JP2011148851A - Flame-retardant polyester resin composition - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a flame-retardant polyester resin composition which exhibits excellent flame retardancy and in particular, self-extinguishing property without containing a halogen atom-containing flame retardant, and which is excellent in mechanical properties such as elastic modulus, bending strength or impact strength. <P>SOLUTION: The flame-retardant polyester resin composition contains: (A) 40-80 wt.% of a polyester resin; (B) 5-40 wt.% of a polycarbonate resin; (C) 5-30 wt.% of a rubber-like polymer; (D) 1-20 wt.% of a polyphenylene sulfide resin and/or a phenol resin; (E) 0.1-25 wt.% of a phosphate compound and/or a polyamide resin; and (F) 2-20 wt.% of an organic modified clay mineral. <P>COPYRIGHT: (C)2011,JPO&amp;INPIT

Description

  The present invention relates to a flame retardant polyester resin composition. The present invention also relates to a technology for reusing a molded product of a thermoplastic resin that has become waste.

  Currently, thermoplastic resins such as polyester resins and polycarbonate resins or resin compositions thereof are used in containers, from the viewpoint of their excellent molding processability, mechanical properties, heat resistance, weather resistance, appearance, hygiene and economy. It is used in a wide range of fields as molding materials for packaging films, household goods, office equipment, AV equipment, electrical / electronic parts, automobile parts, and the like. Therefore, the amount of such thermoplastic resin or molded product of the resin composition used is large, and is still increasing year by year. On the other hand, the amount of molded and processed products that have been used and are no longer needed is increasingly increasing, which is a serious social problem.

  In the background as described above, in recent years, the Law Concerning the Promotion of Procurement of Environmental Goods, etc. by the Containers and Packaging Recycling Law and the State etc. There is an increasing interest in material recycling of molded products of resin compositions. In particular, there is an urgent need to establish a material recycling technology for PET bottles using polyethylene terephthalate (hereinafter sometimes referred to as “PET”) whose usage is rapidly increasing. In addition, with the widespread use of optical recording medium products (optical discs) made of polycarbonate (hereinafter sometimes referred to as PC) such as CD, CD-R, DVD, MD, etc. Studies are being made to reuse a transparent PC material obtained after peeling off a reflective layer, a recording layer, and the like from a recycling method or a waste optical disk.

  However, molded products of polyester resins such as used PET bottles collected from the market and polycarbonate resins such as optical disks are often deteriorated due to hydrolysis or thermal decomposition. For example, even if you try to re-mold those products that have been pulverized from these molded products, the melt viscosity is so drastically reduced that they cannot be molded at all, or even if they can be molded, their mechanical strength is fragile and easily broken. Therefore, in reality, it is extremely difficult to recycle the molded product that can withstand practical use.

  As a method of recovering a resin for recycling from a discarded molded product, for example, an epoxy group-containing ethylene copolymer is melt-kneaded into a pulverized piece of a molded product of a thermoplastic resin such as PET or PC or a resin composition thereof. And a method of melt-kneading an epoxidized diene copolymer (Patent Document 3) have been proposed. Patent Documents 4 to 7 propose a material technology in which a rubbery polymer is combined in order to improve the impact strength of R-PET (recycled PET). However, in these known techniques, a flame retardant containing a halogen atom is used in order to obtain high fire prevention performance. However, when a flame retardant containing a halogen atom is added, the impact strength is not sufficiently improved. For this reason, when the amount of the flame retardant containing a halogen atom is suppressed, poor flame retardancy may occur. As a result, it has become an obstacle to expanding applications. In addition, the flame retardant containing halogen atoms has a problem in safety to the environment and the human body due to the halogen atoms.

JP-A-5-247328 Japanese Patent Application Laid-Open No. 6-298991 JP-A-8-245756 JP 2003-183486 A JP 2003-213112 A JP 2003-221498 A JP 2003-231796 A

  In view of the above circumstances, the inventors of the present invention first studied earnestly a recycling method that can withstand practical use for a pulverized PET bottle, which is a typical polyester resin recovery material, and then based on the knowledge obtained therefrom. In addition, a method for using a crushed optical disk made of polycarbonate resin was also examined. As a result, it has been found that a resin composition containing a combination of predetermined components (A) to (F) exhibits excellent mechanical performance and exhibits self-extinguishing properties in air. And it turned out that such an effect can be obtained not only when PET bottle pulverized products and PC optical disk pulverized products are used, but also when using ordinary virgin PET and PC, and the present invention has been completed. It was.

  The present invention provides a flame retardant polyester resin composition that exhibits excellent flame retardancy without containing a halogen atom-containing flame retardant, particularly self-extinguishing properties, and is excellent in mechanical properties such as elastic modulus, bending strength, and impact strength. The purpose is to provide goods.

  The present invention also provides excellent flame retardancy, particularly self-reliability, even when a polyester resin and / or polycarbonate resin obtained from a molded product that has become waste is reused, without containing a halogen atom-containing flame retardant. An object of the present invention is to provide a flame retardant polyester resin composition exhibiting fire extinguishing properties and excellent in mechanical properties such as elastic modulus, bending strength and impact strength.

The present invention
(A) 40-80% by weight polyester resin;
(B) 5-40% by weight of polycarbonate resin;
(C) 5-30% by weight of a rubbery polymer;
(D) 1 to 20% by weight of polyphenylene sulfide resin and / or phenol resin; (E) 0.1 to 25% by weight of phosphate ester compound and / or polyamide resin; and (F) 2 to 20% by weight of organic decorative clay mineral.
It relates to a flame retardant polyester resin composition characterized by containing.

The flame-retardant polyester resin composition of the present invention and a molded article obtained using the resin composition exhibit excellent flame retardancy, particularly self-extinguishing properties, even without containing a halogen atom-containing flame retardant. Excellent mechanical properties such as elastic modulus, bending strength and impact strength. Such an effect can be obtained even when the polyester resin and / or polycarbonate resin obtained from the molded product that has become waste is reused.
The flame-retardant polyester resin composition of the present invention is manufactured by performing a predetermined gap-passing treatment, and thus has self-extinguishing properties and mechanical performance such as elastic modulus, bending strength and impact strength, particularly self-extinguishing properties. Remarkably improved.

(A) is a schematic perspective view of an example of an apparatus for producing the flame-retardant polyester resin composition of the present invention as seen through the inside of the apparatus from the upper surface, and (B) is an apparatus of (A). It is a schematic sectional drawing in the PQ cross section. (A) is a schematic perspective view of an example of an apparatus for producing the flame-retardant polyester resin composition of the present invention as seen through the inside of the apparatus from the upper surface, and (B) is an apparatus of (A). It is a schematic sectional drawing in the PQ cross section. (A) is a schematic perspective view of an example of an apparatus for producing the flame-retardant polyester resin composition of the present invention as seen through the inside of the apparatus from the upper surface, and (B) is an apparatus of (A). It is a schematic sectional drawing in the PQ cross section. (A) is a schematic sketch of an example of the apparatus for manufacturing the flame-retardant polyester resin composition of this invention, (B) is a schematic cross section in the PQ cross section which passes along the axis | shaft of the apparatus of (A). FIG. The SEM photograph of the test piece using the resin composition of this invention is shown.

[(A) component]
The polyester resin as the component (A) blended in the flame-retardant polyester resin composition of the present invention (hereinafter sometimes referred to as a resin composition) is not particularly limited, and has a dicarboxylic acid unit or ester-forming ability. It is a polyester resin obtained by polycondensing a derivative thereof having a diol unit or an ester-forming derivative with a known method.

  Specific examples of the dicarboxylic acid unit include, for example, terephthalic acid, isophthalic acid, orthophthalic acid, 2,2'-biphenyldicarboxylic acid, 3,3'-biphenyldicarboxylic acid, 4,4'-biphenyldicarboxylic acid, 4,4 '-Diphenyl ether dicarboxylic acid, 1,5-naphthalenedicarboxylic acid, 1,4-naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid, bis (p-carboxyphenyl) methane, anthracene dicarboxylic acid, sodium 5-sulfoisophthalate, etc. Aromatic dicarboxylic acid, adipic acid, sebacic acid, succinic acid, azelaic acid, malonic acid, succinic acid, dodecanedioic acid and other aliphatic dicarboxylic acids, 1,3-cyclohexanedicarboxylic acid, 1,4-cyclohexanedicarboxylic acid, etc. Alicyclic dicarboxylic acids and their ester formation Derivatives (e.g. methyl ester, lower alkyl esters such as ethyl ester, etc.) can be mentioned dicarboxylic acid units derived from such.

  Specific examples of the diol unit include, for example, ethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol, 1,3-propanediol, 1,4-butanediol, 2,3-butanediol, 1, C2-C10 aliphatic diols such as 6-hexanediol, 1,10-decanediol, neopentyl glycol, 2-methylpropanediol, 1,5-pentadiol, 1,4-cyclohexanedimethanol, 1, List diol component units derived from alicyclic diols such as 4-cyclohexanediol, polyalkylene glycols having a molecular weight of 6000 or less, such as diethylene glycol, polyethylene glycol, poly-1,3-propylene glycol, and polytetramethylene glycol. Can do.

  Both of these dicarboxylic acid units and diol units may be used alone or in combination of two or more. Furthermore, the polyester resin of the present invention is derived from a tri- or higher functional monomer such as glycerin, trimethylolpropane, pentaerythritol, trimellitic acid, pyromellitic acid, etc., if it is 1 mol% or less based on the total structural unit. It may have a structural component unit.

  From the viewpoint of further improving flame retardancy and mechanical performance, polyester resins are obtained by polycondensation of aromatic dicarboxylic acids or their derivatives having ester-forming ability with aliphatic diols or their derivatives having ester-forming ability. The obtained aromatic polyester resin is preferable.

  Specific examples of the polyester resin include, for example, polyethylene terephthalate (hereinafter sometimes referred to as PET), polybutylene terephthalate (hereinafter sometimes referred to as PBT), polypropylene terephthalate, and polyethylene naphthalate (hereinafter referred to as PEN). And polybutylene naphthalate, poly-1,4-cyclohexanedimethylene terephthalate, polycaprolactone, p-hydroxybenzoic acid polyester, polyarylate resin and the like. Among these, PET and PEN using ethylene glycol as the diol component are particularly preferable from the standpoint of balance of physical properties such as crystallization behavior, thermal properties, and mechanical properties. A PBT using butylene glycol as the diol component is also preferable because of a good balance of moldability and mechanical properties. A mixture of PET and PBT can also be suitably used. Furthermore, polyethylene naphthalate or a mixture thereof with polyethylene terephthalate (preferably a mixture containing 50% by weight or more of PET) is also preferred.

