本发明，能够提供一种能提高含甲醛系聚合物的树脂材料之间的粘接性、且能抑制结构的热收缩和热变形的树脂材料的粘接方法；以及由该粘接方法得到的结构体。
具体实施方式
[树脂材料的粘接方法]
本发明的树脂材料的粘接方法为通过对含甲醛系聚合物A的树脂材料X和树脂材料Y进行加热处理来进行粘接的方法。以下对各种材料和加热处理的条件进行说明。
(含甲醛系聚合物A的树脂材料X)
作为甲醛系聚合物A，可举出一般市售的甲醛均聚物或甲醛嵌段共聚物等。其中，优选含有下述通式(1)所示的重复单元、且为三噁烷与一种以上的共聚用单体的共聚物，所述共聚用单体相对于100质量份的所述三噁烷为0.5-30.0质量份。所述共聚用单体相对于100质量份的所述三噁烷更优选为0.5-10.0质量份。
[化学式1]
Figure G2007800441411D00041
上述式(1)中，R1、R2各自独立地表示氢原子、烷基、具有烷基的有机基团、苯基、具有苯基的有机基团。m表示1-6的整数。作为烷基，可举出碳原子数为1-8的烷基。
作为上述共聚用单体，可举出环状甲缩醛或环状醚等。具体地优选为1，3-二氧戊环及其衍生物、1，3-二氧杂环庚烷及其衍生物、1，3，5-三氧杂环庚烷及其衍生物、1，3，6-三氧杂环辛烷及其衍生物、以及单官能度缩水甘油醚。
优选树脂材料X中的甲醛系聚合物A为50体积％以上，更优选树脂材料X由甲醛系聚合物A组成。
(树脂材料Y)
树脂材料Y中所含的甲醛系聚合物组合物B满足下述条件(1)和(2)。
(1)甲醛系聚合物组合物B的熔点比甲醛系聚合物A的熔点低，且它们的熔点差小于5℃。熔点差为5℃以上时，粘接时B成分通过熔融会发生显著的变形。
(2)由用DSC测定的表示甲醛系聚合物组合物B的熔融状态的峰求得的峰面积的50％以上，存在于比甲醛系聚合物A的峰温度低5℃以上的温度区域内。
另外，该熔融峰面积的比例小于50％时，用于粘接的温度与甲醛系聚合物A的熔点很接近，因此不仅树脂材料X的热收缩变大，而且有时会发生热变形、甚至会发生熔融而使形状受到损害。优选甲醛系聚合物组合物B的该峰面积的50％以上，存在于比甲醛系聚合物A的峰温度低10℃以上的温度区域内。
由于甲醛系聚合物组合物B中存在较多的具有与甲醛聚合物A接近的耐热性的成分，因此，通过满足上述(1)和(2)的条件，可以避免粘接时存在由B成分的熔融引起的显著的变形或得不到充分的粘接强度的问题。
作为甲醛系聚合物组合物B，同样为上述通式(1)所示的物质，优选为三噁烷与一种以上的共聚用单体的共聚物，所述共聚用单体相对于100质量份的所述三噁烷为5.0-50.0质量份，更优选为10.0-50.0质量份。
为了使甲醛系聚合物组合物B满足上述(1)和(2)的条件，可举出使B成分内的共聚用单体成分维持分布的方法，具体来说，将两种以上的共聚用单体的含量不同的甲醛系聚合物混合即可。
在树脂材料Y含有甲醛系聚合物组合物B的情况下，优选该聚合物组合物B为50体积％以上，更优选仅由该聚合物组合物B构成。
另外，在树脂材料Y不含有甲醛系聚合物组合物B的情况下，即，在甲醛系聚合物组合物B为用于粘接树脂材料X和树脂材料Y的粘接层的情况下，只要将该聚合物组合物B作为主要成分，也可以与其它材料并用。
另外，将甲醛系聚合物组合物B作为粘接层时，树脂材料Y，可以为与树脂材料X相同的材质，也可以为其它种类的材质。作为其它种类的材质，可举出甲醛系聚合物A的含量不同的材质、或者甲醛系聚合物A以外的成分不同的材质等。
(加热处理条件)
加热处理条件(粘接条件)，优选为所述甲醛系聚合物组合物B的开始熔融的温度以上至小于所述甲醛系聚合物A的熔点的温度。通过使加热处理的温度小于上述熔点，能够抑制含甲醛系聚合物A的材料的热收缩，能够防止热变形、以及甚至由熔融引起的形状损害。另外，通过使加热处理的温度在甲醛系聚合物组合物B的开始熔融的温度以上，能够赋予充分的粘接强度。
