JP2013091269A - Laminated adhesive film for insert molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a laminated adhesive film for insert molding which is produced by laminating an adhesive (adhesive film) comprising a modified polyolefin resin and a polyphenylene sulfide-based resin film, and can form, on a metal member, an adhesive layer having favorable adhesion with the polyphenylene sulfide-based resin by a VOC-free high-productivity method.SOLUTION: There is provided the laminated adhesive film for insert molding produced by laminating the adhesive (adhesive film) comprising the modified polyolefin resin graft-modified using a monomer which includes an ethylenic double bond and a polar group in a molecule, and the polyphenylene sulfide-based resin film.

Description

  The present invention relates to a laminated adhesive film for insert molding in which an adhesive film made of a modified polyolefin resin and a polyphenylene sulfide resin film are laminated, and is suitable as an adhesive layer for improving the adhesion between the polyphenylene sulfide resin and a metal member in insert molding. Can be used for

  Conventionally, a composite product in which a metal member and a resin member are integrated is used for an automobile interior member or the like. As a method for integrating the metal member and the resin member, a method of bonding using an adhesive, a fixing member such as a folded piece or a nail is provided on the metal member and the resin member, and both are fixed using this fixing member. And a joining method using screws or the like. However, a composite product in which a metal member and a resin member are integrated without using an adhesive is formed by separately forming the metal member and molding the resin member, and then integrating the two. Therefore, there is a problem that the process is complicated and not economical. In addition, when a solvent-based adhesive is used as an adhesive, there is a concern that the working environment may be deteriorated due to VOC, or a yield rate is reduced due to poor adhesion due to coating unevenness, poor appearance of a molded product due to stringing, or the like. Furthermore, since a solvent-based adhesive requires a drying step after application, it is not economical because the equipment is enlarged and the tact time of production is increased. For example, in Patent Document 1, it is possible to firmly bond a metal member and a resin member by insert molding, but it takes 30 minutes or more to dry the adhesive.

  On the other hand, Patent Document 2 describes a method that does not use an adhesive, in which a surface of a metal material is processed to form ultra-fine irregularities and then the metal material is combined with a resin by insert molding. Yes. However, there are problems such as complicated metal surface treatment and limited adherends.

  In Patent Document 3, it is described that a modified polyolefin graft-polymerized with an epoxy group-containing ethylenically unsaturated monomer is suitably used as an adhesive resin for a multilayer injection molded article containing polyphenylene sulfide. However, neither an industrially efficient process method nor a handling method thereof is disclosed.

JP 2009-73088 A JP 2010-64397 A JP 2003-268051 A

    TECHNICAL FIELD The present invention relates to an adhesive film for insert molding in which an adhesive film made of a modified polyolefin resin and a polyphenylene sulfide resin film are laminated, and the adhesive property to a polyphenylene sulfide resin on a metal member by a VOC-free and highly productive method. It aims at providing the laminated adhesive film which can form a favorable adhesive layer.

    As a result of intensive investigations in view of the above-mentioned present situation, the present inventors are injection molded by laminating an adhesive film made of a modified polyolefin resin in which a polar group is introduced into a polyolefin resin with a polyphenylene sulfide resin film. Adhesion failure due to the adhesive film layer being washed away with molten resin can be suppressed and uniform adhesion can be achieved, and workability when laminating a metal member and an adhesive film can be dramatically improved, and heating of the metal member can be achieved. It has been found that the thermal deterioration of the adhesive film can be greatly reduced in the bonding process, the peeling due to the destruction of the adhesive film layer of the insert molded product can be reduced, and that it can adhere well to the polyphenylene sulfide resin to be injection molded. The present invention has been completed.

  That is, the present invention has the following configuration.

