JP2012007088A - Polyorganosiloxane-based resin modifier, process for producing the same, thermoplastic resin composition and molded product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a resin modifier containing a polyorganosiloxane-based rubber having an effect of improving impact resistance, flame retardance, and flowability by being incorporated into a thermoplastic resin and a process for producing the same.SOLUTION: The process for producing a resin modifier comprises mixing a latex of a graft copolymer (C) obtained by polymerizing 7-40 mass% vinyl monomer (B) having a polyfunctional vinyl monomer (b1) as the main component in the presence of 60-93 mass% polyorganosiloxane-based rubber (A) and a latex of a vinyl polymer (S) obtained by polymerizing a vinyl monomer (s) in an amount of 55-90 mass% graft copolymer (C) and 10-45 mass% vinyl polymer (S) and thereafter powderizing the resulting mixture.

Description

  The present invention relates to a resin modifier containing a polyorganosiloxane rubber and a method for producing the same, a thermoplastic resin composition in which the resin modifier is blended with a thermoplastic resin, and a molding of the thermoplastic resin composition. The present invention relates to a molded article to be obtained.

In various fields including the home appliance field, the electric / electronic device field, and OA devices such as printers, molded articles using thermoplastic resins are widely used. The molded body is required to have excellent impact resistance, flame retardancy, weather resistance, and the like, and the resin composition used for molding is required to have excellent fluidity. In particular, in recent years, the thickness and weight of molded products have been reduced for the purpose of cost reduction. Therefore, it is necessary to obtain sufficient impact resistance, flame retardancy, and fluidity even if the weight and thickness are reduced.
As a method for improving functions such as impact resistance and flame retardancy of a molded body using a thermoplastic resin, the following methods are shown.
For example, a method of blending a composite rubber graft copolymer obtained by graft polymerization of a vinyl monomer into a composite rubber composed of a polyorganosiloxane rubber and a polyalkyl (meth) acrylate rubber is disclosed (Patent Document 1). Yes.
In addition, a method of blending a graft copolymer obtained by graft-polymerizing a vinyl monomer mainly composed of a polyfunctional vinyl monomer with a low-crosslinking polyorganosiloxane rubber (Patent Document 2) is shown. Has been.
However, the methods disclosed in Patent Documents 1 and 2 are not sufficient in improving the flame retardancy, and the fluidity is not sufficient.

JP 2000-17029 A Japanese Patent Laid-Open No. 2003-238639

  The present invention relates to a resin modifier containing polyorganosiloxane rubber, which has an effect of improving impact resistance, flame retardancy, and fluidity by being blended with a thermoplastic resin, a method for producing the same, and the resin modification It aims at providing the thermoplastic resin composition which mix | blended the agent, and the molded object obtained by shape | molding this thermoplastic resin composition.

The present invention employs the following configuration in order to solve the above problems.
[1] Polymerize 7 to 40% by mass of vinyl monomer (B) mainly composed of polyfunctional vinyl monomer (b1) in the presence of 60 to 93% by mass of polyorganosiloxane rubber (A). The graft copolymer (C) latex obtained by polymerizing the latex of the graft copolymer (C) and the vinyl polymer (S) obtained by polymerizing the vinyl monomer (s). A method for producing a resin modifier, which is mixed in a proportion of 10% by mass and 10 to 45% by mass of a vinyl polymer (S) and then pulverized.
[2] A thermoplastic resin composition obtained by blending 1 to 20 parts by mass of the resin modifier according to [1] with respect to 100 parts by mass of the thermoplastic resin.
[3] A molded product obtained by molding the thermoplastic resin composition according to [2].

The resin modifier obtained by the production method of the present invention can be blended with a thermoplastic resin to make a thermoplastic resin composition excellent in impact resistance, flame retardancy and fluidity.
The thermoplastic resin composition of the present invention is excellent in impact resistance, flame retardancy and fluidity.
Moreover, the molded object of this invention is excellent in impact resistance, and has sufficient flame retardance.

  The resin modifier of the present invention is obtained by polymerizing the vinyl monomer (B) mainly composed of the polyfunctional vinyl monomer (b1) in the presence of the polyorganosiloxane rubber (A). The latex of the graft copolymer (C) and the latex of the vinyl polymer (S) are mixed at a specific ratio and then powdered.

The polyorganosiloxane rubber (A) used in the present invention is preferably a polyorganosiloxane rubber having a vinyl polymerizable functional group.
The polyorganosiloxane rubber (A) is obtained by polymerizing the following components (a1) to (a3).
Component (a1): Dimethylsiloxane Component (a2): Siloxane having a vinyl polymerizable functional group Component (a3): Siloxane-based crosslinking agent

As a component (a1), the dimethylsiloxane type | system | group cyclic body of 3 or more member ring is mentioned, for example, The thing of 3-7 membered ring is preferable. Specific examples include hexamethylcyclotrisiloxane, octamethylcyclotetrasiloxane, decamethylcyclopentasiloxane, and dodecamethylcyclohexasiloxane. Especially, it is preferable to use octamethylcyclotetrasiloxane as a main component from the point that control of particle diameter distribution is easy.
A component (a1) can be used individually by 1 type or in combination of 2 or more types.