Although there is no restriction | limiting in particular in the intrinsic viscosity of a polyester resin, In this invention, Preferably it is 0.50-1.50dl / g, More preferably, it is the range of 0.65-1.30dl / g. If the intrinsic viscosity is too small, sufficient impact resistance cannot be obtained, and chemical resistance may be lowered. On the other hand, if the intrinsic viscosity is too large, the flow viscosity increases and the kneading temperature must be set high, and the kneading is carried out at a temperature unfavorable for other additives to be combined.
In the present specification, the intrinsic viscosity is a value measured at 30 ° C. using a phenol / tetrachloroethane (weight ratio: 1/1) mixed solvent.

  The polyester resin usually has a melting point of 180 to 300 ° C, preferably 220 to 290 ° C, and a glass transition temperature of 50 to 180 ° C, preferably 60 to 150 ° C.

In the present specification, the melting point refers to the end point temperature of the crystal melting endothermic peak that appears during temperature rise measurement by a differential scanning calorimeter (DSC).
The glass transition temperature refers to the temperature at which the base line changes in a stepped manner in the same measurement as the melting point. Specifically, in the same measurement as the melting point, the glass transition temperature is a straight line that is equidistant in the vertical direction from a straight line that extends from the base line before and after the stepped portion and a curve of the stepped changed portion. This is the temperature at the point where and intersect.

  As the polyester resin, a resin piece obtained by pulverizing a discarded polyester resin product can be used. In particular, a pulverized product of a PET product such as a used waste PET bottle can be suitably used as the PET having an intrinsic viscosity in the above range. It is possible to use resin pieces obtained by pulverizing bottles, sheets, clothes, and molding wastes and fiber wastes produced when molding these molded products into appropriate sizes, which are PET products collected as waste. Among them, a crushed product of a beverage bottle that is large in quantity can be suitably used. In general, PET bottles are recycled into transparent clear flakes having a size of 5 to 10 mm after separating and collecting, through a process of removing different materials, crushing, and washing. Usually, the range of intrinsic viscosity of such clear flake is approximately 0.60 to 0.80 dl / g.

  The polyester resin piece of the discarded polyester resin product can be obtained by pulverizing and washing, kneading at a temperature of 180 ° C. or higher and lower than 260 ° C., cooling and pulverizing.

  Virgin polyester resins are commercially available in the form of pellets, but these are pressed at a temperature above the glass transition temperature, or once melted with an extruder or the like, and the molten strand is crushed by passing it through a roller in cooling water. It can be used as a resin piece by cutting with a normal pelletizer.

  By using the polyester resin as the resin piece, the supply to the kneader is facilitated during the production of the resin composition, and the load on the kneading apparatus is reduced in the kneading until melting. As a shape of the polyester resin piece, for example, a flake shape, a block shape, a powder shape and a pellet shape are preferable, and a particularly preferable shape is a flake shape. The preferred maximum length of the resin piece is 30 mm or less, more preferably 20 mm, and even more preferably 10 mm or less. Kneading is possible even if a resin piece having a maximum length exceeding 30 mm is contained, but it may be clogged in the supply process, which is not preferable. However, since it can be prevented by improving the supply device, there is no particular limitation as long as the object of the present invention is not impaired.

  (A) The compounding quantity of a component is 40 to 80 weight% with respect to the composition whole quantity, From a viewpoint of the further improvement of a flame retardance and mechanical performance, Preferably it is 50 to 75 weight%. When the blending amount of the component (A) is too small, the dispersion state of other components changes, and mechanical properties, particularly impact strength and bending strength are lowered. If the amount is too large, the flame retardancy is lowered and the self-extinguishing property is lost, so the object of the present invention cannot be achieved. Also, mechanical properties, particularly impact strength, are reduced. The polyester resin may be a mixture of two or more kinds of polyester resins having different structural units and / or intrinsic viscosities, such as a mixture of PET and PEN, or a copolymer of PET and PEN containing a PEN component in the primary bond of PET. In such a case, the total blending amount thereof may be within the above range.

[Component (B)]
The polycarbonate resin (hereinafter sometimes referred to as PC) as the component (B) is an aromatic polycarbonate obtained by reacting a dihydric phenol and a carbonate precursor. A known method can be adopted as the production method, for example, a method in which dihydric phenol is directly reacted with a carbonate precursor such as phosgene (interfacial polymerization method), or a dihydric phenol and a carbonate precursor such as diphenyl carbonate are melted. A method of transesterification using a solution (solution method) is known.

  Dihydric phenols include hydroquinone, resorcin, dihydroxydiphenyl, bis (hydroxyphenyl) alkane, bis (hydroxyphenyl) cycloalkane, bis (hydroxyphenyl) sulfide, bis (hydroxyphenyl) ether, bis (hydroxyphenyl) ketone, bis (Hydroxyphenyl) sulfone, bis (hydroxyphenyl) sulfoxide, bis (hydroxyphenyl) benzene, and derivatives thereof in which the nucleus is substituted with an alkyl group or a halogen atom. Representative examples of particularly suitable dihydric phenols include 2,2-bis (4-hydroxyphenyl) propane (commonly called bisphenol A), 2,2-bis {(4-hydroxy-3-methyl) phenyl} propane, , 2-bis {(3,5-dibromo-4-hydroxy) phenyl} propane, 2,2-bis (4-hydroxyphenyl) butane, 1,1-bis (4-hydroxyphenyl) cyclohexane, 1,1- And bis (4-hydroxyphenyl) -3,3,5-trimethylcyclohexane, 4,4'-dihydroxydiphenylsulfone, bis {(3,5-dimethyl-4-hydroxy) phenyl} sulfone, and the like. Or more can be mixed and used. Of these, the use of bisphenol A is particularly preferred.

  Examples of the carbonate precursor include diaryl carbonates such as diphenyl carbonate, ditoluyl carbonate and bis (chlorophenyl) carbonate, dialkyl carbonates such as dimethyl carbonate and diethyl carbonate, carbonyl halides such as phosgene, and haloformates such as dihaloformates of dihydric phenols. However, it is not limited to these. Preferably, diphenyl carbonate is used. These carbonate precursors may also be used alone or in combination of two or more.

  Polycarbonate resin is a trifunctional or higher polyfunctionality such as 1,1,1-tris (4-hydroxyphenyl) ethane and 1,1,1-tris (3,5-dimethyl-4-hydroxyphenyl) ethane. It may be a branched polycarbonate resin copolymerized with an aromatic compound or a polyester carbonate resin copolymerized with an aromatic or aliphatic bifunctional carboxylic acid. Moreover, the mixture which mixed 2 or more types of the obtained polycarbonate resin may be sufficient.

The molecular weight of the polycarbonate resin is usually about 1 × 10 ⁴ to 1 × 10 ^{5 in} terms of viscosity average molecular weight, but the viscosity average molecular weight of the polycarbonate resin used in the present invention is preferably about 10,000 to 40,000, 000-35,000 is more preferable.
In the present specification, the viscosity average molecular weight is a value measured by a CBM-20 Alite system and GPC software (manufactured by Shimadzu Corporation).

  The polycarbonate resin usually has a glass transition temperature of 120 to 290 ° C, preferably 140 to 270 ° C.

  As the polycarbonate resin, a resin piece obtained by pulverizing a discarded polycarbonate resin product can be used. In particular, as the polycarbonate having the above molecular weight range, a discarded pulverized product such as an optical disk can be suitably used. CDs, CD-Rs, DVDs, MDs, and other optical discs and optical lenses that have been formed and processed from scraps and waste optical discs that have had their reflective layer, recording layer, etc. removed to an appropriate size of 10 mm or less If it is the resin piece grind | pulverized to the inside, it will not specifically limit, It can use in this invention. Generally, these polycarbonate resins for optical disks are of a high flow type and have a low molecular weight of 13,000 to 18,000.

  The discarded polycarbonate resin piece of the polycarbonate resin product can be obtained by kneading at a temperature of 180 ° C. or higher and lower than 260 ° C., cooling and pulverizing after grinding and washing.

  Virgin polycarbonate resins are commercially available in the form of pellets, but these are pressed at a temperature above the glass transition temperature, or once melted with an extruder or the like, and the molten strand is crushed by passing it through a roller in cooling water. It can be used as a resin piece by cutting with a normal pelletizer.

  By using the polycarbonate resin as the resin piece, the supply to the kneader is facilitated during the production of the resin composition, and the load on the kneading apparatus is reduced in the kneading until melting. As the shape of the polycarbonate resin piece, for example, a flake shape, a block shape, a powder shape, and a pellet shape are preferable, and a particularly preferable shape is a flake shape. The preferred maximum length of the resin piece is 30 mm or less, more preferably 20 mm or less, and even more preferably 10 mm or less. Kneading is possible even if a resin piece having a maximum length exceeding 30 mm is contained, but it may be clogged in the supply process, which is not preferable. However, since it can be prevented by improving the supply device, there is no particular limitation as long as the object of the present invention is not impaired.

  (B) The compounding quantity of a component is 5 to 40 weight% with respect to the composition whole quantity, Preferably it is 10 to 30 weight% from a viewpoint of the further improvement of an elasticity modulus and a flame retardance. When the blending amount of the component (B) is too small, flame retardancy is lowered and self-extinguishing properties are lost. In addition, mechanical properties, particularly bending strength, are reduced. If the amount is too large, mechanical properties, particularly impact strength, are reduced. Two or more kinds of polycarbonate resins may be used in combination, but at that time, the total blending amount is within the above range as the component (B).

[Component (C)]
The rubber-like polymer as component (C) is a component necessary for imparting impact resistance to the resin composition of the present invention, and is an introduction to rubber technology (published by Japan Rubber Association edited by Maruzen Co., Ltd.) and thermoplastic elastomer. The rubber-like compounds described in the material design and molding process (published by Shinzo Yamashita's supervising technology information association) can be used.

  The rubber-like polymer is a polymer having at least one glass transition point (Tg) at 20 ° C. or lower.

  If the number average molecular weight of the rubber-like polymer is too small, the mechanical properties such as the strength and elongation at break of the polymer itself are lowered, and there is a risk of lowering the strength when it is made into a composition. If the amount is too high, the workability is deteriorated and a composition having sufficient performance may not be obtained. Therefore, the number average molecular weight is preferably in the range of 30,000 to 500,000, more preferably 50,000 to 50,000. The range is 300,000.

  As such a rubbery polymer, for example, conjugated diene rubber, urethane rubber (UR), or silicone rubber can be used.

  The conjugated diene rubber is a homopolymer or copolymer rubber containing a conjugated diene monomer. The content of the conjugated diene monomer is usually 10% by weight or more, preferably 10 to 50% by weight, based on all monomer components.

  Specific examples of the conjugated diene rubber include, for example, natural rubber, polybutadiene rubber (BR), butadiene-styrene copolymer rubber (SBR), polyisoprene rubber (IR), butadiene-acrylonitrile copolymer rubber, ethylene-propylene- (Dienemethylene) copolymer rubber (EPDM), isobutylene-isoprene copolymer rubber (IIR), styrene-butadiene-styrene copolymer rubber, styrene-butadiene-styrene radial telecopolymer rubber, styrene-isoprene-styrene Examples include copolymer rubber and polychloroprene (CR). Among the above specific examples, the copolymer rubber is meant to include a graft copolymer rubber and a block copolymer rubber.