  1). A laminated adhesive film for insert molding in which an adhesive is laminated on a polyphenylene sulfide-based resin film. The laminated adhesive film for insert molding is laminated so that the adhesive surface is in contact with a metal member, and then heated to form an adhesive. The adhesive film laminated metal member for insert molding is placed in the mold so that the surface of the polyphenylene sulfide-based resin film is on the void side in the mold, and the polyphenylene sulfide-based resin is bonded. A laminated adhesive film for insert molding characterized by injection molding.

  2). The laminated adhesive film for insert molding according to 1), wherein the adhesive contains a modified polyolefin resin graft-modified with a monomer containing an ethylenic double bond and a polar group in the same molecule. .

  3). 2) A description, wherein the adhesive contains a modified polyolefin resin graft-modified with a monomer containing an ethylenic double bond and a polar group in the same molecule and an aromatic vinyl monomer. Laminated adhesive film for insert molding.

  4). 2) to 3) wherein the monomer containing the ethylenic double bond and the polar group in the same molecule is at least one selected from (meth) acrylic acid, maleic anhydride, and glycidyl (meth) acrylate. Laminated adhesive film for insert molding.

  5). The laminated adhesive film for insert molding according to claim 2, wherein the heat of fusion of the modified polyolefin resin is in the range of 1 to 50 J / g.

  6). The modified polyolefin resin composition according to any one of 2) to 5) has two or more melting points, and has at least one melting point exceeding 150 ° C and melting point not exceeding 150 ° C. A laminated adhesive film for insert molding.

  7). The laminated adhesive film for insert molding according to 1) to 6), wherein the thickness is 30 to 300 μm.

  8). After laminating the laminated adhesive film for insert molding described in 1) to 7) so that the adhesive surface is in contact with the metal member, the adhesive part is heated to melt the adhesive portion and adhere to the metal member, and the adhesive for insert molding An insert molding method in which a film-laminated metal member is placed in a mold such that the polyphenylene sulfide-based resin film surface is on the inner cavity side, and the polyphenylene sulfide-based resin is injection-molded.

  In the present invention, when an adhesive (adhesive film) made of a modified polyolefin resin and an adhesive film for insert molding in which a polyphenylene sulfide resin film is laminated is used, in insert molding of a metal member and a polyphenylene sulfide resin, VOC is free. It becomes possible to form an adhesive layer with good adhesion to the polyphenylene sulfide-based resin on the metal member by a method with high productivity.

Details of the present invention will be described below.
(Polyolefin resin)
In the present invention, the polyolefin resin before graft modification (hereinafter referred to as a raw material polyolefin resin) is, for example, any of polyethylene, polypropylene, poly-1-butene, polyisobutylene, propylene and ethylene and / or 1-butene. Random or block copolymers in proportions, ethylene-propylene-diene terpolymers with a diene component of 50% by weight or less in any proportion of ethylene and propylene, polymethylpentene, cyclopentadiene and ethylene and And / or a cyclic polyolefin such as a copolymer with propylene, a random copolymer of ethylene or propylene with 50% by weight or less of a vinyl compound, a block copolymer, and the like.

  Among these, from the viewpoint of surface adhesive strength, an olefin elastomer is preferably used. The olefin-based elastomer is a C2-C20 α-olefin polymer or copolymer having a melting point of 160 ° C. or lower, preferably 150 ° C. or lower, more preferably 140 ° C. or lower. Specifically, ethylene / propylene copolymer, ethylene / 1-butene copolymer, ethylene / 1-hexene copolymer, ethylene / 4-methylpentene-1 copolymer, ethylene / 1-octene copolymer , Propylene homopolymer, propylene / ethylene copolymer, propylene / ethylene / 1-butene copolymer, 1-butene homopolymer, 1-butene / ethylene copolymer, 1-butene / propylene copolymer, 4 -Methylpentene-1 homopolymer, 4-methylpentene-1 / propylene copolymer, 4-methylpentene-1 / 1-butene copolymer, 4-methylpentene-1 / propylene / 1-butene copolymer , Propylene / 1-butene copolymer, ethylene / vinyl acetate copolymer, ethylene / methacrylic acid copolymer, ethylene / methyl methacrylate copolymer, etc. It can be mentioned. A propylene homopolymer, a propylene / ethylene copolymer, and a propylene / 1-butene copolymer are preferable. Particularly preferred is a propylene / ethylene copolymer.