Component (a2) is a siloxane compound having a vinyl polymerizable functional group and capable of binding to component (a1) via a siloxane bond. The component (a2) is a component for introducing a vinyl polymerizable functional group into the side chain or terminal of the polyorganosiloxane, and this vinyl polymerizable functional group is formed from the vinyl monomer (B) described later. It acts as a graft active site when chemically bonding to the vinyl (co) polymer.
Examples of the component (a2) include β-methacryloyloxyethyldimethoxymethylsilane, γ-methacryloyloxypropyldimethoxymethylsilane, γ-methacryloyloxypropylmethoxydimethylsilane, γ-methacryloyloxypropyltrimethoxysilane, and γ-methacryloyloxypropyl. Methacryloyloxysilane such as ethoxydiethylsilane, γ-methacryloyloxypropyldiethoxymethylsilane and δ-methacryloyloxybutyldiethoxymethylsilane; vinylsiloxane such as tetramethyltetravinylcyclotetrasiloxane; p-vinylphenyldimethoxymethylsilane Vinylphenylsilane; γ-mercaptopropyldimethoxymethylsilane, γ-mercaptopropyltrimethoxysilane, etc. Mercaptopurine siloxanes.
A component (a2) can be used individually by 1 type or in combination of 2 or more types.

Examples of the component (a3) include trifunctional or tetrafunctional silane crosslinking agents. Examples thereof include trimethoxymethylsilane, triethoxyphenylsilane, tetramethoxysilane, tetraethoxysilane, and tetrabutoxysilane.
The component (a3) is preferably contained in the polyorganosiloxane rubber (A) in an amount of 1 to 5% by mass because the molded article obtained is excellent in impact resistance and flame retardancy.

As a method for producing the polyorganosiloxane rubber (A), for example, a siloxane mixture containing the components (a1) to (a3) is emulsified with an emulsifier and water to form an organosiloxane latex, which is finely divided by shearing force by high-speed rotation. The organosiloxane latex is made into fine particles using a homomixer or a homogenizer that makes fine particles by jet output from a high-pressure generator, then polymerized at a high temperature using an acid catalyst, and then neutralized with an alkaline substance. And a method of obtaining a polyorganosiloxane latex.
Examples of the method for adding an acid catalyst used for polymerization include a method of mixing with a siloxane mixture, an emulsifier and water, and a method of dropping an organosiloxane latex in which a siloxane mixture is finely divided into a high-temperature acid aqueous solution at a constant rate. Can be mentioned.
As a method for producing the polyorganosiloxane rubber (A), a method in which polymerization is carried out by mixing a siloxane mixture, an emulsifier and water with an acid aqueous solution having no micelle-forming ability is preferable from the viewpoint of easy control of the particle diameter.

As the emulsifier used in the production of the polyorganosiloxane rubber (A), an anionic emulsifier is preferable. Examples of the anionic emulsifier include sodium lauryl sulfate, sodium alkylbenzene sulfonate, and sodium polyoxyethylene nonylphenyl ether sulfate. Of these, sodium alkylbenzenesulfonate is particularly preferable.
These emulsifiers can be used alone or in combination of two or more.

Examples of the acid catalyst used for the polymerization of the polyorganosiloxane rubber (A) include sulfonic acids such as aliphatic sulfonic acid, aliphatic substituted benzenesulfonic acid, and aliphatic substituted naphthalenesulfonic acid; minerals such as sulfuric acid, hydrochloric acid, and nitric acid Examples include acids. Among these, it is preferable to use mineral acids such as sulfuric acid, hydrochloric acid, and nitric acid that do not have the ability to form micelles. By using mineral acids, it becomes easy to narrow the particle size distribution of the polyorganosiloxane latex, and it is easy to reduce appearance defects of the resin composition due to the emulsifier component of the polyorganosiloxane latex. Moreover, it is preferable also at the point of the impact strength improvement in low temperature.
These acid catalysts can be used alone or in combination of two or more.

50-95 degreeC is preferable and, as for the polymerization temperature at the time of manufacturing a polyorganosiloxane type rubber (A), 70-90 degreeC is more preferable.
The polymerization time of the polyorganosiloxane rubber (A) is preferably 2 to 15 hours, preferably 5 to 10 hours when the acid catalyst is mixed with a siloxane mixture, an emulsifier and water and polymerized after finely divided. More preferred.
The polymerization can be stopped by cooling the reaction solution and neutralizing the polyorganosiloxane latex with an alkaline substance such as sodium hydroxide, potassium hydroxide, or sodium carbonate.

  The volume average particle diameter (dv) of the polyorganosiloxane rubber (A) is preferably 50 to 600 nm, and more preferably 100 to 500 nm. Here, the volume average particle diameter means a value measured by a capillary type particle size distribution measuring device. When the volume average particle diameter is 50 nm or more, impact resistance at low temperatures is easily developed. Moreover, if the said volume average particle diameter is 600 nm or less, the flame retardance of the obtained molded object will be excellent.

The toluene insoluble content of the polyorganosiloxane rubber (A) is not particularly limited, but is preferably 50% by mass or more, and more preferably 80% by mass or more. If the toluene insoluble content is 50% by mass or more, excellent impact resistance is obtained, and if it is 80% by mass or more, impact resistance is further improved.
The toluene insoluble content of the polyorganosiloxane rubber (A) can be controlled by adjusting the content of the component (a3) in the polyorganosiloxane rubber (A). The higher the content of component (a3), the higher the toluene insoluble content of the polyorganosiloxane rubber (A).