  Specific examples of urethane rubber (UR) include, for example, polyether-based UR and polyester-based UR as soft segments that exhibit rubber-like properties.

  Specific examples of the silicone rubber include, for example, a millable type silicone rubber and a LIMS type silicone rubber. The millable type silicone rubber having a crosslinking group is preferable for the present invention, but the LIMS type is also produced by a crosslinking reaction. Any crushed rubber can be used.

For example, a rubber-like polymer composed of a single monomer such as polydimethyl silicone rubber, natural rubber, polybutadiene rubber (BR), polyisoprene rubber (IR), and polychloroprene (CR) is one Tg. And the Tg is 20 ° C. or lower.
Also, for example, thermoplastic elastomers such as urethane rubber, butadiene-styrene graft copolymer rubber (SBR), butadiene-acrylonitrile graft copolymer rubber, ethylene-propylene- (dienemethylene) graft copolymer rubber (EPDM) ), Isobutylene-isoprene graft copolymer rubber (IIR)), styrene-butadiene-styrene graft copolymer rubber, styrene-butadiene-styrene radial telegraft copolymer rubber, styrene-isoprene-styrene graft copolymer rubber Such a graft copolymer rubber composed of two or more types of monomers has only one Tg, and the Tg is 20 ° C. or less.
Also, for example, styrene-butadiene-styrene block copolymer rubber, styrene-butadiene-styrene radial teleblock copolymer rubber, styrene-isoprene-styrene block copolymer rubber, butadiene-styrene block copolymer rubber (SBR), Block copolymer consisting of two or more monomers such as butadiene-acrylonitrile block copolymer rubber, ethylene-propylene- (dienemethylene) block copolymer rubber (EPDM), isobutylene-isoprene block copolymer rubber (IIR) The united rubber has Tg for each segment of each block, so it has two or more Tg, of which at least one Tg is 20 ° C. or lower and the other Tg may be 20 ° C. or lower, Or you may exceed 20 degreeC.

  Among the rubber-like polymers described above, conjugated diene rubber, urethane rubber, and silicone rubber are preferably used from the viewpoint of the appearance of the molded body. Conjugated diene rubbers, particularly BR, SBR, EPDM and IIR are preferred because they are easily cross-linked during kneading.

  The rubbery polymer may be obtained by any production method or may be obtained as a commercial product.

  As commercial products of conjugated diene rubbers, for example, EPDM (manufactured by Dow Corp .; Nordel IP), Esprene (manufactured by Sumitomo Chemical Co., Ltd.), and Royalene (manufactured by Uniroyal Chemical) can be used.

  As commercially available products of urethane rubber, for example, iron rubber (manufactured by Unimatec Co., Ltd.) and E885PFAA adipate (manufactured by Nippon Milactolan) can be used.

  As a commercially available product of silicone rubber, for example, one-component RTV rubber (manufactured by Shin-Etsu Chemical Co., Ltd.), silicone varnish (manufactured by Shin-Etsu Chemical Co., Ltd.), and millable silicone rubber (manufactured by Momentive) can be used.

  The blending amount of the component (C) is 5 to 30% by weight with respect to the total amount of the composition, and preferably 5 to 20% by weight, more preferably 5 to 5% by weight from the viewpoint of further improving flame retardancy and mechanical performance. 15% by weight. When the blending amount of the component (C) is too small, mechanical properties, particularly bending strength, is lowered. When the amount is too large, the self-extinguishing property is lowered, and mechanical properties, particularly bending strength and impact strength are lowered.

[(D) component]
As component (D), polyphenylene sulfide (hereinafter sometimes referred to as PPS) and / or phenol resin is used.

  PPS is a polyphenylene sulfide useful as a so-called engineering plastic.

PPS having a softening point Tm of 240 to 300 ° C, preferably 240 to 290 ° C is used.
In this specification, the softening point is a value measured by DSC7020 (manufactured by Seiko Instruments Inc.).

  As the PPS, one produced by a known method may be used, or one obtained as a commercial product may be used.

  As commercial products of PPS, for example, Torelina (manufactured by Toray Industries, Inc.), PPS (manufactured by DIC), and the like are available.

  A phenol resin is a polymer substance obtained by addition / condensation of phenols and aldehydes.

  Examples of phenols include phenol, cresol, xylenol, p-alkylphenol, p-phenylphenol, chlorophenol, bisphenol A, phenolsulfonic acid, and resorcinol.

  Examples of aldehydes include formalin and furfural.

As the phenol resin, for example, a phenol / formalin resin, a cresol / formalin resin, a modified phenol resin, a phenol / furfural resin, a resorcin resin and the like are known based on the raw material.
As phenol-formalin resin, based on the production method, a novolak type in which a precursor is manufactured with an acidic catalyst and a curing reaction is performed with an alkali catalyst, a precursor is manufactured with an alkali catalyst and a curing reaction is performed with an acid catalyst. Can be mentioned.

  As the phenol resin, a phenol / formalin resin, particularly a novolac type phenol / formalin resin is preferably used.

  The object of the present invention can be achieved whether the phenol resin is a powder or a liquid. A preferred phenolic resin is a phenolic resin that is powdered at room temperature. This is because the handleability is excellent during weighing. The melting point of such a phenol resin is preferably 30 ° C. or higher and 150 ° C. or lower because it can be used as a crosslinking agent for a rubbery polymer. More preferably, it is 60 degreeC120 degrees C or less.

  As the phenol resin, one produced by a known method may be used, or one obtained as a commercial product may be used.

  As commercially available products of phenol resin, for example, PR-HF-3 (manufactured by Sumitomo Bakelite Co., Ltd.), phenol resin SP90 (manufactured by Asahi Organic Materials Industries Co., Ltd.) and the like are available.

  From the viewpoint of self-extinguishing properties, it is preferable to use at least a phenol resin, and it is more preferable to use a phenol resin and PPS in combination.

  (D) The compounding quantity of a component is 1 to 20 weight% with respect to the composition whole quantity, From a viewpoint of the further improvement of a flame retardance performance, Preferably it is 2 to 20 weight%, More preferably, it is 2 to 5 weight% is there. When the blending amount of the component (D) is 1% by weight or more, the molded product produced from the resulting resin composition exhibits self-extinguishing properties, and when it is 2% by weight or more, the burning rate is also slowed down. It becomes difficult to ignite even if a match fire is approached. When the blending amount of the component (D) is too small, the self-extinguishing property is lowered, and mechanical properties, particularly impact strength and bending strength are lowered. If the amount is too large, mechanical properties, particularly impact strength and bending strength are lowered. Each of the PPS and the phenol resin may be a mixture of two or more types having different types and / or softening points / melting points, and the PPS or the phenol resin may be used alone or in combination. In that case, those total compounding quantity should just be in the said range.

[(E) component]
As the component (E), a phosphate ester compound and / or a polyamide resin (hereinafter sometimes referred to as PA) are used.

  As the phosphoric acid ester compound, phosphorous acid, phosphoric acid, phosphonous acid, an esterified product of phosphonic acid, and the like are used.

  Specific examples of the phosphite ester include, for example, triphenyl phosphite, tris (nonylphenyl) phosphite, tris (2,4-di-t-butylphenyl) phosphite, distearyl pentaerythritol diphosphite, bis ( 2,6-di-t-butyl-4-methylphenyl) pentaerythritol diphosphite, bis (2,4-di-t-butylphenyl) pentaerythritol diphosphite, and the like.

  Specific examples of the phosphate ester include, for example, triphenyl phosphate (TPP), tris (nonylphenyl) phosphate, tris (2,4-di-t-butylphenyl) phosphate, distearyl pentaerythritol diphosphate, bis (2, 6-di-t-butyl-4-methylphenyl) pentaerythritol diphosphate, bis (2,4-di-t-butylphenyl) pentaerythritol diphosphate, tributyl phosphate, bisphenol A bis-diphenyl phosphate, and the like.

  Specific examples of the phosphonous acid ester include tetrakis (2,4-di-t-butylphenyl) -4,4'-biphenylenephosphonite.

  Specific examples of the phosphonic acid ester include dimethyl benzenephosphonate, benzenephosphonic acid ester, and the like.

  The phosphoric acid ester compound is preferably an esterified product of phosphorous acid, phosphoric acid and phosphonic acid, and particularly preferably a phosphoric acid ester.

  PA is a resin also called a nylon resin. PA is not particularly limited, and various polyamides can be used. Specific examples include polyamides obtained by ring-opening polymerization of lactams such as ε-caprolactam and ω-dodecalactam; polyamides derived from amino acids such as 6-aminocaproic acid, 11-aminoundecanoic acid, and 12-aminododecanoic acid; Ethylenediamine, tetramethylenediamine, hexamethylenediamine, undecamethylenediamine, dodecamethylenediamine, 2,2,4- / 2,4,4-trimethylhexamethylenediamine, 1,3- and 1,4-bis (aminomethyl) ) Aliphatic, alicyclic or aromatic diamines such as cyclohexane, bis (4,4'-aminocyclohexyl) methane, meta and paraxylylenediamine, adipic acid, suberic acid, sebacic acid, dodecanedioic acid, 1, 3- and 1,4-cyclohexanedicar Polyamides derived from acid, isophthalic acid, terephthalic acid, dimer acid and other aliphatic, alicyclic or aromatic dicarboxylic acids, or acid derivatives such as their acid halides (eg acid chloride) and their copolymers Polymerized polyamides; and mixed polyamides thereof. In the present invention, among these, polytetramethylene adipamide (nylon 46), polyamide of metaxylylenediamine and adipic acid, polycaproamide (nylon 6), polyundecanamide (nylon 11), polydodecanamide ( Nylon 12), polyhexamethylene adipamide (nylon 66) and copolymer polyamides based on these polyamide raw materials are useful.

  PA is preferably 6 nylon, 6, 6, nylon, 4, 6 nylon, or 12 nylon from the viewpoint of economy.

  The degree of polymerization of PA is not particularly limited, and for example, a polyamide having a relative viscosity (1 g of polymer dissolved in 100 ml of 98% concentrated sulfuric acid and measured at 25 ° C.) in the range of 2.0 to 5.0 is used. .

The polymerization method of PA is not particularly limited, and generally known melt polymerization methods, solution polymerization methods, and a combination thereof can be employed.
As commercial products of PA, 6 nylon (manufactured by Toray Industries, Inc.), MXD6 (manufactured by Mitsubishi Gas Chemical Company), 4,6 nylon (manufactured by DSM Japan Engineering Plastics), Zeitel (manufactured by DuPont) and the like are available.