  In addition, a polyolefin resin into which a polar group is introduced can also be used because it is easily compatible with an unsaturated carboxylic acid monomer having a polar group. Specific examples of polyolefin resins having polar groups introduced include acid-modified polypropylene such as maleic anhydride-modified polypropylene, maleic acid-modified polypropylene, and acrylic acid-modified polypropylene; ethylene / vinyl chloride copolymer, ethylene / vinylidene chloride copolymer Polymer, ethylene / acrylonitrile copolymer, ethylene / methacrylonitrile copolymer, ethylene / vinyl acetate copolymer, ethylene / acrylamide copolymer, ethylene / methacrylamide copolymer, ethylene / acrylic acid copolymer, ethylene / Methacrylic acid copolymer, ethylene / maleic acid copolymer, ethylene / methyl acrylate copolymer, ethylene / ethyl acrylate copolymer, ethylene / isopropyl acrylate copolymer, ethylene / butyl acrylate copolymer ,ethylene/ Isobutyl crylate copolymer, ethylene / 2-ethylhexyl acrylate copolymer, ethylene / methyl methacrylate copolymer, ethylene / ethyl methacrylate copolymer, ethylene / isopropyl methacrylate copolymer, ethylene / butyl methacrylate Copolymer, ethylene / isobutyl methacrylate copolymer, ethylene / 2-ethylhexyl methacrylate copolymer, ethylene / maleic anhydride copolymer, ethylene / ethyl acrylate / maleic anhydride copolymer, ethylene / acrylic acid Metal salt copolymer, ethylene / methacrylic acid metal salt copolymer, ethylene / vinyl acetate copolymer or saponified product thereof, ethylene / vinyl propionate copolymer, ethylene / glycidyl methacrylate copolymer, ethylene / acrylic Ethylate / Glycidyl methacrylate Coalescence, ethylene or α- olefin / vinyl monomer copolymers such as ethylene / vinyl acetate / glycidyl methacrylate copolymer; and chlorinated polyolefins such as chlorinated polypropylene chlorinated polyethylene. These polar group-introduced polyolefin resins can be used by mixing two or more kinds.

  If necessary, other raw materials or rubbers may be added to the raw material polyolefin resin as long as the effects of the present invention are not impaired.

  Examples of the other resin or rubber include poly α-olefins such as polypentene-1 and polymethylpentene-1, ethylene such as propylene / butene-1 copolymer having a propylene content of less than 75% by weight, or α- Olefin / α-olefin copolymer; ethylene or α-olefin / α-olefin / diene monomer copolymer such as ethylene / propylene / 5-ethylidene-2-norbornene copolymer having a propylene content of less than 75% by weight Polymer; Polydiene copolymer such as polybutadiene and polyisoprene; Vinyl monomer / diene monomer random copolymer such as styrene / butadiene random copolymer and styrene / isoprene random copolymer; Styrene / butadiene / styrene block Copolymer, styrene / isoprene / styrene block copolymer Vinyl monomer such as polymer / diene monomer / vinyl monomer block copolymer; Hydrogenation (styrene / butadiene random copolymer), hydrogenation (styrene / isoprene random copolymer), etc. (Vinyl monomer / diene monomer random copolymer); hydrogenation (styrene / butadiene / styrene block copolymer), hydrogenation (styrene / isoprene / styrene block copolymer), etc. Monomer / diene monomer / vinyl monomer block copolymer); vinyl monomer / diene monomer such as acrylonitrile / butadiene / styrene graft copolymer, methyl methacrylate / butadiene / styrene graft copolymer / Vinyl monomer graft copolymer; polyvinyl chloride, polyvinylidene chloride, polyacrylonitrile, polyvinyl acetate, poly Vinyl polymers such as ethyl acrylate, polybutyl acrylate, polymethyl methacrylate, polystyrene; vinyl chloride / acrylonitrile copolymer, vinyl chloride / vinyl acetate copolymer, acrylonitrile / styrene copolymer, methyl methacrylate / styrene Examples thereof include vinyl copolymers such as copolymers.