  The polyorganosiloxane rubber (A) may be a composite rubber in which a polyalkyl (meth) acrylate is combined. The polyalkyl (meth) acrylate is preferably obtained by polymerizing butyl acrylate, 2-ethylhexyl acrylate or the like because excellent impact resistance is obtained.

The vinyl monomer (B) used in the present invention contains a polyfunctional vinyl monomer (b1) as a main component.
A vinyl monomer (B) contains 55-100 mass% of polyfunctional vinyl monomers (b1), and it is preferable to contain 75-100 mass%. When the content of the polyfunctional vinyl monomer (b1) in the vinyl monomer (B) is 55% by mass or more, the effect of improving flame retardancy is sufficiently exhibited.

The polyfunctional vinyl monomer (b1) is a monomer having two or more polymerizable unsaturated bonds in the molecule. For example, allyl methacrylate, triallyl cyanurate, triallyl isocyanurate, diallyl phthalate, ethylene Examples include glycol dimethacrylate, 1,3-butylene glycol dimethacrylate, and divinylbenzene. Of these, allyl methacrylate is preferred because of its high effect of developing impact resistance, fluidity and flame retardancy.
These polyfunctional vinyl monomers (b1) can be used alone or in combination of two or more.

A vinyl monomer (B) can contain another vinyl monomer (b2) as needed.
A vinyl monomer (B) contains 0-45 mass% of other vinyl monomers (b2), and it is preferable to contain 0-25 mass%. When the content of the other vinyl monomer (b2) in the vinyl monomer (B) is 45% by mass or less, the effect of improving flame retardancy is sufficiently exhibited.

Examples of other vinyl monomers (b2) include (meth) acrylates such as methyl (meth) acrylate, ethyl (meth) acrylate, 2-ethylhexyl methacrylate, and phenyl methacrylate; styrene, α-methylstyrene, vinyltoluene, and the like. Aromatic vinyl monomers; vinyl cyanide monomers such as (meth) acrylonitrile; unsaturated carboxylic acids such as (meth) acrylic acid, (anhydrous) maleic acid, fumaric acid; maleimide, N-methylmaleimide, etc. Maleimides may be mentioned.
These monomers can be used alone or in combination of two or more.

  In the presence of the polyorganosiloxane rubber (A), the method of polymerizing the vinyl monomer (B) containing the polyfunctional vinyl monomer (b1) as a main component is the method of the polyorganosiloxane rubber (A). The vinyl monomer (B) is added to the latex, and the polymerization can be carried out in one or more stages by radical polymerization.

The graft copolymer (C) is obtained by polymerizing 7 to 40% by mass of the vinyl monomer (B) in the presence of 60 to 93% by mass of the polyorganosiloxane rubber (A). Here, the sum total of (A) and (B) is 100 mass%.
The graft copolymer (C) is preferably obtained by polymerizing 7 to 30% by mass of the vinyl monomer (B) in the presence of 70 to 93% by mass of the polyorganosiloxane rubber (A).

When the amount of the polyorganosiloxane rubber (A) used is 60% by mass or more, sufficient flame retardancy is exhibited. Moreover, if the said usage-amount of a polyorganosiloxane type rubber (A) is 93 mass% or less, sufficient impact resistance will express.
When the amount of the vinyl monomer (B) used is 7% by mass or more, sufficient impact resistance is exhibited. Moreover, if the said usage-amount of a vinyl monomer (B) is 40 mass% or less, sufficient flame retardance will express.

The vinyl polymer (S) of the present invention is obtained by polymerizing the vinyl monomer (s).
Examples of the vinyl monomer (s) include (meth) acrylates such as methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, 2-ethylhexyl methacrylate, and phenyl methacrylate; styrene, α-methylstyrene Aromatic vinyl monomers such as vinyltoluene; vinyl cyanide monomers such as (meth) acrylonitrile; unsaturated carboxylic acids such as (meth) acrylic acid, (anhydrous) maleic acid and fumaric acid; maleimide, N- And maleimides such as methylmaleimide.
These monomers can be used alone or in combination of two or more.

Since the vinyl polymer (S) has good dispersibility of the resin modifier in various thermoplastic resins, there is no risk of toxic gas generation during combustion, and the polymerizability is good. It is preferable to contain 70% by mass or more of an alkyl (meth) acrylate unit having a C 1-4 alkyl group.
As an alkyl (meth) acrylate having an alkyl group having 1 to 4 carbon atoms, for example,
Examples include methyl (meth) acrylate, ethyl (meth) acrylate, and butyl (meth) acrylate, and methyl methacrylate is preferable because the handling property and storage stability of the resin modifier are improved.

The vinyl polymer (S) can be produced using a vinyl monomer (s) by a known polymerization method, for example, an emulsion polymerization method using a radical polymerization initiator.
Examples of the radical polymerization initiator include organic peroxides, inorganic peroxides, azo initiators, and redox initiators in which an oxidizing agent and a reducing agent are combined.
Examples of the organic peroxide include cumene hydroperoxide, t-butyl hydroperoxide, benzoyl peroxide, t-butyl peroxyisopropyl carbonate, di-t-butyl peroxide, t-butyl peroxylaurate, lauroyl. Examples include peroxide, succinic acid peroxide, cyclohexane non-peroxide, and acetylacetone peroxide.
Examples of inorganic peroxides include potassium persulfate and ammonium persulfate.