  (E) The compounding quantity of a component is 0.1-25 weight% with respect to the composition whole quantity, From a viewpoint of the further improvement of a flame retardance, Preferably it is 0.1-12 weight%, More preferably, it is 0.00. 1 to 10% by weight. When the blending amount of the component (E) is too small, the flame retardancy is remarkably lowered and the resin composition continues to burn in the air after being ignited, so that self-extinguishing properties cannot be obtained. Furthermore, the mechanical properties, in particular the bending strength, are reduced. If the amount is too large, mechanical properties, particularly impact strength and bending strength are lowered. Furthermore, self-extinguishing properties cannot be obtained. Each of the phosphate ester compound and PA may be a mixture of two or more substances having different types and / or relative viscosities, and the phosphate ester compound or PA may be used alone or in combination. In that case, those total compounding quantity should just be in the said range.

[(F) component]
As the component (F), an organic decorative clay mineral (hereinafter sometimes referred to as OMCM) is used. The organic decorative clay mineral is a clay mineral decorated with an organic compound. Specifically, the organic decorative clay mineral is a substance obtained by replacing metal ions between layers in a layered clay mineral with an organic compound.

  Examples of layered clay minerals include, for example, montmorillonite, beidellite, hectorite, saponite, stevensite, soconite, nontronite, and other smectite clays, as well as vermiculite, halloysite, swelling mica, and natural and synthetic clays and mixtures thereof. Can be given. A preferred layered clay mineral is a smectite clay, more preferably montmorillonite. In the present invention, such a layered clay mineral is used in which part or all of the metal ions inherently retained between the layers are replaced with an organic compound.

  The organic compound that replaces the metal ions of the layered clay mineral has a low molecular weight that can be introduced between the layers of the layered clay mineral. The low molecular weight is usually a molecular weight of less than 1000, preferably 300 to 1000.

Examples of the organic compound that substitutes the metal ion of the layered clay mineral include organic cations; radical polymerizable monomers such as acrylonitrile, ethylene, and acetylene and polymers thereof; and mixtures thereof. The polymer of the radical polymerizable monomer may be a homopolymer or a copolymer formed by polymerizing two or more monomers selected from the group consisting of the above radical polymerizable monomers as long as it has the low molecular weight described above. It may be a coalescence.
.

  Examples of organic cations that can be used in the present invention include quaternary ammonium salts, phosphonium salts, organic cations constituting sulfonium salts, and mixtures thereof. A preferred organic cation is an organic cation constituting a quaternary ammonium salt.

  Specific examples of the organic cation constituting the quaternary ammonium salt, that is, quaternary ammonium include, for example, benzyltrimethylammonium, benzyltriethylammonium, benzyltributylammonium, benzyldimethyldodecylammonium, benzyldimethyloctadecylammonium, benzalkonium, and the like. Benzyltrialkylammonium ions; alkyltrimethylammonium ions such as trimethyloctylammonium, trimethyldodecylammonium, trimethyloctadecylammonium; dimethyldialkylammonium ions such as dimethyldioctylammonium, dimethyldidodecylammonium, dimethyldioctadecylammonium, dimethyldistearylammonium; Trioctirme Le ammonium, trialkyl methyl ammonium ions such as tridodecylmethylammonium; benzethonium ion having two benzene ring. Preferred quaternary ammoniums are benzyltrialkylammonium ions and dimethyldialkylammonium ions.

  Preferred organic compounds are quaternary ammonium and ethylene and its homopolymer.

  The substitution rate of the organic compound in OMCM is 20 to 100%, preferably 30 to 80%. A substitution rate of less than 20% is not preferred because it tends to be in an aggregated state in the composition.

  The substitution rate can be calculated on the basis of metal ions existing between clay mineral layers. The amount of substituted organic compound is estimated from the amount of carbon measured by LECO's total carbon analyzer. In this specification, an average value measured five times is adopted for the replacement rate in consideration of errors.

  The OMCM used in the present invention can be produced by treating a layered clay mineral with an organic compound. As a detailed manufacturing method of OMCM, for example, JP2003-292793A, JP2005-89261A, JP2005-126301A, JP2005-139030A, JP2009-23874A, The method etc. which are described in Unexamined-Japanese-Patent No. 2009-17396 are mentioned.

  OMCM can also be obtained as a commercial product from Hojun Co., Ltd., for example.

  The blending amount of the component (F) is 2 to 20% by weight based on the total amount of the composition, and preferably 5 to 20% by weight, more preferably 10 to 20% by weight, from the viewpoint of further improving the elastic modulus. . When the blending amount of the component (F) is too small, the desired elastic modulus and self-extinguishing properties cannot be obtained, and the bending strength is lowered. When the blending amount is too large, aggregated particles are generated and the impact strength is deteriorated. Further, the bending strength is reduced. OMCM may be a mixture of two or more kinds of substances having different types of clay mineral and / or organic compound, and in that case, the total blending amount thereof may be within the above range.

  By combining the components (A) to (F) described above into the resin composition, the resin composition and the molded body obtained using the resin composition do not contain a halogen atom-containing flame retardant. Both exhibit excellent flame retardancy, particularly self-extinguishing properties, and mechanical properties such as elastic modulus, bending strength and impact strength are improved. The details of the mechanism that can provide the effect of the present invention are not clear, but are considered to be based on the following mechanism. As is known, the component (A) constituting the substrate has a low crystallization rate, so that the moldability is poor and a molded article having good mechanical properties cannot be obtained. In the present invention, by using the component (A) in combination with the component (D) and the component (F), the component (D) and the component (F) become crystal nuclei, thereby increasing the crystallization speed and improving the moldability. Can be improved. In particular, by using the component (F), not only the moldability is improved, but also an elastic modulus improving effect can be imparted as a filler. However, even if the crystallization speed is increased and the elastic modulus can be further improved, toughness deterioration accompanying an increase in elastic modulus becomes a problem. In the present invention, in order to improve this, it is necessary to further use the rubber component (C) in combination with the addition amount of the present invention. In addition, the component (A) is combustible in the air and burns more easily than the component (B). In this invention, it discovered that a flame retardance improved newly by using (B) component in combination with (D) component and (E) component, and reached | attained this invention. Surprisingly, even if the (B), (D), and (E) components are combined with a relatively large amount of the component (A), the effect of improving flame retardancy is not changed. As a result, the (A), (B), (C), (D), (E), and (F) components are used in combination with predetermined amounts, while exhibiting self-extinguishing properties while being practical. A resin composition having excellent mechanical properties can be obtained.

Examples of preferred combinations of the components (A) to (F) include the combinations shown below.
<1> (A) R-PET- (B) R-PC- (C) EPDM- (D) PNR- (E) MXD6- (F) Organically modified clay;
<2> (A) R-PET- (B) PC- (C) EPDM- (D) PNR- (E) MXD6- (F) organically modified clay;
<3> (A) R-PET- (B) R-PC- (C) EPDM- (D) PPS + PNR- (E) MXD6- (F) Organically modified clay;
<4> (A) R-PET- (B) PC- (C) EPDM- (D) PPS + PNR- (E) MXD6- (F) Organically modified clay;
<5> (A) R-PET- (B) R-PC- (C) EPDM- (D) PNR- (E) Nylon 6- (F) Organically modified clay;
<6> (A) R-PET- (B) PC- (C) EPDM- (D) PNR- (E) Nylon 6- (F) Organically modified clay;
<7> (A) R-PET- (B) R-PC- (C) EPDM- (D) PPS + PNR- (E) Nylon 6- (F) Organically modified clay;
<8> (A) R-PET- (B) PC- (C) EPDM- (D) PPS + PNR- (E) Nylon 6- (F) Organically modified clay.

  In the resin composition of the present invention, other conventional additives such as a crosslinking agent, pigment, dye, reinforcing material (glass fiber, carbon fiber, talc, mica, Clay minerals, potassium titanate fibers, etc.), fillers (titanium oxide, metal powder, wood powder, rice husks, etc.), thermal stabilizers, antioxidants, UV absorbers, lubricants, mold release agents, crystal nucleating agents, plastics An agent, a flame retardant, an antistatic agent, a foaming agent and the like can be blended. Among these, in the resin composition of the present invention, addition of a stabilizer such as a cross-linking agent, a heat stabilizer or an antioxidant is also preferable from the viewpoint of suppressing the transesterification reaction and thermal decomposition of the polyester resin and the polycarbonate resin. It is.

  A crosslinking agent accelerates | stimulates bridge | crosslinking of rubber-like polymer (C), for example, a peroxide is used preferably. Specific examples of the peroxide include, for example, acetylcyclohexylsulfonyl peroxide, isobutyl peroxide, diisopropyl peroxydicarbonate, di-n-propylperoxydicarbonate, di (2-methoxyethyl) peroxydicarbonate, di ( Methoxyisopropyl) peroxydicarbonate, di (2-methylhexyl) peroxydicarbonate, t-butylperoxyneodecanoate, 2,4-dichlorobenzoyl peroxide, t-butylperoxypivalate, 3,5 , 5-trimethylhexanol peroxide, octanol peroxide, decanol peroxide, laurol peroxide, stearol peroxide, propionyl peroxide, acetyl peroxide, t Butylperoxy (2-ethylhexanoate), Benzoxyperoxide, t-butylperoxyisobutyrate, 1,1-bis (t-butylperoxy) 3,3,5-trimethylcyclohexanone, 1,1 -Bis (t-butylperoxy) cyclohexanone, t-butylperoxymaleic acid, oxalic acid oxide, t-butylperoxylaurate, t-butylperoxy3,5,5-trimethylhexanoate, cyclohexanone peroxide T-butylperoxyisopropyl carbonate, 2,5-dimethyl-2,5-di (benzoylperoxy) hexane, t-butylperoxyacetate, 2,2-bis (t-butylperoxy) butane, t -Butyl peroxybenzoate, di-t-butyl diperoxyphthalate n-butyl-4,4-bis (t-butylperoxy) valerate, methyl ethyl ketone peroxide, dicumyl peroxide, 2,5-dimethyl-2,5-di (t-butylperoxy) hexane, t-butyl Cumyl peroxide, t-butyl hydroperoxide, di-isopropylbenzene hydroperoxide, di-t-butyl peroxide, p-menthane hydroperoxide, 2,2-dimethyl-2,5-di (t-butyl peroxide Oxy) hexyne-3, 1,1,3,3-tetramethylbutyl hydroperoxide, 2,5-dimethylhexane-2,5-dihydroxyperoxide, cumene hydroperoxide and the like.

  The amount of the crosslinking agent is preferably 0.01 to 0.1% by weight, more preferably 0.01 to 0.05% by weight, based on the total amount of the resin composition.

As the heat stabilizer, compounds such as phosphorus-based, hindered phenol-based, amine-based, and thioether-based compounds can be used. Of these, thioether compounds are preferred, and examples of thioether compounds include dilauryl thiodipropionate, dimyristyl thiodipropionate, distearyl thiodipropionate, lauryl stearyl thiodipropionate, tetrakis [methylene-3- (Dodecylthio) propionate] methane and the like.
The blending amount of the heat stabilizer is preferably 0.001 to 1% by weight, more preferably 0.01 to 0.5% by weight, based on the total amount of the resin composition.