  The amount of these other resins or rubbers added to the raw material polyolefin resin is different depending on the type of this resin or the type of rubber, and may be within the range not impairing the effects of the present invention as described above. The content is preferably about 25% by weight or less.

  The raw material polyolefin-based resin (which may contain various additive materials) may be in the form of particles or pellets, and the size and shape are not particularly limited.

  In addition, when the above-mentioned additive materials (other resins and rubbers) are used, this additive material is added when the raw polyolefin resin is melted even if it is previously added to the raw polyolefin resin. It may be a thing.

  Regarding the propylene component in the raw material polyolefin resin, it is preferable that the propylene unit is a majority amount in that radicals are easily generated in the raw material polyolefin resin. The majority amount here means that the propylene component is 50% by weight or more based on the polyolefin resin. (Monomer containing an ethylenic double bond and a polar group in the same molecule) Especially limited as a monomer containing an ethylenic double bond and a polar group in the same molecule for graft modification of the above raw material polyolefin resin Various types can be used. As the polar group, a carboxylic acid, an acid anhydride, or a derivative thereof can be preferably used. Specific examples of such monomers include acrylic acid, methacrylic acid, maleic acid, fumaric acid, tetrahydrophthalic acid, itaconic acid, citraconic acid, crotonic acid, isocrotonic acid, norbornene dicarboxylic acid, bicyclo [2,2, 1] Unsaturated carboxylic acids such as hept-2-ene-5,6-dicarboxylic acid, or acid anhydrides or derivatives thereof (for example, acid halides, amides, imides, esters, etc.). Specific examples of the compound include maleenyl chloride, maleenylimide, maleic anhydride, itaconic anhydride, citraconic anhydride, tetrahydrophthalic anhydride, bicyclo [2,2,1] hept-2-ene-5,6-dicarboxylic acid. Anhydride, dimethyl maleate, monomethyl maleate, diethyl maleate, diethyl fumarate, dimethyl itaconate, diethyl citraconic acid, dimethyl tetrahydrophthalate, bicyclo [2,2,1] hept-2-ene-5,6-dicarboxylic acid Dimethyl acid, hydroxyethyl (meth) acrylate, hydroxypropyl (meth) acrylate, glycidyl (meth) acrylate, monoglycidyl maleate, diglycidyl maleate, monoglycidyl itaconate, diglycidyl itaconate, monoglycidyl allyl succinate, allyl succinate Diglycidyl succinate, glycidyl p-styrenecarboxylate, allyl glycidyl ether, methallyl glycidyl ether, styrene-p-glycidyl ether, p-glycidyl styrene, 3,4-epoxy-1-butene, 3,4-epoxy-3- Mention may be made of methyl-1-butene, vinylcyclohexene monoxide, aminoethyl methacrylate and aminopropyl methacrylate. Among these, (meth) acrylic acid, maleic anhydride, and glycidyl (meth) acrylate are preferable.

  The amount of the monomer containing an ethylenic double bond and a polar group in the same molecule is not particularly limited, but is preferably 0.1 to 20 parts by weight with respect to 100 parts by weight of the raw material polyolefin resin. When the amount is less than 0.1 part by weight, the adhesiveness when the adhesive film is formed is not sufficient. When the amount is more than 20 parts by weight, a large amount of residual monomer is generated, which adversely affects physical properties.

  When a monomer containing an ethylenic double bond and a polar group in the same molecule is graft-modified to the raw material polyolefin resin, other monomers may be used as long as the object of the present invention is not impaired. Good. Other monomers include hydroxyl group-containing ethylenically unsaturated compounds, amino group-containing ethylenically unsaturated compounds, aromatic vinyl monomers, conjugated diene compounds, vinyl ester compounds, vinyl chloride, oxazoline group-containing unsaturated monomers. Examples include masses.