作为加热处理的条件，更优选为比甲醛系聚合物A的熔点低5℃以上的温度、且为甲醛系聚合物组合物B的开始熔融的温度以上。
另外，本发明的含甲醛系聚合物的材料，主要含有上述甲醛系聚合物，在不损害本发明本来的目的的范围内，可以添加公知的添加剂和填充剂。
作为添加剂，可举出例如：晶核剂、抗氧剂、增塑剂、消光剂、发泡剂、润滑剂、脱模剂、防静电剂、紫外线吸收剂、光稳定剂、热稳定剂、除臭剂、阻燃剂、滑动剂、香料、抗菌剂等。另外，作为填充剂，可举出玻璃纤维、滑石、云母、碳酸钙、钛酸钾晶须等。而且，通过加入颜料、染料，能够调节至所希望的色调。另外，还能通过加入各种单体、偶合剂、末端处理剂、其它树脂、木粉、淀粉等来进行改性。
而且，对本发明涉及的树脂材料X和树脂材料Y的形态没有特别的限定，优选为注塑成型品、挤出成型品、延伸成型品、或者将它们二次加工后的成型品。除此以外，还可以例示出吹塑成型品、薄膜、薄板、纤维、复合丝、单纤丝、绳、网、织物、编织物、无纺布、过滤器、甚至是将它们二次加工后的材料，但是并不限定于此。在使这些材料之间介入甲醛系聚合物B并进行热粘接的情况下，作为介入的方式，优选预先使所述低熔点甲醛系聚合物B以层状、或区域状存在于树脂材料A的表面上。
另外，不管是连续(层状、棒状、波浪状)、或不连续(区域状、点状)，也可以在含甲醛系聚合物A的材料的一次加工时，同时或依次使其预先存在于所述表面；或者也可以在含甲醛系聚合物A的材料的一次加工以后，在形成结构体之前的期间的工序中使其存在于所述表面。
[结构体]
本发明的结构体，可以通过上述本发明的树脂材料的粘接方法得到。该结构体，含甲醛系聚合物的树脂材料之间的粘接性良好，热收缩和热变形被抑制。
该结构体，可以直接使用，也可以进一步进行加工后使用。例如，通过重复相同的粘接操作、或者同时进行相同的粘接操作，能够得到由多层含甲醛系聚合物A的至少一种以上的树脂材料构成的结构体。另外，通过使粘接一次以后的结构体重新与形状不同的含其它的甲醛系聚合物A的树脂材料粘接，能够形成更高度的结构体。
例如，作为结构体为多层纤维的情况下的层结构，在同一纤维中，在其截面，均具有露出纤维表面的两个以上的层，构成该层的成分，至少含有上述树脂材料X和Y。向表面的露出比例，没有特别的限定，但是熔点低、二次加工时作为粘接层起作用的树脂材料Y(尤其是甲醛系聚合物B成分)的露出比例越高，粘接强度越好。因此，也可以将树脂材料Y作为各自分开的多层而形成。
以下列举实施例对本发明进行更具体的说明，但是本发明并不限制于以下所示的具体例子。
另外，实施例中所使用的材料、熔点的测定方法、以及粘接方法和判断基准如下所示。
(树脂材料)
作为树脂材料X，使用将甲醛系聚合物a进行熔融纺纱、延伸4倍、加工成单纤度计为5分特的复合丝后的成型品，所述甲醛系聚合物a为具有172℃的熔点的三菱エンジニアリングプラスチツク株式会社制的ユピタ一ルA40。
作为树脂材料Y，使用对将甲醛系聚合物a和甲醛系聚合物b分别以1∶1、1∶2、3∶1的质量比进行熔融掺合后的物质(分别称为b-1、b-2、b-3)进行熔融纺纱、延伸1倍、加工成单纤度为5分特的复合丝后的成型品，所述甲醛系聚合物b为具有155℃的熔点的三菱エンジニアリングプラスチツク株式会社制的ユピタ一ルV40。
(熔点的测定方法)
以10℃/分钟的速度从30℃升温到210℃，使用差示扫描热量计(セイコ一インスツルメンツ(株)制DSC6200)，来测定熔融峰温度，得到熔点。另外，使用手动分数次积分(fractional integration)的分析模式求出在比甲醛系聚合物a的熔融峰温度低5℃以上和10℃以上的温度区域内的树脂材料Y的峰面积的比例，并作为相对于峰整体的吸热量(mJ/mg)的该区域的吸热量的比例。
(粘接方法和判定基准)