[Method for Producing Flame Retardant Polyester Resin Composition]
The resin composition according to the present invention can be produced by a so-called melt-kneading method. That is, a polymer mixture containing at least the components (A) to (F) is melted and kneaded and cooled. The cooling material is usually pelletized by pulverization in order to facilitate processing in the next step (for example, a molding step).

The melting / kneading method is not particularly limited, and for example, a known extrusion kneader using a shearing force can be used. Specifically, an extrusion kneader that can be used in preferred embodiments described below can be used.
Melting and kneading conditions are not particularly limited. For example, the screw rotation speed and the processing temperature are within a range that can be used in a preferred embodiment described later.
The cooling method is not particularly limited, and it may be left standing or may be rapidly cooled as will be described later.

(Manufacturing method according to a preferred embodiment)
When the resin composition according to the present invention is produced by the production method according to a preferred embodiment described below, fine dispersion of the rubber-like polymer (C) is achieved. In addition, self-extinguishing properties and mechanical performance such as elastic modulus, bending strength and impact strength, particularly bending strength, are significantly improved.

  A preferred method for producing the resin composition according to the present invention is characterized in that a polymer mixture containing at least the above-described components (A) to (F) is subjected to a gap passing treatment in a molten state.

  The gap passing process is a process of passing the polymer mixture in a molten state through a gap between two parallel surfaces having an inter-surface distance x of 5 mm or less. In the present embodiment, the gap passing process is preferably performed once or more. Is performed twice or more, more preferably three times or more. As a result, sufficiently uniform mixing and dispersion of each component contained in the polymer mixture is achieved. As a result, even without containing a halogen atom-containing flame retardant, even better flame retardancy, particularly self-extinguishing properties, is achieved. In addition, a resin composition having significantly improved mechanical performance such as elastic modulus, bending strength and impact strength can be obtained. Such an effect is also obtained in a molded body obtained using the resin composition. The self-extinguishing property and the mechanical performance are remarkably improved as the number of the gap passing treatments is increased. For example, when the number of times of the gap passing process is increased from 1 to 2, the self-extinguishing property and the mechanical performance are further remarkably improved. When the number of times of the gap passing treatment is increased from 2 times to 3 times, the self-extinguishing property and the mechanical performance are further remarkably improved. The upper limit of the number of times of the gap passing process is usually 1000 times, particularly 100 times. Even if the polymer mixture is passed through a gap having an interplane distance x exceeding 5 mm, the flame retardancy and mechanical performance such as elastic modulus, bending strength and impact strength are not significantly improved. Even if the distance in the moving direction of the polymer mixture in such a gap is increased, flame retardancy and mechanical performance are not significantly improved. It is possible to reduce the number of times the gap passing process is performed after kneading with a single or twin screw kneader. For example, when the gap passing process is continuously performed with a device attached to the discharge port of the twin screw kneader. The number of times can be reduced from 3 to 10 times.

  The details of the mechanism that provides the effect of significantly improving flame retardancy and mechanical performance are not clear, but are considered to be based on the following mechanism. When the molten polymer mixture enters the gap, the pressure applied to the polymer mixture and the moving speed of the polymer mixture vary greatly. At this time, it is considered that a shearing action, an extension action, and a folding action work effectively on the melt. Therefore, when such a change is received by the polymer mixture, as a result, sufficiently uniform mixing and dispersion of each component is effectively achieved, and a remarkable improvement effect of flame retardancy and mechanical performance is obtained. Conceivable.

  When the gap passing process is performed twice or more, the gap passing process may be achieved by passing the gap once in an apparatus having two or more gaps, or an apparatus having only one gap. And may be accomplished by repeating the treatment more than once. From the viewpoint of the efficiency of continuous operation, the gap passing process is preferably achieved by passing the gap once in an apparatus having two or more gaps.

  The distance between two parallel planes x in one or more gaps is independently 5 mm or less, particularly 0.05 to 5 mm, from the viewpoint of more uniform mixing / dispersion, downsizing of the apparatus, and prevention of vent-up. Is preferably 0.5 to 5 mm, more preferably 0.5 to 3 mm.

  The distance y in the movement direction MD of the polymer mixture in one or more gaps may be independently 2 mm or more, and is preferably 3 mm or more, more preferably 5 mm or more, from the viewpoint of further improving the effect of the treatment. Preferably it is 10 mm or more. The upper limit value of the distance y is not particularly limited, but if it is too long, not only is the efficiency low, but it is not economical because it is necessary to increase the pressure for moving the polymer mixture in the movement direction MD. Accordingly, the distance y is preferably 2 to 100 mm independently, more preferably 3 to 50 mm, and still more preferably 5 to 30 mm.

  The distance z in the width direction WD in one or more gaps is not particularly limited, and is, for example, 20 mm or more, and usually 100 to 1000 mm.

The flow rate when the polymer mixture passes through the gap in a molten state may be 1 g / min or more as a value per 1 cm ² of the cross-sectional area of the gap. In this embodiment, the upper limit is not particularly limited, It is not economical because the pressure for moving the polymer mixture in the movement direction MD needs to be increased. Preferably it is 10-5000 g / min, More preferably, it is 10-500 g / min.

In the present specification, the cross-sectional area means an area in a vertical cross section with respect to the movement direction MD.
The flow rate can be measured by dividing the discharge amount (g / min) of the polymer mixture discharged from the discharge port by the cross-sectional area (cm ² ) of the gap.

The viscosity of the polymer mixture during the gap passing treatment is not particularly limited as long as the flow velocity during the gap passing is achieved, and can be controlled by the heating temperature. The viscosity is, for example, 1 to 10000 Pa · s, preferably 10 to 8000 Pa · s.
As the viscosity of the polymer mixture, a value measured by a viscoelasticity measuring apparatus MARS (manufactured by Harker) is used.

  The pressure for moving the polymer mixture in the molten state in the movement direction MD is not particularly limited as long as the flow velocity at the time of passing through the gap is achieved, and is 0.1 MPa or more as the resin pressure indicated by the differential pressure from the atmospheric pressure. Is preferred. The resin pressure is the pressure of the polymer mixture measured 1 mm or more inside from the resin discharge port in the gap, and can be measured by directly measuring with a pressure gauge. The higher the pressure, the more effective, but if the resin pressure is too high, significant shearing heat is generated and the polymer may be decomposed. Therefore, the resin pressure is preferably 500 MPa or less, more preferably 50 MPa or less. This resin pressure is a guideline for producing a polymer composition exhibiting good physical properties, and if the purpose of the present embodiment can be achieved at other than the described resin pressure, there is no limitation to this. Absent.

The temperature of the polymer mixture at the time of the gap passing treatment is not particularly limited as long as the flow velocity at the time of passing the gap is achieved. However, since the polymer is decomposed at a high temperature exceeding 400 ° C., 400 ° C. or less is recommended. The polymer mixture temperature is preferably a temperature equal to or higher than the Tg of the polymer because the resin pressure does not increase significantly. When two or more kinds of polymers are used, Tg is a value calculated from the ratio and each Tg by a weighted average. For example, when the Tg of the polymer A is Tg _A (° C.) and the usage rate is R _A (%), the Tg of the polymer B is Tg _B (° C.), and the usage rate is R _B (%) (R _A + R _B = 100), “(Tg _A × R _A / 100) + (Tg _B × R _B / 100)” is Tg.
The polymer mixture temperature during the gap passing treatment can be controlled by adjusting the heating temperature of the apparatus for performing the treatment.

In this embodiment, the polymer mixture is usually melted and kneaded by an extrusion kneader immediately before the gap passing treatment, and the gap passing treatment is performed a predetermined number of times for the molten polymer mixture extruded after the kneading. The melting / kneading method is not particularly limited, and for example, a known extrusion kneader using a shearing force can be used. Specifically, for example, an extrusion kneader such as a twin-screw extrusion kneader KTX30, KTX46 (manufactured by Kobe Steel) can be used.
Melting / kneading conditions are not particularly limited. For example, the screw rotation speed can be 50 to 1000 rpm, and the melting and kneading temperature can be the same as the temperature of the polymer mixture during the gap passing treatment described above. .

  Hereinafter, the gap passing treatment method will be described in detail with reference to the drawings showing an apparatus for producing a polymer composition that performs the gap passing treatment. Such a polymer composition manufacturing apparatus includes an inflow port for allowing an object to be processed to flow in and an outlet port for discharging the processed object, and an object to be processed between the inflow port and the discharge port. In this flow path, a gap between two parallel surfaces is provided at one or more places.

  For example, an apparatus (die) for producing a polymer composition that performs the gap passage treatment once does not have a gap 2a, and the reservoir 1a and the reservoir 1b have the same height as the maximum height of the reservoirs. Since it is the same as that of the apparatus shown in FIG. 1 mentioned later except communicating by this, description of the said apparatus is abbreviate | omitted.

  For example, FIG. 1 shows an example of an apparatus (die) for producing a polymer composition that performs the gap passage treatment twice. FIG. 1 (A) is a schematic perspective view of a polymer composition manufacturing apparatus that performs the gap passage treatment twice when the inside of the apparatus is seen through from above, and FIG. 1 (B) is a perspective view of FIG. 1 (A). It is a schematic sectional drawing in the PQ cross section of an apparatus. The apparatus of FIG. 1 has a substantially rectangular parallelepiped shape as a whole. In the apparatus of FIG. 1, the inlet 5 is connected to the discharge port of an extrusion kneader (not shown), so that the pushing force of the extrusion kneader is used as a driving force for movement of the polymer mixture, and the molten state It is possible to move the polymer mixture as a whole in the movement direction MD and pass through the gaps 2a and 2b. Thus, since the apparatus of FIG. 1 is used by being connected to the discharge port of the extrusion kneader, it can also be called a die.

Specifically, the apparatus of FIG. 1 includes an inlet 5 for allowing an object to be processed to flow in and an outlet 6 for discharging an object to be processed, and the object between the inlet 5 and the outlet 6 is provided. In the flow path of the processed material, there are two gaps (2a, 2b) consisting of two parallel planes. Usually, further, reservoirs 1a and 1b having a cross-sectional area larger than the cross-sectional area of the gap are provided immediately before the gaps 2a and 2b, respectively. The polymer mixture extruded from the extrusion kneader at the time of processing is in a molten state, and flows into the pool portion 1a from the inlet 5 in the apparatus 10A of FIG. 1 based on the pushing force of the extrusion kneader, and in the width direction WD. spread. Next, the polymer mixture continuously moves in the movement direction MD and the width direction WD through the gap 2a and moves to the pool portion 1b, and then passes through the gap 2b and is discharged from the discharge port 6.
In this specification, the cross-sectional area of the reservoir portion means the maximum cross-sectional area of the reservoir portion in a cross section perpendicular to the movement direction MD.