Examples of the azo initiator include 2,2′-azobisisobutyronitrile and 2,2′-azobis-2,4-dimethylvaleronitrile.
Examples of the redox initiator include a combination of ferrous sulfate, ethylenediaminetetraacetic acid disodium salt, longalite, and hydroperoxide.

Various chain transfer agents can be added to the vinyl polymer (S) in order to adjust the molecular weight or the graft ratio.
Examples of the chain transfer agent include t-dodecyl mercaptan, n-octyl mercaptan, n-tetradecyl mercaptan, and n-hexyl mercaptan.

  As an emulsifier used for emulsion polymerization of the vinyl polymer (S), an anionic emulsifier is preferable, and a sulfonate emulsifier, a sulfate emulsifier, and a carboxylate emulsifier are more preferable. In particular, when a thermoplastic resin having an ester bond is used as the thermoplastic resin, a sulfonate emulsifier is more preferable from the viewpoint of suppressing hydrolysis.

The weight average molecular weight (Mw) of the vinyl polymer (S) is preferably 20,000 to 4,000,000, more preferably 20,000 to 100,000, and still more preferably 20,000 to 50,000.
If Mw is 20,000 or more, the handleability as a powder will improve. If it is 4,000,000 or less, the improvement effect of fluidity will be expressed.

The volume average particle diameter (dv) of the vinyl polymer (S) is preferably 50 to 150 nm, and more preferably 50 to 100 nm.
If the volume average particle diameter of the vinyl polymer (S) is within this range, the dispersibility of the resin modifier will be good.

The resin modifier of the present invention is obtained by mixing the latex at a ratio of 55 to 90% by mass of the graft copolymer (C) and 10 to 45% by mass of the vinyl polymer (S) and then pulverizing it. Here, the sum total of (C) and (S) is 100 mass%.
The resin modifier is preferably mixed with the latex in a ratio of 65 to 85% by mass of the graft copolymer (C) and 15 to 35% by mass of the vinyl polymer (S).

If the said usage-amount of a graft copolymer (C) is 55 mass% or more, a flame-retardant improvement effect will fully express. Moreover, if the said usage-amount of a graft copolymer (C) is 90 mass% or less, the impact-resistance and a flame retardance improvement effect will be excellent.
If the said usage-amount of a vinyl polymer (S) is 10 mass% or more, the impact resistance and a flame retardance improvement effect will be excellent. Moreover, if the said usage-amount of a vinyl polymer (S) is 45 mass% or less, a flame-retardant improvement effect will fully express.

The mixed latex of graft copolymer (C) and vinyl polymer (S) is poured into hot water in which metal salts such as calcium chloride, calcium acetate, magnesium sulfate, aluminum sulfate are dissolved, and salted out and coagulated. To powder. By this operation, the resin modifier can be obtained as a powder.
Moreover, the mixed latex of the graft copolymer (C) and the vinyl polymer (S) can be spray-dried to form a powder, and the resin modifier can be obtained as a powder.
In particular, when a thermoplastic resin having an ester bond is used as the thermoplastic resin, it is preferably pulverized by salting out with a calcium salt from the viewpoint of suppressing hydrolysis.

  Examples of the thermoplastic resin used in the present invention include polycarbonate resin (PC resin); acrylic resin (Ac resin) such as polymethyl methacrylate (PMMA); polystyrene (PS) and high impact polystyrene (HIPS). (Meth) acrylic acid ester / styrene copolymer (MS), styrene / acrylonitrile copolymer (SAN), styrene / maleic anhydride copolymer (SMA), acrylonitrile / butadiene / styrene copolymer (ABS), Styrenic resins (St-based resins) such as acrylonitrile / styrene / acrylate copolymer (ASA), acrylonitrile / ethylene-propylene-diene / styrene (AES); Polyesters such as polyethylene terephthalate (PET) and polybutylene terephthalate (PBT) system Fat (PEs resin); Olefin resin such as polypropylene (PP) and polyethylene (PE); Polyamide resin (PA resin); (Modified) Polyphenylene ether resin (PPE resin), Polyoxymethylene resin ( Engineering plastics such as POM resin), polysulfone resin (PSO resin), polyarylate resin (PAr resin), polyphenylene resin (PPS resin), and thermoplastic polyurethane resin (PU resin) Can be mentioned.

Also, thermoplastic elastomers such as styrene elastomers, olefin elastomers, vinyl chloride elastomers, urethane elastomers, polyester elastomers, polyamide elastomers, fluorine elastomers, 1,2-polybutadiene, trans 1,4-polyisoprene ( TPE); PC resin such as PC / ABS / St resin alloy, PVC resin such as polyvinyl chloride (PVC) / ABS / St resin alloy, PA resin such as PA / ABS / St resin alloy, PA resin / TPE alloy, PA resin such as PA / PP / polyolefin resin alloy, PBT resin / TPE, PC resin such as PC / PBT / PEs resin alloy, polyolefin resin / TPE, PP / PE Alloys between olefin resins such as PPE / H PS, PPE / PBT, PPE-based resin alloys such as PPE / PA, polymer alloy such as PVC resin / Ac resin alloy such as PVC / PMMA; rigid, semi-rigid, and a soft vinyl chloride resin.
These can be used alone or in combination of two or more.
Among these, polycarbonate resins are preferable because impact resistance, flame retardancy, and fluidity are improved.