  When aromatic vinyl monomer is used, molecular chain scission is suppressed during grafting to polypropylene or other molecular chain-breaking polyolefin, and the same ethylenic double bond and polar group are maintained while maintaining a high molecular weight. It is preferable because the monomer contained in the molecule can be introduced at a high ratio.

  Examples of aromatic vinyl monomers include styrene; methyl styrene such as o-methyl styrene, m-methyl styrene, p-methyl styrene, α-methyl styrene, β-methyl styrene, dimethyl styrene, and trimethyl styrene; o -Chlorostyrene such as chlorostyrene, m-chlorostyrene, p-chlorostyrene, α-chlorostyrene, β-chlorostyrene, dichlorostyrene, trichlorostyrene; o-bromostyrene, m-bromostyrene, p-bromostyrene, dibromo Bromostyrene such as styrene and tribromostyrene; fluorostyrene such as o-fluorostyrene, m-fluorostyrene, p-fluorostyrene, difluorostyrene, and trifluorostyrene; o-nitrostyrene, m-nitrostyrene, p-nitrostyrene Nitrostyrenes such as dinitrostyrene and trinitrostyrene; vinylphenols such as o-hydroxystyrene, m-hydroxystyrene, p-hydroxystyrene, dihydroxystyrene and trihydroxystyrene; o-divinylbenzene, m-divinylbenzene and p-divinyl 1 type, or 2 or more types, such as divinylbenzene, such as benzene; diisopropenylbenzene, such as o-diisopropenylbenzene, m-diisopropenylbenzene, and p-diisopropenylbenzene; Of these, methylstyrene such as styrene, α-methylstyrene, p-methylstyrene, divinylbenzene monomer or divinylbenzene isomer mixture is preferable in that it is inexpensive.

  The amount of the aromatic vinyl monomer added is preferably 0.01 to 10 parts by weight and more preferably 0.1 to 5 parts by weight with respect to 100 parts by weight of the polyolefin resin. If the amount added is too small, the graft ratio of the monomer containing an ethylenic double bond and a polar group in the same molecule tends to be poor. On the other hand, when the addition amount exceeds 10 parts by weight, the graft efficiency of the monomer containing an ethylenic double bond and a polar group in the same molecule reaches a saturation range. The above raw material polyolefin resin, a monomer containing an ethylenically unsaturated group and a polar functional group in the same molecule, and if necessary, a vinyl aromatic monomer are heated in the presence of a radical polymerization initiator. By reacting, a modified polyolefin resin can be obtained.

(Radical polymerization initiator)
Examples of radical polymerization initiators include organic peroxides and azo compounds. Illustrative examples include ketone peroxides such as methyl ethyl ketone peroxide and methyl acetoacetate peroxide; 1,1-bis (t-butylperoxy) -3,3,5-trimethylcyclohexane, 1,1-bis (t- Peroxyketals such as butylperoxy) cyclohexane, n-butyl-4,4-bis (t-butylperoxy) valerate, 2,2-bis (t-butylperoxy) butane; permethane hydroperoxide, 1 , 1,3,3-tetramethylbutyl hydroperoxide, diisopropylbenzene hydroperoxide, cumene hydroperoxide, etc .; dicumyl peroxide, 2,5-dimethyl-2,5-di (t-butyl Peroxy) hexane, α, α′-bis ( -Butylperoxy-m-isopropyl) benzene, t-butylcumyl peroxide, di-t-butyl peroxide, dialkyl such as 2,5-dimethyl-2,5-di (t-butylperoxy) hexyne-3 Peroxides; diacyl peroxides such as benzoyl peroxide; peroxydicarbonates such as di (3-methyl-3-methoxybutyl) peroxydicarbonate and di-2-methoxybutylperoxydicarbonate; t-butylperoxy Octate, t-butyl peroxyisobutyrate, t-butyl peroxylaurate, t-butyl peroxy-3,5,5-trimethylhexanoate, t-butyl peroxyisopropyl carbonate, 2,5-dimethyl -2,5-di (benzoylperoxy) hexa , T- butyl peroxy acetate, t- butyl peroxybenzoate, one or more organic peroxides such as peroxy esters such as di -t- butyl peroxy isophthalate and the like.