In FIG. 1, two parallel inter-surface distances x ₁ and x ₂ in the gaps 2 a and 2 b correspond to the distance x, and may be independently within the same range as the distance x.

Distance y ₂ in the moving direction MD at a distance y ₁ and the gap 2b in the moving direction MD in the gap 2a in FIG. 1 corresponds to the distance y, it may be any independently within the same range as the distance y.

Gap 2a in FIG. 1, the distance z ₁ in the width direction WD in 2b corresponds to the distance z, it may be within the same range as the distance z each independently, but it is usually common value.

In FIG. 1, the maximum heights h ₁ and h ₂ at the reservoir portions 1a and 1b are larger than the inter-surface distances x ₁ and x _{2 of} the immediately following gaps 2a and 2b, respectively, and usually 3 to 100 mm independently of each other. , Preferably 3 to 50 mm.

  In the present specification, the maximum height of the reservoir portion means the maximum height in a vertical section with respect to the width direction WD in the case of a rectangular parallelepiped device.

The maximum cross-sectional area of the cross-sectional area _{S 2a} and the maximum cross-sectional area _{S 1a} and the ratio _S 1a _{/ S 2a} and cross-sectional area of the gap 2b _{S 2b} and the immediately preceding reservoir 1b of the immediately preceding reservoir 1a of the gap 2a in FIG. 1 each ratio _S 1b _{/ S 2b} of the S _1b independently least 1.1, in particular at from 1.1 to 1000, more uniform mixing and dispersion, the size of the apparatus, and from the viewpoint of prevention of vent up 2-100 are preferable, More preferably, it is 3-15.

In FIG. 1, the distance m ₁ in the movement direction MD in the pool portion _{1 a} and the distance m ₂ in the movement direction MD in the pool portion ₁ b may be independently 1 mm or more, and 2 mm or more from the viewpoint of the efficiency of continuous operation. Preferably, it is 5 mm or more, more preferably 10 mm or more. The upper limit value of the distances m ₁ and m ₂ is not particularly limited, but if it is too long, not only is the efficiency low, but it is necessary to increase the pushing force of the extrusion kneader connected to the inflow port 5. Not right. Therefore, the distances m ₁ and m ₂ are each preferably preferably 1 to 300 mm, more preferably 2 to 100 mm, and still more preferably 5 to 50 mm.

  For example, FIG. 2 shows an example of a polymer composition production apparatus (die) that performs the gap passage treatment three times. FIG. 2 (A) is a schematic perspective view of the polymer composition manufacturing apparatus that performs the gap passage treatment three times when the inside of the apparatus is seen through from above, and FIG. 2 (B) is a perspective view of FIG. 2 (A). It is a schematic sectional drawing in the PQ cross section of an apparatus. The apparatus of FIG. 2 has a substantially rectangular parallelepiped shape as a whole. The apparatus shown in FIG. 2 uses the pushing force of the extrusion kneader as a driving force for the movement of the polymer mixture by connecting the inlet 5 to the discharge port of the extrusion kneader (not shown). The polymer mixture as a whole can be moved in the movement direction MD and can pass through the gaps 2a, 2b and 2c. Thus, since the apparatus of FIG. 2 is also used by being connected to the discharge port of the extrusion kneader, it can be called a die.

  Specifically, the apparatus of FIG. 2 includes an inflow port 5 for inflowing an object to be processed and an outlet port 6 for discharging the processed object, and an object between the inflow port 5 and the discharge port 6 is provided. In the flow path of the processed material, there are three gaps (2a, 2b, 2c) consisting of two parallel planes. Usually, in addition, immediately before each of the gaps 2a, 2b, and 2c, there are reservoir portions 1a, 1b, and 1c having a cross-sectional area larger than that of the gap immediately after. The polymer mixture extruded from the extrusion kneader at the time of processing is in a molten state, and flows into the reservoir 1a from the inlet 5 in the apparatus 10B of FIG. 2 based on the pushing force of the extrusion kneader, and in the width direction WD. spread. Next, the polymer mixture continuously moves in the movement direction MD and the width direction WD through the gap 2a and moves to the pool portion 1b, then further passes through the gap 2b and moves to the pool portion 1c. It passes through 2c and is discharged from the discharge port 6.

In FIG. 2, two parallel inter-surface distances x ₁ , x ₂ , x ₃ in the gaps 2 a, 2 b, 2 c correspond to the distance x and may be independently within the same range as the distance x.

Distance _{y 1} in the moving direction MD in the gap 2a, the distance _{y 3} in the moving direction MD at a distance _{y 2} and the gap 2c in the moving direction MD in the gap 2b corresponds to the distance y in FIG. 2, the distance y independently As long as it is within the same range.

Gap 2a in FIG. 2, 2b, the distance z ₁ in the width direction WD in 2c corresponds to the distance z, it may be within the same range as the distance z each independently, but it is usually common value.

In FIG. 2, the maximum heights h ₁ , h ₂ , and h _{3 at the} reservoir portions 1a, 1b, and 1c are larger than the inter-surface distances x ₁ , x ₂ , and x _{3 of} the immediately following gaps 2a, 2b, and 2c, respectively. Usually, they are independently in the same range as the maximum heights h ₁ and h ₂ in FIG.

The maximum cross-sectional area of the cross-sectional area _{S 2a} and the maximum cross-sectional area _{S 1a} and the ratio _S 1a _{/ S 2a,} the cross-sectional area of the gap 2b _{S 2b} and the immediately preceding reservoir 1b of the immediately preceding reservoir 1a of the gap 2a in FIG. 2 the ratio _S 1c _{/ S 2c} of the cross-sectional area _{S 2c} of the ratio _S 1b _{/ S 2b} and gaps 2c and S _1b and the maximum cross-sectional area _{S 1c} of the preceding reservoir 1c are independently ratio in FIG. 1 S It is in the same range as _1a / _S2a and ratio _S1b / _S2b .

In FIG. 2, the distance m ₁ in the movement direction MD in the pool portion 1a, the distance m ₂ in the movement direction MD in the pool portion 1b, and the distance m ₃ in the movement direction MD in the pool portion 1c are independent from each other, the distance m ₁ in FIG. And within the same range as the distance m ₂ .

  In this specification, “parallel” is used in a concept including not only a parallel relationship achieved between two planes but also a parallel relationship achieved between two curved surfaces. That is, in FIGS. 1 and 2, the gaps 2a, 2b, and 2c are formed of two parallel planes, but are not limited thereto. For example, the gap 2a shown in FIG. 3 and the gap 2a shown in FIG. It may consist of two parallel curved surfaces, such as 2b and 2c. “Parallel” means that the distance between the two surfaces is constant, and it does not need to be strictly “constant” in consideration of the accuracy in manufacturing the device. In other words, it may be “constant”. Therefore, “parallel” may be “substantially parallel” as long as the object of the present embodiment is achieved. In the substantially rectangular parallelepiped device, the shape and position of the gap in the cross section perpendicular to the width direction WD are not changed in the width direction. In the substantially cylindrical device, the shape and position of the gap in the cross section passing through the axis are not changed in the circumferential direction with the axis of the device as the central axis.

  FIG. 3 shows an example of a polymer composition production apparatus (die) that performs the gap passage treatment twice. FIG. 3 (A) is a schematic perspective view of the polymer composition production apparatus that performs the gap passage treatment twice when the inside of the apparatus is seen through from above, and FIG. 3 (B) is a perspective view of FIG. 3 (A). It is a schematic sectional drawing in the PQ cross section of an apparatus. The apparatus shown in FIG. 3 has a substantially rectangular parallelepiped shape as a whole. In the apparatus of FIG. 3, the inlet 5 is connected to the discharge port of an extrusion kneader (not shown) so that the pushing force of the extrusion kneader is used as a driving force for moving the polymer mixture, and the molten state It is possible to move the polymer mixture as a whole in the movement direction MD and pass through the gaps 2a and 2b. Thus, since the apparatus of FIG. 3 is also used by being connected to the discharge port of the extrusion kneader, it can be called a die.

  The apparatus of FIG. 3 is the same as the apparatus of FIG. 1 except that the gap 2a is composed of two parallel curved surfaces, and thus detailed description of the apparatus of FIG. 3 is omitted.

  FIG. 4 shows an example of an apparatus (die) for producing a polymer composition that performs the gap passage treatment three times. FIG. 4 (A) is a schematic sketch of a polymer composition production apparatus that performs the gap passage treatment three times, and FIG. 4 (B) is a PQ cross section passing through the axis of the apparatus of FIG. 4 (A). It is a schematic sectional drawing. The apparatus of FIG. 4 has a substantially cylindrical shape as a whole, and enables downsizing of the apparatus. The apparatus shown in FIG. 4 uses the pushing force of the extrusion kneader as a driving force for moving the polymer mixture by connecting the inlet 5 to the discharge port of an extrusion kneader (not shown), so that the molten state The polymer mixture as a whole can be moved in the movement direction MD and can pass through the gaps 2a, 2b and 2c. Thus, since the apparatus of FIG. 4 is also used by being connected to the discharge port of the extrusion kneader, it can be called a die.

  Specifically, the apparatus of FIG. 4 includes an inflow port 5 for allowing an object to be processed to flow in and an outlet port 6 for discharging a processed object, and the object between the inflow port 5 and the discharge port 6 is provided. In the flow path of the processed material, there are three gaps (2a, 2b, 2c) composed of two parallel curved surfaces. Usually, in addition, immediately before each of the gaps 2a, 2b, and 2c, there are reservoir portions 1a, 1b, and 1c having a cross-sectional area larger than that of the gap immediately after. The polymer mixture extruded from the extrusion kneader at the time of processing is in a molten state and flows into the reservoir 1a from the inlet 5 in the apparatus 10D of FIG. 4 based on the pushing force of the extrusion kneader and spreads in the radial direction. . Next, the polymer mixture continuously moves in the movement direction MD and the circumferential direction PD through the gap 2a and moves to the pool portion 1b, and further passes through the gap 2b and moves to the pool portion 1c. It passes through 2c and is discharged from the discharge port 6.

In FIG. 4, two parallel inter-surface distances x ₁ , x ₂ , x ₃ in the gaps 2 a, 2 b, 2 c correspond to the distance x and may be independently within the same range as the distance x.

Distance _{y 1} in the moving direction MD in the gap 2a, the distance _{y 3} in the moving direction MD at a distance _{y 2} and the gap 2c in the moving direction MD in the gap 2b corresponds to the distance y in Figure 4, the independently distance y As long as it is within the same range.

Maximum height _{h 1} of the reservoir 1a in Fig. 4 is not particularly limited, usually 1 to 100 mm, preferably 1 to 50 mm.
In FIG. 4, the maximum heights h ₂ and h ₃ at the reservoir portions 1b and 1c are values larger than the inter-surface distances x ₂ and x _{3 of} the immediately following gaps 2b and 2c, respectively. Is within the same range as the maximum heights h ₁ and h ₂ .
In the present specification, the maximum height of the reservoir portion means the maximum height in the diameter direction in a cross section passing through the axis of the device in the case of a substantially cylindrical device.