The thermoplastic resin composition of the present invention is obtained by blending 1 to 20 parts by mass of a resin modifier with 100 parts by mass of a thermoplastic resin. The compounding amount of the resin modifier is preferably 2 to 10 parts by mass.
If the said compounding quantity of the resin modifier is 1 mass part or more, the outstanding impact resistance and flame retardance will express. Moreover, if the said compounding quantity of a resin modifier is 20 mass parts or less, the original property of a thermoplastic resin will not be impaired.

You may mix | blend various additives with the thermoplastic resin composition of this invention as needed.
Examples of additives include pigments; dyes; reinforcing agents such as glass fibers, metal fibers, metal flakes, and carbon fibers; fillers; compatibilizers such as graft copolymers; 2,6-di-butyl-4- Phenolic antioxidants such as methylphenol and 4,4'-butylidene-bis (3-methyl-6-t-butylphenol); Tris (mixed, mono and dinylphenyl) phosphites, diphenyl isodecyl phosphites, etc. Phosphite antioxidants; sulfur antioxidants such as dilauryl thiodipropionate, dimyristyl thiodipropionate diasterial thiodipropionate; 2-hydroxy-4-octoxybenzophenone, 2- (2-hydroxy Benzotriazole ultraviolet absorbers such as -5-methylphenyl) benzotriazole; bis (2,2,6 , 6-tetramethyl-4-piperidinyl), etc .; antistatic agents such as hydroxylalkylamines and sulfonates; lubricants such as ethylenebisstearylamide and metal soaps; tetrabromophenol A, decabromophenol oxide, Flame retardants such as tetrabromobisphenol A (TBA) epoxy oligomer, TBA polycarbonate oligomer, antimony trioxide, triphenyl phosphite (TPP), phosphate ester; PTFE (polytetrafluoroethylene); Examples thereof include modified fluororesins in which the obtained hard polymer and fluororesin are mixed.

The modified fluororesin can be obtained by polymerizing a vinyl monomer in a liquid in which a fluororesin is dispersed, or by mixing a hard polymer obtained by polymerizing a vinyl monomer and a fluororesin in a dispersion or solid. Examples of vinyl monomers that can be obtained include (meth) acrylates such as methyl (meth) acrylate; aromatic vinyl monomers such as styrene; vinyl carboxylates such as vinyl acetate and vinyl butyrate An olefinic monomer such as ethylene or propylene.

  As the modified fluororesin, modified PTFE is preferable. Examples of commercially available modified PTFE include, for example, trade names “Metabrene A3800”, “Metabrene A3750” (above, manufactured by Mitsubishi Rayon Co., Ltd.), trade names “TSAD001”, “CX-500” (above, Pacific Interchem ( Product name) “Blendex 449” (manufactured by Chemtura Inc.).

When mix | blending a modified | denatured fluororesin, 0.05-10 mass parts is preferable with respect to 100 mass parts of thermoplastic resins, and, as for the compounding quantity of a modified fluororesin, 0.1-5 mass parts is more preferable.
If the said compounding quantity of a modified fluororesin is 0.05 mass part or more, a flame retardance will improve. Moreover, if the said compounding quantity of fluororesin is 10 mass parts or less, a shaping | molding external appearance will not be impaired.

The thermoplastic resin composition of the present invention contains a predetermined amount of a thermoplastic resin, a resin modifier, and various additives as required, and is usually a roll, a Banbury mixer, a single screw extruder, a twin screw extruder, or the like. It can be prepared by kneading with a kneader. These can be operated batchwise or continuously, and the mixing order of each component is not particularly limited. Moreover, you may use a small amount of solvent together as needed.
The thermoplastic resin composition of the present invention is preferably in the form of pellets.

The molded product of the present invention is obtained by molding the above-mentioned thermoplastic resin composition. The molded product of the present invention has excellent impact resistance and sufficient flame retardancy.
The molded product of the present invention can be widely used for molded products that require low temperature impact resistance and flame resistance, such as building materials, automobiles, toys, stationery and other miscellaneous goods, OA equipment, and home appliances.
The manufacturing method of the molded object of this invention can use a well-known manufacturing method except using the thermoplastic resin composition of this invention.

Hereinafter, the present invention will be described in detail with reference to examples. However, the present invention is not limited by the following description. “Parts” and “%” in this example mean “parts by mass” and “% by mass”, respectively.
Each measurement in this example was performed as follows.

[Toluene insoluble matter]
The polyorganosiloxane rubber (A) is extracted from the latex of the polyorganosiloxane rubber (A) using 2-propanol, dried at room temperature, and then vacuum dried to completely remove 2-propanol. did.
0.5 g of the obtained polyorganosiloxane rubber (A) was precisely weighed, immersed in 80 mL of toluene at room temperature for 24 hours, and centrifuged at 12,000 rpm for 60 minutes. Thereafter, the polyorganosiloxane rubber (A) was weighed again to calculate the toluene insoluble content (%).