将树脂材料X的复合丝切断成10cm的长度，并将其以直线状配置在铁板上，然后将树脂材料Y的复合丝切断成3cm的长度，并将其以与树脂材料X交叉的方式配置在树脂材料X上，再用另一个铁板夹住。通过预先加热到下述表1所述的温度的油压式热压装置，在所定时间的加热、加压条件下，对其实施热粘接处理(加热处理)。
处理后，目视确认树脂材料X和树脂材料Y的粘接状态，进行各自熔融、未熔融的确认。另外，测定树脂材料X处理后的长度，并测定处理前后的热收缩率。
[实施例1-4]
利用上述粘接方法，并在下述表1中记载的条件下，对树脂材料X和树脂材料Y进行粘接。评价结果也如表1所示。
[比较例1-3]
利用上述粘接方法，并在下述表1中记载的条件下，对树脂材料X和树脂材料Y进行粘接。评价结果也如表1所示。

Claims (7)

1.一种树脂材料的粘接方法，该方法为将含甲醛系聚合物A的树脂材料X，与树脂材料Y粘接的树脂材料的粘接方法，其中，该方法包括：
(I)将满足下述条件(1)和(2)的甲醛系聚合物组合物B作为所述树脂材料Y，或者
将所述树脂材料X或其它种类的树脂材料作为所述树脂材料Y且使所述甲醛系聚合物组合物B介于该树脂材料Y和树脂材料X之间，以及
(II)实施加热处理，
(1)所述甲醛系聚合物组合物B的熔点比所述甲醛系聚合物A的熔点低，且它们的熔点差小于5℃；
(2)由用DSC测定的表示甲醛系聚合物组合物B的熔融状态的峰求得的峰面积的50％以上，存在于比甲醛系聚合物A的峰温度低5℃以上的温度区域内，
其中，所述甲醛系聚合物A含有下述通式(1)所示的重复单元，且为三噁烷与一种以上的共聚用单体的共聚物，所述共聚用单体相对于100质量份的所述三噁烷为0.5-30.0质量份，
所述甲醛系聚合物组合物B含有下述通式(1)所示的重复单元，且为三噁烷与一种以上的共聚用单体的共聚物，所述共聚用单体相对于100质量份的所述三噁烷为5.0-50.0质量份，
Figure FSB00000768663200011
式中，R1、R2各自独立地表示氢原子、具有烷基的有机基团、具有苯基的有机基团，m表示1-6的整数，
条件(1)中，所述熔点是以10℃/分钟的速度从30℃升温到210℃，使用DSC测定的，
条件(2)中，由表示甲醛系聚合物组合物B的熔融状态的峰求得的峰面积的比例的测定方法为使用手动分数次积分的分析模式求出使用DSC测定的在比甲醛系聚合物A的熔融峰温度低5℃以上和低10℃以上的温度区域内的树脂材料Y的峰面积的比例，并作为相对于峰整体的吸热量的该区域的吸热量的比例，所述吸热量以mJ/mg计。
2.根据权利要求1所述的树脂材料的粘接方法，其中，在条件(2)中，由用DSC测定的表示甲醛系聚合物组合物B的熔融状态的峰求得的峰面积的50％以上，存在于比甲醛系聚合物A的峰温度低10℃以上的温度区域内。
3.根据权利要求1所述的树脂材料的粘接方法，其中，将步骤(II)所述加热处理的温度设定为所述甲醛系聚合物组合物B的开始熔融的温度以上至小于所述甲醛系聚合物A的熔点的温度。
4.根据权利要求1所述的树脂材料的粘接方法，其中，所述甲醛系聚合物A和所述甲醛系聚合物B中的所述共聚用单体为选自由1，3-二氧戊环及其衍生物、1，3-二氧杂环庚烷及其衍生物、1，3，5-三氧杂环庚烷及其衍生物、1，3，6-三氧杂环辛烷及其衍生物、以及单官能度缩水甘油醚所组成的组中的至少一种共聚用单体。
5.根据权利要求1所述的树脂材料的粘接方法，其特征在于，所述树脂材料X为注塑成型品、挤出成型品、延伸成型品、或者将它们二次加工后的成型品。
6.根据权利要求1所述的树脂材料的粘接方法，其中，该方法还包括预先使所述甲醛系聚合物组合物B以层状、或区域状存在于所述树脂材料X的表面上。
7.一种结构体，该结构体是通过使用权利要求1所述的粘接方法而得到的，其中，该结构体含有多层纤维，在同一纤维中，在其截面，均具有露出纤维表面的两个以上的层，构成该层的成分，至少含有所述树脂材料X和树脂材料Y。
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