In FIG. 4, the ratio S _1a / S _2a between the cross-sectional area S _2a of the gap 2a and the maximum cross-sectional area S _1a of the reservoir 1a just before is 1.2 or more, particularly 1.2 to 10, and more uniform mixing -1.2-7 are preferable from a viewpoint of dispersion | distribution, size reduction of an apparatus, and prevention of vent up, More preferably, it is 1.2-5.

Figure 4 in sectional area _{S 2b} of the gap 2b and the cross-sectional area _{S 2c} of the ratio _S 1b _{/ S 2b} and gaps 2c and the maximum cross-sectional area _{S 1b} of the immediately preceding reservoir 1b maximum cross-sectional area of the reservoir 1c immediately before each ratio _S 1c _{/ S 2c} of the S _1c independently within the same range as the ratio _S 1a _{/ S 2a} and ratio _S 1b _{/ S 2b} in Figure 1.

In FIG. 4, the distance m ₁ in the movement direction MD in the pool portion 1a, the distance m ₂ in the movement direction MD in the pool portion 1b, and the distance m ₃ in the movement direction MD in the pool portion 1c are independent from each other, the distance m ₁ in FIG. And within the same range as the distance m ₂ .

  The apparatus shown in FIGS. 1-4 is normally manufactured from the material used for manufacture of the die conventionally attached to a discharge outlet in the field | area of a resin kneading apparatus and an extrusion apparatus.

  After the gap passing treatment, the polymer mixture subjected to the gap passing treatment is rapidly cooled. A sufficiently uniform mixing / dispersing form of various components achieved by the gap passing treatment is effectively maintained by rapid cooling.

  The rapid cooling can be achieved by immersing the molten polymer composition obtained by the gap passing treatment in water at 0 to 60 ° C. as it is. Quenching may be achieved by cooling with a gas at -40 ° C to 60 ° C or by contacting with a metal at -40 ° C to 60 ° C. The rapid cooling is not necessarily performed. For example, even if the cooling is allowed to stand, a sufficiently uniform mixed / dispersed form of various components can be maintained.

  The cooled polymer composition is usually pelletized by pulverization to facilitate processing in the next step.

  In the present embodiment, all components constituting the polymer mixture may be mixed in advance before the melting / kneading process performed immediately before the polymer mixture is subjected to the gap passing process. For example, after all the components are mixed in advance, a melting / kneading process immediately before the gap passing process is performed, and then the gap passing process is performed a predetermined number of times. After such mixing treatment, immediately before the melting and kneading treatment, it is preferable to sufficiently dry the polymer mixture from the viewpoint of suppressing the hydrolysis reaction of the polyester resin and the transesterification reaction of the polyester resin and the polycarbonate resin. .

  As a mixing method, a dry blend method in which predetermined components are simply mixed in a dry manner may be employed, or a melt kneading method in which predetermined components are melt kneaded, cooled and pulverized by a conventional melt kneading method is employed. Also good. When adopting the melt-kneading method, the same extrusion kneader as described above can be used. At this time, the extrusion kneader may be used with a conventionally known die attached to the discharge port.

  In the resin composition produced by the above-described gap passing treatment, the rubbery polymer (C) is dispersed with an average particle size of 1 nm to 20 μm, and a preferable dispersed particle size is 1 nm to 15 μm from the viewpoint of impact strength and elastic modulus. More preferably, it is 10 nm-10 micrometers, More preferably, it is 100 nm-5 micrometers, Most preferably, it is 400 nm-2.5 micrometers. Such a dispersed particle size is maintained even in a molded body obtained using the resin composition.

  In the resin composition produced without performing the above-described gap passing treatment, that is, the resin composition of the present invention produced by a simple melt-kneading method, the rubber-like polymer (C) usually has an average particle size of 0.1. Dispersed at ˜5 μm. Even the resin composition in which the rubber-like polymer (C) is dispersed with such an average particle diameter can obtain the effects of the present invention as long as the components (A) to (F) are contained. it can.

  In the resin composition of the present invention, the rubbery polymer (C) exists as an island with respect to the sea containing at least the component (A). The component (B) is also present as an island with respect to the sea containing at least the component (A), and the component (D) is preferably compatible with the phase (A) or the phase (B), more preferably (B ) To form islands with the component. The component (E) is compatible with the component (A) to form the sea. Although the component (F) exists as an island with respect to the sea containing at least the component (A), it is finely dispersed. Specifically, the rubber-like polymer (C) may exist as an island so as to have an interface directly to the sea containing the component (A) and the component (E), or the component (A) and the component (E) ) It may exist as an island so as to indirectly have an interface with the sea containing the component, or may exist as an island in a complex form thereof. When the rubber-like polymer (C) exists as an island so as to have an interface directly to the sea containing the component (A) and the component (E), the island of the component (B) and the component (D) is The rubbery polymer (C) is present separately from the island. For example, as shown in FIG. 5, the rubbery polymer (C) exists as an island so as to indirectly have an interface with the sea containing the components (A) and (E). There is an island containing the component (B) and the component (D) with respect to the sea containing the component and the component (E), and in the island containing the component (B) and the component (D), a rubbery polymer ( This means that C) exists as an island. The rubbery polymer (C) becomes an island floating directly in the sea containing the components (A) and (E), or an island floating directly in the sea containing the components (B) and (D). This is due to the composition ratio of each component and the process conditions. The component (F) is finely dispersed independently of other components in the sea containing at least the component (A).

  The dispersed particle diameter of the rubber-like polymer (C) can be measured by the following method. A resin composition (pellet) or a molded product obtained by using the resin composition is cut by a thin piece cutting machine for an electron microscope, and the rubbery polymer (C) is dyed with osmium tetroxide or the like in the cross section. The cross section is observed with a scanning electron microscope at a magnification of 2000 to 10,000. The maximum length of the dyed rubber-like polymer (C) particles is measured for any 100 particles, and the average value is obtained.

[Use of flame retardant polyester resin composition]
Since the resin composition of the present invention produced by the above method is usually cooled and pulverized to have a pellet form, the pellet is formed by an injection molding method, an extrusion molding method, a compression molding method, or a blow molding method. By applying to various known molding methods such as an injection compression molding method, it is possible to produce a molded body having an arbitrary shape. From the viewpoint of suppressing the hydrolysis reaction of the polyester resin and the transesterification reaction of the polyester resin and the polycarbonate resin, it is preferable that the resin composition is sufficiently dried before molding.

  Alternatively, a molded product having an arbitrary shape can be obtained by continuously applying the resin composition of the present invention in a molten state, which has been subjected to a gap passing treatment, to the various known molding methods described above without being cooled and pulverized. The body can also be manufactured.

  The flame-retardant polyester resin composition of the present invention is a molding material or a constituent material for applications in which excellent flame retardancy, particularly self-extinguishing properties, and excellent mechanical properties such as elastic modulus, bending strength and impact strength are utilized. Useful. Examples of such applications include containers, packaging films, household goods, office equipment, AV equipment, electric / electronic parts, automobile parts, and the like.

  EXAMPLES Hereinafter, although this invention is demonstrated using an Example and a comparative example, it cannot be overemphasized that the scope of this invention is not limited by the following examples, unless the summary is exceeded.

First, raw materials and a kneading apparatus used in the following examples and comparative examples will be described.
(A) component; polyester resin R-PET1 (recovered polyethylene terephthalate);
A flaked pulverized product (cleaned product) having a size of 2 to 8 mm of a used waste PET bottle having an intrinsic viscosity of 0.68 dl / g. The end point temperature (melting point) of the crystal melting peak by DSC method (using DSC 7000 manufactured by Seiko Instruments Inc.) at a temperature rising rate of 20 ° C./min of this PET flake was 263 ° C. Moreover, the glass transition temperature by the DSC method was 69 degreeC.
PET1;
Polyethylene terephthalate resin pellets having an intrinsic viscosity of 0.78 dl / g. The melting point by the same DSC method was 267 ° C., and the glass transition temperature was 73 ° C.
PET2;
Polyethylene terephthalate resin pellets having an intrinsic viscosity of 0.90 dl / g. The melting point by the same DSC method was 272 ° C., and the glass transition temperature was 76 ° C.
PEN1;
Polyethylene naphthalate resin pellets having an intrinsic viscosity of 1.1 dl / g. The melting point by the same DSC method was 269 ° C., and the glass transition temperature was 113 ° C.

(B) component; polycarbonate resin R-PC1 (recovered polycarbonate);
A reflective layer, a recording layer, etc. are peeled off from a compact disc, and then crushed into flakes of 1 to 5 mm in size (PC of the substrate is Iupilon H4000 manufactured by Mitsubishi Engineering Plastics Co., Ltd., molecular weight of about 15,000). The glass transition temperature by the same DSC method was 148 ° C.
PC1;
Toughlon A2500 (manufactured by Idemitsu Petrochemical Co., Ltd., molecular weight of about 23,500). The glass transition temperature by DSC method as described above was 168 ° C.

(C) component; rubbery polymer EPDM1;
Ethylene-propylene-diene copolymer rubber (EPDM, manufactured by Dow Co., Ltd., Nordel IP). Diene content 17% by weight. Number average molecular weight 10 ⁵ . Tg was -37 ° C.
SBR1;
Butadiene-styrene copolymer rubber (JSR dry SBR; manufactured by JSR). Diene content 26% by weight. Number average molecular weight 5 × 10 ⁵ . Tg was -35.
BR1;
Polybutadiene rubber (BR01; manufactured by JSR). Diene content 48% by weight. Number average molecular weight 6 × 10 ⁵ . Tg was -34.
PUR1;
Urethane rubber (Elastolan 1154D; manufactured by BASF Japan). Number average molecular weight 10 ⁵ . Hardness (JIS A: 54). Tg was −20 ° C.
SIR1;
Silicone rubber (silastic HCR; manufactured by Toray Dow Corning). Number average molecular weight 35,000. Tg was -42 ° C.

(D) component;
PPS1;
Polyphenylene sulfide (Torelina; manufactured by Toray Industries, Inc., Tm 283 ° C.).
PNR1;
Phenolic resin (Sumitomo Bakelite, PR-12687, novolac type phenolic resin, melting point 78 ° C., powder).

(E) component;
TPP: triphenyl phosphate.
P1: Tris (nonylphenyl) phosphite.
P2: Bisphenol A bis-diphenyl phosphate.
NY1: 6 nylon. Amilan CM1021FS (manufactured by Toray Industries, Inc.). Melting point 225 ° C., melt viscosity 1200 Pa / s (230 ° C.).
NY2: MXD-6 (Mitsubishi Chemical).

(F) component;
FA: Montmorillonite combined with dimethyl distearyl ammonium (manufactured by Hojun Co., Ltd., substitution rate 33%.
FI; montmorillonite combined with benzyltrimethylammonium (manufactured by Hojun Co., Ltd., substitution rate 55%.
FU: Montmorillonite combined with low molecular weight polyethylene (Hojun Co., Ltd., substitution rate 78%.