[Volume average particle diameter (dv)]
The latex was diluted with distilled water to prepare 0.1 mL of a sample having a concentration of about 3%, and measurement was performed using a capillary type particle size distribution analyzer (CHDF2000 type, manufactured by MATEC (USA)).
The measurement conditions were a flow rate of 1.4 mL / min, a pressure of about 2.76 MPa (about 4,000 psi), and a temperature of 35 ° C. For the measurement, a capillary cartridge for particle separation and a carrier liquid were used, and the liquidity was made almost neutral.
Before measuring the sample, use a monodisperse polystyrene with a known particle size (manufactured by DUKE (USA)) as the standard particle size material, measure the particle size at a total of 12 points from 20 to 800 nm, and create a calibration curve. did.

[Mass average molecular weight (Mw)]
The measurement was performed using gel permeation chromatography (GPC) using a polymer acetone solution as a sample.
The measurement conditions were as follows, and Mw was determined from a calibration curve using standard polystyrene.
Apparatus: “HLC8220” (manufactured by Tosoh Corporation)
Column: “TSKgel SuperHZM-M” (manufactured by Tosoh Corporation)
(Inner diameter 4.6 mm × length 15 cm × 4, exclusion limit 4 × 10 ⁶ )
Eluent: Tetrahydrofuran Eluent flow rate: 0.35 mL / min Measuring temperature: 40 ° C
Sample injection volume: 10 μL (sample concentration 0.1%)

[Shock resistance]
According to ASTM D-256, an Izod impact test at 23 ° C. and −30 ° C. was performed using a 1/4 inch bar with a notch to evaluate impact resistance.

[Flame retardance]
Flame retardance was evaluated by a UL94V test using a 1/16 inch combustion rod.

[Liquidity]
In accordance with JIS K7210, the flowability was evaluated by measuring the melt flow rate (MFR) using the pellets of the thermoplastic resin composition.
MFR was measured under the conditions of temperature: 280 ° C. and load: 5.0 kgf.

[Production Example 1] Production of polyorganosiloxane rubber (A1) latex The following raw material mixture was stirred with a homomixer at 10,000 rpm for 5 minutes, and then passed twice through a homogenizer at a pressure of 20 MPa to provide a stable premixed latex. (1) was obtained.
Raw material mixture;
Component (a1): 96 parts of YF393 Component (a2): KBM502 2 parts Component (a3): AY43-101 2 parts Emulsifier: Sodium dodecylbenzenesulfonate 1 part Deionized water 150 parts

250 parts of the premixed latex (1) was put into a separable flask equipped with a cooling tube, and a mixture of 0.2 part of sulfuric acid and 49.8 parts of deionized water was added dropwise over 3 minutes. Thereafter, the aqueous solution was heated to 80 ° C. for 7 hours for polymerization, and then cooled.
Next, the reaction product was held at room temperature for 6 hours and then neutralized with an aqueous sodium hydroxide solution to obtain a polyorganosiloxane rubber (A1) latex.

The polyorganosiloxane rubber (A1) latex was dried at 180 ° C. for 30 minutes to obtain a solid content (hereinafter, the same method was used as a method for measuring the solid content).
The solid content of the polyorganosiloxane rubber (A1) latex was 29.8%, and the volume average particle size was 260 nm.

[Production Example 2] Production of polyorganosiloxane rubber (A2) latex The following raw material mixture was stirred with a homomixer at 10,000 rpm for 5 minutes, and then passed twice through a homogenizer at a pressure of 20 MPa to provide a stable premixed latex. (2) was obtained.
Raw material mixture;
Component (a1): 96 parts of YF393 Component (a2): KBM502 2 parts Component (a3): AY43-101 2 parts Emulsifier: Sodium dodecylbenzenesulfonate 0.67 parts Acid catalyst: Dodecylbenzenesulfonic acid 0.67 parts Deionized 200 parts of water

300 parts of the premixed latex (2) was put into a separable flask equipped with a cooling tube, and the mixture was heated to 80 ° C. for 7 hours for polymerization, and then cooled.
Next, the reaction product was held at room temperature for 6 hours and then neutralized with an aqueous sodium hydroxide solution to obtain a polyorganosiloxane rubber (A2) latex.
The solid content of the polyorganosiloxane rubber (A2) latex was 29.3%, and the volume average particle size was 140 nm.

The breakdown of components (a1) to (a3) used in Production Examples 1 and 2 is as follows.
YF393 (trade name, octamethylcyclotetrasiloxane, manufactured by Momentive Performance Materials Japan)
KBM502 (trade name, γ-methacryloyloxypropyldimethoxymethylsilane, manufactured by Shin-Etsu Chemical Co., Ltd.)
AY43-101 (trade name, tetraethoxysilane, manufactured by Toray Dow Corning Silicone Co., Ltd.)

  Table 1 shows the toluene-insoluble content and volume average particle diameter of the polyorganosiloxane rubbers (A) obtained in Production Examples 1 and 2.