  Of these, those having a particularly high hydrogen abstraction ability are preferred. Examples of such radical polymerization initiators include 1,1-bis (t-butylperoxy) -3,3,5-trimethylcyclohexane, 1,1. Peroxyketals such as bis (t-butylperoxy) cyclohexane, n-butyl-4,4-bis (t-butylperoxy) valerate, 2,2-bis (t-butylperoxy) butane; dicumyl Peroxide, 2,5-dimethyl-2,5-di (t-butylperoxy) hexane, α, α'-bis (t-butylperoxy-m-isopropyl) benzene, t-butylcumyl peroxide, di Dialkyl peroxides such as t-butyl peroxide, 2,5-dimethyl-2,5-di (t-butylperoxy) hexyne-3; Diacyl peroxides such as nzoyl peroxide; t-butyl peroxyoctate, t-butyl peroxyisobutyrate, t-butyl peroxylaurate, t-butylperoxy-3,5,5-trimethylhexano Ate, t-butylperoxyisopropyl carbonate, 2,5-dimethyl-2,5-di (benzoylperoxy) hexane, t-butylperoxyacetate, t-butylperoxybenzoate, di-t-butylperoxyiso 1 type, or 2 or more types, such as peroxyesters, such as a phthalate, is mention | raise | lifted.

  The addition amount of the radical polymerization initiator is preferably in the range of 0.01 to 10 parts by weight and in the range of 0.2 to 5 parts by weight with respect to 100 parts by weight of the raw polyolefin resin. Is more preferable. If it is less than 0.01 part by weight, the modification does not proceed sufficiently, and if it exceeds 10 parts by weight, fluidity and mechanical properties may be lowered.

  The polymerization reaction for graft modification used in the present invention is not particularly limited, and solution polymerization, impregnation polymerization, melt polymerization and the like can be used. In particular, melt polymerization is simple and preferable.

  In the melt polymerization, a raw material polyolefin resin and a radical polymerization initiator, a monomer containing an ethylenic double bond and a polar group in the same molecule, and an aromatic vinyl monomer to be added as necessary, This is a method of kneading while the resin is melted.

  The heating temperature at the time of melt kneading is preferably 100 to 300 ° C. from the viewpoint that the raw polyolefin resin is sufficiently melted and is not thermally decomposed. The melt kneading time is usually 30 seconds to 60 minutes.

  Further, as the melt kneading apparatus, an extruder, a Banbury mixer, a mill, a kneader, a heating roll, or the like can be used. From the viewpoint of productivity, a method using a single-screw or twin-screw extruder is preferred. Moreover, in order to mix each material sufficiently uniformly, the melt kneading may be repeated a plurality of times.

  The modified polyolefin resin of the present invention has a melting point of 80 to 190 ° C, preferably 90 to 170 ° C. That is, when the melting point is less than 80 ° C., good adhesiveness cannot be maintained in a high temperature range, and when it exceeds 190 ° C., the design of the adherend surface may be impaired due to overheating. Next, the heat of fusion is 1 to 100 J / g, preferably 1 to 50 J / g. That is, when the heat of fusion exceeds 100 J / g, the modified polyolefin resin may be insufficiently melted and peeled off when insert molding.

  Furthermore, it has two or more melting points, and it is preferable to have at least one melting point exceeding 150 ° C. and at least one melting point not exceeding 150 ° C., because the heat resistance is increased without impairing the productivity at the time of insert molding.