Kneading equipment;
The kneading apparatus used was a twin screw extruder KTX30 with a vacuum vent manufactured by Kobe Steel. The cylinder part of this device consists of 9 blocks C1 to C9 for each temperature control block. The raw material supply port is located in C1, the rotor and kneader combination is located in C3 and C7, and the vent is located in C8. did. In addition, a predetermined die was attached to the discharge port. In any case of using any die, the kneading apparatus was used under the following conditions.
Cylinder set temperature: C1-C2 / C3-C9 / die = 120/220/260 ° C.
Screw rotation speed: 250 rpm.

Die A1; die shown in FIG. 2 having gaps at three locations.
Reservoir 1a; maximum height h ₁ = 10 mm, maximum cross-sectional area S _1a = 10 cm ² , moving direction distance m ₁ = 20 mm;
Gap 2a; inter-surface distance x ₁ = 1 mm, cross-sectional area S _2a = 6 cm ² , movement direction distance y ₁ = 30 mm, width direction distance z ₁ = 300 mm;
Reservoir 1b; maximum height h ₂ = 10 mm, maximum cross-sectional area S _1b = 30 cm ² , moving direction distance m ₂ = 20 mm;
Gap 2b; inter-surface distance x ₂ = 1 mm, cross-sectional area S _2b = 6 cm ² , movement direction distance y ₂ = 30 mm, width direction distance z ₁ = 300 mm;
Reservoir 1c; maximum height h ₃ = 10 mm, maximum cross-sectional area S _1c = 30 cm ² , moving direction distance m ₃ = 20 mm;
Gap 2c; inter-surface distance x ₃ = 1 mm, cross-sectional area S _2c = 6 cm ² , moving direction distance y ₃ = 30 mm.

Die A2: the die shown in FIG. 2 having gaps at three locations.
Reservoir 1a; maximum height h ₁ = 10 mm, maximum cross-sectional area S _1a = 10 cm ² , moving direction distance m ₁ = 20 mm;
Gap 2a; inter-surface distance x ₁ = 2 mm, cross-sectional area S _2a = 12 cm ² , moving direction distance y ₁ = 30 mm, width direction distance z ₁ = 300 mm;
Reservoir 1b; maximum height h ₂ = 10 mm, maximum cross-sectional area S _1b = 30 cm ² , moving direction distance m ₂ = 20 mm;
Gap 2b; inter-surface distance x ₂ = 2 mm, cross-sectional area S _2b = 12 cm ² , movement direction distance y ₂ = 30 mm, width direction distance z ₁ = 300 mm;
Reservoir 1c; maximum height h ₃ = 10 mm, maximum cross-sectional area S _1c = 30 cm ² , moving direction distance m ₃ = 20 mm;
Gap 2c; inter-surface distance x ₃ = 2 mm, cross-sectional area S _2c = 12 cm ² , moving direction distance y ₃ = 30 mm.

Die B1: the die shown in FIG. 1 having two gaps.
Reservoir 1a; maximum height h ₁ = 10 mm, maximum cross-sectional area S _1a = 30 cm ² , moving direction distance m ₁ = 50 mm;
Gap 2a; inter-surface distance x ₁ = 1 mm, cross-sectional area S _2a = 6 cm ² , movement direction distance y ₁ = 10 mm, width direction distance z ₁ = 300 mm;
Reservoir 1b; maximum height h ₂ = 10 mm, maximum cross-sectional area S _1b = 30 cm ² , moving direction distance m ₂ = 50 mm;
Gap 2b; inter-surface distance x ₂ = 1 mm, cross-sectional area S _2b = 6 cm ² , movement direction distance y ₂ = 10 mm, width direction distance z ₁ = 300 mm.

Die B2: the die shown in FIG. 1 having gaps at two locations.
Reservoir 1a; maximum height h ₁ = 10 mm, maximum cross-sectional area S _1a = 30 cm ² , moving direction distance m ₁ = 50 mm;
Gap 2a; inter-surface distance x ₁ = 3 mm, cross-sectional area S _2a = 18 cm ² , movement direction distance y ₁ = 10 mm, width direction distance z ₁ = 300 mm;
Reservoir 1b; maximum height h ₂ = 10 mm, maximum cross-sectional area S _1b = 30 cm ² , moving direction distance m ₂ = 50 mm;
Gap 2b; inter-surface distance x ₂ = 3 mm, cross-sectional area S _2b = 18 cm ² , movement direction distance y ₂ = 10 mm, width direction distance z ₁ = 300 mm.

  Die C1; a die having a gap (inter-surface distance = 1 mm) at one location. The die does not have a gap 2a and is shown in FIG. 1 except that the reservoir 1a and the reservoir 1b communicate with each other through a communication path having a height of 10 mm and a distance in the width direction of 300 mm instead of the gap 2a. Same as die.

  Die C2: A die having a gap (inter-surface distance = 3 mm) at one location. The die does not have a gap 2a and is shown in FIG. 1 except that the reservoir 1a and the reservoir 1b communicate with each other through a communication path having a height of 10 mm and a distance in the width direction of 300 mm instead of the gap 2a. Same as die.

Die D1: Die having a gap (inter-surface distance = 8 mm) at one location. The die does not have a gap 2a, and the reservoir portion 1a and the reservoir portion 1b communicate with each other through a communication path having a height of 10 mm and a width direction distance of 300 mm instead of the gap 2a, and the surface of the gap 2b. except during distance _{x 2} is 8 mm, the cross-sectional area _{S 2b} is 24cm ^2, is similar to the die shown in FIG.

<Example / comparative example>
The components shown in Table 1 or Table 2 were dry blended at a predetermined weight fraction using a V-type mixer, and the mixture was dried at 100 ° C. under reduced pressure for 4 hours using a vacuum dryer. The dried mixture was charged from the raw material supply port of the biaxial kneader and melt-kneaded under the conditions of a discharge rate of 30 kg / hour and a resin pressure of 4 MPa. Specifically, the resin composition discharged from the biaxial kneader was in a molten state, and after flowing into a predetermined die from the inlet, passed through a predetermined gap and discharged from the outlet. The kneaded material discharged from the die was quenched by immersing it in water at 30 ° C., and pulverized into pellets by a pelletizer to obtain a resin composition.

<Evaluation>
(1) Mechanical properties of the resin composition After drying the pellet-shaped resin composition at 100 ° C for 4 hours, using an injection molding machine (manufactured by Nippon Steel Works, J55ELII), a cylinder set temperature of 280 ° C, gold A strip-shaped test piece of 100 mm × 10 mm × 4 mm was molded at a mold temperature of 40 ° C. About the test piece, the Charpy impact test (U notch, R = 1 mm) was performed based on JIS-K7111, and the bending test was performed based on JIS-K7171. The elastic modulus was obtained from the result of the initial strain in the bending test. Ranking was made according to the following criteria.

-Elastic modulus ◎◎; 3.0 GPa or more;
A: 2.7 GPa or more and less than 3.0 GPa;
○: 2.1 GPa or more and less than 2.7 GPa;
Δ: 2.0 GPa or more and less than 2.1 GPa (no problem in practical use);
X: Less than 2.0 GPa (practical problem).

・ Bending strength ◎◎; 82 MPa or more;
A: 70 MPa or more and less than 82 MPa;
○: 66 MPa or more and less than 70 MPa;
Δ: 50 MPa or more and less than 66 MPa (no problem in practical use);
X: Less than 50 MPa; (practical problem).

Charpy impact strength ◎◎; 62 kj / m ² or more;
A: 42 kj / m ² or more and less than 62 kj / m ² ;
○: 32 kj / m ² or more and less than 42 kj / m ² ;
Δ: 6 kj / m ² or more and less than 32 kj / m ² (no problem in practical use);
X: Less than 6 kj / m ² (practical problem).

(2) Flame retardance test A kneading apparatus similar to the kneading apparatus was used except that the die was changed to a strand die. Specifically, after drying the pellet-shaped resin composition at 100 ° C. for 4 hours, the pellet-shaped resin composition was extruded into a strand shape using the kneader and cooled. The strand was cut to a length of 10 cm, and the sample was tilted at 45 degrees to fix a portion having a length of 1 cm from the end, and ignited with a lighter. Ranking was made according to the following criteria.
A: Self-extinguishing at a combustion distance of less than 0.3 cm, and the combustion part was less than 0.3 cm;
○: Self-extinguishing was performed at a combustion distance of less than 2 cm, and the combustion part was 0.3 cm or more and less than 2 cm;
Δ: self-extinguishing at a combustion distance of less than 5 cm, combustion portion was 2 cm or more and less than 5 cm (no problem in practical use);
X: Self-extinguishing was not performed at a combustion distance of less than 5 cm, and the combustion part was 5 cm or more (problematically problematic).

(3) Dispersed particle size of component (C) The dispersed particle size of component (C) was measured by the method described above using the test piece used in the method for evaluating the mechanical properties of the resin composition. The SEM photograph of the test piece using the resin composition of Example 2 is shown in FIG.

<Reference Examples 1-4>
A resin composition was obtained in the same manner as in Example 1 except that the components shown in Table 2 were used, a die was not used, and kneading was performed at the following temperature.
Cylinder set temperature: C1-C2 / C3-C9 = 160/220 ° C.
Screw rotation speed: 250 rpm.
Evaluation was performed in the same manner as in the above examples. The results are shown in Table 4.

1a: 1b: 1c: pool part,
2a: 2b: 2c: gap,
5: Inlet,
6: Discharge port,
10A: 10B: 10C: 10D: apparatus for producing a resin composition.

Claims (6)

(A) 40-80% by weight polyester resin;
(B) 5-40% by weight of polycarbonate resin;
(C) 5-30% by weight of a rubbery polymer;
(D) 1-20% by weight of polyphenylene sulfide resin and / or phenol resin;
(E) Phosphate ester compound and / or polyamide resin 0.1 to 25% by weight; and (F) Organic decorative clay mineral 2 to 20% by weight
Containing a flame retardant polyester resin composition.   The flame-retardant polyester resin composition according to claim 1, wherein the polyester resin is polyethylene terephthalate and / or polyethylene naphthalate.   The flame-retardant polyester resin composition according to claim 1, wherein the polyester resin is a discarded polyethylene terephthalate resin.   The flame-retardant polyester resin composition according to claim 1, wherein the polycarbonate resin is a discarded polycarbonate resin.   The flame-retardant polyester resin composition according to any one of claims 1 to 4, wherein the rubber-like polymer is dispersed with an average particle diameter of 1 nm to 20 µm.   6. The difficulty according to claim 5, wherein the polymer mixture containing the components (A) to (F) is passed through a gap between two parallel surfaces having an inter-surface distance x of 5 mm or less in a molten state. A flammable polyester resin composition.