[Production Example 3] Production of Graft Copolymer (C1) Latex The following raw material mixture was put into a separable flask, and nitrogen substitution was performed in the flask through a nitrogen stream, and the temperature was raised while stirring.
When the liquid temperature reached 50 ° C., the following reducing agent aqueous solution was added to initiate polymerization, and the liquid temperature was maintained at 70 ° C. for 1 hour to complete the polymerization.
Raw material mixture;
302 parts of polyorganosiloxane rubber (A1) latex
(90 parts in terms of polymer)
Polyfunctional vinyl monomer (b1): Allyl methacrylate 10 parts Polymerization initiator: t-butyl hydroperoxide 2.2 parts Deionized water 200 parts Reducing agent aqueous solution;
Ferrous sulfate 0.001 parts Ethylenediaminetetraacetic acid disodium salt 0.003 parts Rongalite 0.24 parts Deionized water 10 parts

[Production Examples 4 to 9] Production of Graft Copolymers (C2) to (C7) Latex Production was performed in the same manner as Production Example 3 using the raw materials shown in Table 2.

  Table 2 shows the volume average particle diameters of the graft copolymers (C) obtained in Production Examples 3 to 9.

尚、表中の略号は下記の通り。
ＡＭＡ ：アリルメタクリレート
ＭＭＡ ：メチルメタクリリレート
ＰｈＭＡ：フェニルメタクリレート

The abbreviations in the table are as follows.
AMA: Allyl methacrylate MMA: Methyl methacrylate PhMA: Phenyl methacrylate

[Production Example 10] Production of vinyl polymer (S1) latex The following raw material mixture was put into a separable flask, and nitrogen substitution was performed in the flask through a nitrogen stream, and the temperature was increased while stirring.
When the liquid temperature reached 50 ° C., the following reducing agent aqueous solution was added to initiate polymerization, and the liquid temperature was maintained at 70 ° C. for 2 hours to complete the polymerization.
Raw material mixture;
Methyl methacrylate 80 parts Butyl acrylate 20 parts Emulsifier: Sodium dodecylbenzenesulfonate 3 parts Polymerization initiator: t-butyl hydroperoxide 0.1 part Deionized water 200 parts Reducing agent aqueous solution;
Ferrous sulfate 0.001 parts Ethylenediaminetetraacetic acid disodium salt 0.003 parts Rongalite 0.24 parts Deionized water 10 parts

[Production Example 11] Production of vinyl polymer (S2) latex Production was performed in the same manner as in Production Example 10 using the raw materials shown in Table 3.

  Table 3 shows the mass average molecular weight and volume average particle diameter of the vinyl polymers (S) obtained in Production Examples 10 and 11.

尚、表中の略号は下記の通り。
ＭＭＡ：メチルメタクリリレート
ＢＡ ：ブチルアクリレート

The abbreviations in the table are as follows.
MMA: Methyl methacrylate BA: Butyl acrylate

[Example 1] Resin modifier (1) powder Graft copolymer (C1) and vinyl polymer (S1) were blended in the ratios shown in Table 4 and mixed at room temperature for 30 minutes to modify the resin. Agent (1) Latex was obtained.
500 parts of an aqueous solution containing 5% calcium acetate are heated to 60 ° C. while stirring, and the resin modifier (1) latex is gradually dropped into the aqueous solution to solidify it, separated, washed with water, dried and dried. A quality agent (1) powder was obtained.

(Manufacture of thermoplastic resin composition)
Using a 30 mmφ twin-screw extruder (PCM-30, manufactured by Ikegai Seisakusho), the following blending components were melt-kneaded at 280 ° C. and shaped into pellets to obtain a thermoplastic resin composition.
Next, the obtained thermoplastic resin composition was molded at 280 ° C. using a 100 t injection molding machine (SE-100DU, manufactured by Sumitomo Heavy Industries, Ltd.) to obtain an Izod test piece and a combustion test piece.
The evaluation results are shown in Table 4.

Compounding ingredients;
Resin modifier (1) Powder 5 parts Thermoplastic resin: "Iupilon S2000F" (trade name, bisphenol A type polycarbonate, viscosity average molecular weight of about 22,000, manufactured by Mitsubishi Engineering Plastics) 100 parts Antioxidant : "Irganox 245" (trade name, manufactured by Ciba Japan Co., Ltd.)
0.3 parts
“ADK STAB PEP36” (trade name, manufactured by ADEKA Corporation)
0.3 part Anti-drip agent: “Metabrene A3800” (trade name, acrylic modified polytetrafluoroethylene, manufactured by Mitsubishi Rayon Co., Ltd.) 1 part

[Examples 2-12, Comparative Examples 1-2]
A resin modifier powder was obtained in the same manner as in Example 1 except that the formulation was changed as shown in Table 4.
Moreover, using the resin modifier powder, a thermoplastic resin composition was produced in the same manner as in Example 1 to obtain an Izod test piece and a combustion test piece. The evaluation results are shown in Table 4.