  As necessary, the modified polyolefin resin composition includes antioxidants, metal deactivators, phosphorus processing stabilizers, UV absorbers, UV stabilizers, fluorescent brighteners, metal soaps, antacid adsorbents, etc. Additives such as stabilizers, cross-linking agents, chain transfer agents, nucleating agents, lubricants, plasticizers, fillers, reinforcing materials, pigments, dyes, flame retardants, antistatic agents, etc., within a range not impairing the effects of the present invention It may be added. When these stabilizers and additives are used, they may be added to the raw polyolefin resin in advance, or may be added when the raw polyolefin resin is graft-modified, After the modified polyolefin resin is produced, it may be added to the modified polyolefin resin by an appropriate method.

  Furthermore, the modified polyolefin resin can be used even if it is used by mixing with other thermoplastic resins.

  Examples of the thermoplastic resin mixed with the modified polyolefin resin include polypropylene homopolymer, high density polyethylene, low density polyethylene, linear low density polyethylene, poly-1-butene, polyisobutylene, polypentene-1, and polymethylpentene. Poly-α-olefins such as -1; ethylene or α-olefin / α-olefin copolymers such as propylene / butene-1 copolymers having a propylene content of less than 75% by weight; propylene content of less than 75% by weight Ethylene such as ethylene / propylene / 5-ethylidene-2-norbornene copolymer or α-olefin / α-olefin / diene monomer copolymer; polydiene copolymer such as polybutadiene and polyisoprene; styrene / butadiene random copolymer Polymer, styrene / isoprene lander Vinyl monomer / diene monomer random copolymer such as styrene copolymer; vinyl monomer / diene monomer such as styrene / butadiene / styrene block copolymer, styrene / isoprene / styrene block copolymer / Vinyl monomer block copolymer; hydrogenation (vinyl monomer / diene monomer random copolymer) such as hydrogenation (styrene / butadiene random copolymer), hydrogenation (styrene / isoprene random copolymer) Hydrogenation (styrene / butadiene / styrene block copolymer), hydrogenation (styrene / isoprene / styrene block copolymer), etc. (vinyl monomer / diene monomer / vinyl monomer block) Copolymer); acrylonitrile / butadiene / styrene graft copolymer, methyl methacrylate / butadiene / styrene graft copolymer Vinyl monomers such as coalescence / diene monomer / vinyl monomer graft copolymer; polyvinyl chloride, polyvinylidene chloride, polyacrylonitrile, polyvinyl acetate, polyethyl acrylate, polybutyl acrylate, polymethacrylic acid Vinyl polymers such as methyl and polystyrene; vinyl copolymers such as vinyl chloride / acrylonitrile copolymer, vinyl chloride / vinyl acetate copolymer, acrylonitrile / styrene copolymer, methyl methacrylate / styrene copolymer, etc. These can be used alone or in admixture of two or more.

  Among these, since it has high heat resistance when it is used as an adhesive film and it is easy to maintain surface adhesion, vinyl monomers such as styrene / butadiene / styrene block copolymers, styrene / isoprene / styrene block copolymers, etc. / Diene monomer / vinyl monomer block copolymer, hydrogenation (styrene / butadiene / styrene block copolymer), hydrogenation (styrene / isoprene / styrene block copolymer), etc. (vinyl) Monomer / diene monomer / vinyl monomer block copolymer) is preferred.

  The blending amount of the thermoplastic resin mixed with the modified polyolefin resin is preferably 0.1 to 50 parts by weight with respect to 100 parts by weight of the modified polyolefin resin from the viewpoint of adhesiveness when used as an adhesive film. 0.1-30 weight part is preferable.