[Comparative Example 3]
The following 1st raw material mixture was thrown into the separable flask, nitrogen substitution was performed through nitrogen stream in the flask, and it heated up, stirring.
When the liquid temperature reached 50 ° C., the following reducing agent aqueous solution was added to initiate polymerization, and the liquid temperature was maintained at 70 ° C. for 1 hour to complete the polymerization.
First raw material mixture;
Polyorganosiloxane rubber (A1) Latex 242 parts
(72 parts in terms of polymer)
Polyfunctional vinyl monomer (b1): Allyl methacrylate 8 parts Polymerization initiator: t-butyl hydroperoxide 2.2 parts Deionized water 200 parts Reducing agent aqueous solution;
Ferrous sulfate 0.001 parts Ethylenediaminetetraacetic acid disodium salt 0.003 parts Rongalite 0.24 parts Deionized water 10 parts

Subsequently, the following 2nd raw material mixture was dripped over 10 minutes, liquid temperature was hold | maintained at 60 degreeC or more for 1 hour, superposition | polymerization was completed, and resin modifier (15) latex was obtained.
Second raw material mixture;
Other vinyl monomer (b2): methyl methacrylate 18 parts Other vinyl monomer (b2): butyl acrylate 2 parts Polymerization initiator: t-butyl hydroperoxide 2.2 parts

500 parts of a 5% calcium acetate aqueous solution is heated to 60 ° C. with stirring, and the resin modifier (15) latex is gradually dropped into the aqueous solution to solidify it, separated, washed with water, dried and then modified with resin. A material (15) powder was obtained.
Using the resin modifier (15) powder, a thermoplastic resin composition was produced in the same manner as in Example 1 to obtain Izod test pieces and combustion test pieces. The evaluation results are shown in Table 5.

[Comparative Example 4]
A resin modifier (16) powder was obtained in the same manner as in Comparative Example 3 except that the formulation was changed as shown in Table 5.
Further, a thermoplastic resin composition was produced using the resin modifier (16) powder in the same manner as in Example 1 to obtain Izod test pieces and combustion test pieces. The evaluation results are shown in Table 5.

The abbreviations in the table are as follows.
PC: “Iupilon S2000F” (trade name, manufactured by Mitsubishi Engineering Plastics Co., Ltd.)
Irg245: “Irganox 245” (trade name, manufactured by Ciba Japan Co., Ltd.)
PEP36: “ADK STAB PEP36” (trade name, manufactured by ADEKA Corporation)
A3800: “Metabrene A3800” (trade name, manufactured by Mitsubishi Rayon Co., Ltd.)

As is apparent from Tables 4 and 5, the thermoplastic resin compositions of Examples 1 to 12 containing the resin modifier of the present invention were excellent in impact resistance, flame retardancy and fluidity. In particular, the combustion time is shortened and the fluidity is improved.
The thermoplastic resin composition of Comparative Example 1 containing a resin modifier (13) having a high content of polyorganosiloxane rubber (A) and a low content of polyfunctional vinyl monomer (b1), The impact resistance was poor and the fluidity was poor.
The thermoplastic resin composition of Comparative Example 2 blended with the resin modifier (14) having a low content of the graft copolymer (C) and a high content of the vinyl polymer (S) has an impact resistance at low temperatures. The result was that the property was poor and the combustion time was long.

  After the polyfunctional vinyl monomer (b1) was polymerized in the presence of the polyorganosiloxane rubber (A), another vinyl monomer (b2) was polymerized (without using the vinyl polymer (S)). The thermoplastic resin composition of Comparative Example 3 in which the resin modifier (15) was blended resulted in a long combustion time and poor fluidity.

  In the presence of the polyorganosiloxane rubber (A), after polymerizing the vinyl monomer (B) mainly composed of the other vinyl monomer (b2), the other vinyl monomer (b2) is polymerized. The thermoplastic resin composition of Comparative Example 4 in which the resin modifier (16) (without using the vinyl polymer (S)) was blended had a long combustion time and poor fluidity.

The resin modifier (15) is obtained by graft polymerization of a polyfunctional vinyl monomer (b1) and another vinyl monomer (b2) to the polyorganosiloxane rubber (A). The resin modifier (16) is obtained by graft polymerization of the polyorganosiloxane rubber (A) with another vinyl monomer (b2) as a main component.
Since the vinyl polymer obtained by polymerizing the vinyl monomer (b2) is a highly flammable component, the polyorganosiloxane rubber (A) is expected to be affected by the highly flammable component. . From this, it is presumed that the flame retardancy of the resin modifiers (15) and (16) was lowered and the combustion time was prolonged.
Since the graft copolymer (C) and the vinyl polymer (S) are not chemically bonded to the resin modifier of the present invention, the thermoplastic resin composition includes the graft copolymer (C) and It is expected that the vinyl polymer (S) exists independently. From this, it is presumed that the polyorganosiloxane rubber (A) was not affected by highly flammable components and sufficiently exhibited the effect of improving flame retardancy.

Claims (3)

Obtained by polymerizing 7 to 40% by mass of vinyl monomer (B) mainly composed of polyfunctional vinyl monomer (b1) in the presence of 60 to 93% by mass of polyorganosiloxane rubber (A). A latex of the graft copolymer (C) obtained,
A latex of vinyl polymer (S) obtained by polymerizing vinyl monomer (s),
After mixing at a ratio of 55 to 90% by mass of the graft copolymer (C) and 10 to 45% by mass of the vinyl polymer (S), it is pulverized.
A method for producing a resin modifier.   The thermoplastic resin composition obtained by mix | blending 1-20 mass parts of resin modifiers of Claim 1 with respect to 100 mass parts of thermoplastic resins.   A molded product obtained by molding the thermoplastic resin composition according to claim 2.