  Moreover, in this invention, you may mix | blend a tackifier for the purpose of improving the surface adhesive force of an adhesive film. Examples of the tackifier include rosin resins (gum rosin, tall oil rosin, wood rosin, hydrogenated rosin, disproportionated rosin, polymerized rosin, maleated rosin, rosin ester, etc.), terpene phenol resin, terpene resin (α -Polymers such as pinene, β-pinene and limonene), aromatic hydrocarbon modified terpene resins, petroleum resins (aliphatic, alicyclic, aromatic, etc.), coumarone / indene resins, styrene resins, phenols Resins (alkyl phenol, phenol xylene formaldehyde, rosin-modified phenol resin, etc.), xylene resins and the like can be mentioned, and these can be used alone or in combination of two or more. Among these, from the viewpoint of thermal stability, rosin resin, terpene phenol resin, terpene resin, aromatic hydrocarbon modified terpene resin, petroleum resin, hydrogenated petroleum resin are preferable, and are compatible with the modified polyolefin resin of the present invention. And since it can contribute also to adhesion | attachment with polar resin, rosin-type resin and terpene phenol resin are especially preferable.

  The blending amount of the tackifier mixed with the modified polyolefin resin is preferably 0.1 to 50 parts by weight, more preferably 0.1 to 100 parts by weight of the modified polyolefin resin from the viewpoint of heat resistance of the adhesive film. -30 parts by weight is preferred.

(Laminated adhesive film for insert molding)
In the present invention, an adhesive (adhesive film) made of a modified polyolefin resin is laminated with a polyphenylene sulfide resin film and used as a laminated adhesive film for insert molding. In particular, it can be suitably used when the metal member and the polyphenylene sulfide-based resin are integrally formed by insert molding.

  A method for insert molding using the laminated adhesive film for insert molding in the present invention will be described below. After the laminated adhesive film for insert molding is laminated so that the adhesive (adhesive film) surface is in contact with the metal member, the adhesive (adhesive film) part is heated to melt the adhesive (adhesive film) part and adhere to the metal member. The adhesive film laminated metal member is placed in the mold such that the polyphenylene sulfide-based resin film surface is on the void side in the mold, and injection molding of the polyphenylene sulfide-based resin is performed. The method for adhering the adhesive (adhesive film) part to the metal member is not particularly limited, and examples thereof include oven heating, hot pressing, and heat lamination with a roll-to-roll.

  The laminated adhesive film for insert molding in the present invention has a polyphenylene sulfide-based resin film laminated on an adhesive (adhesive film), so that the adhesive film layer melts and flows due to a molten resin that is injection-molded, resulting in poor adhesion. So-called adhesion layer scattering is suppressed, and uniform adhesion can be achieved without unevenness. Moreover, since air is interrupted | blocked in the heating for adhere | attaching on a metal member, deterioration of the adhesive film which consists of modified polyolefin resin can be suppressed. Furthermore, it has moderate hardness compared to a single-layer adhesive film, so it can be easily punched into the desired shape, and if the adhesive film has surface tackiness, it can be attached. Because it does not stick to the hand sometimes, it is excellent in workability. In addition, when the resin to be injection-molded in the insert molding is a polyphenylene sulfide resin, since it is the same kind of resin, the adhesion is good.

  The polyphenylene sulfide-based resin film in the present invention is a polymer mainly composed of a unit in which a phenylene group and a sulfur atom are bonded, and is composed of structural units represented by 80 mol% or more (preferably 90 mol% or more) of repeating units. Refers to a polymer. Although not particularly limited, corona treatment is preferably performed in order to enhance adhesion to the modified polyolefin resin film. When the adhesiveness between the polyphenylene sulfide resin film and the adhesive film made of the modified polyolefin resin is high, inconveniences such as peeling off hardly occur in the processing step.

  The thickness of the laminated adhesive film for insert molding of the present invention is preferably from 30 μm to 300 μm, more preferably from 50 μm to 200 μm, since an adhesive force is sufficiently developed at the time of insert molding and the injection pressure is hardly increased. Further, both the adhesive film layer and the polyphenylene sulfide-based resin film layer have a thickness of 10 μm or more.

  The production method of the laminated adhesive film for insert molding according to the present invention is not particularly limited. For example, after the modified polyolefin resin is formed into a film using an extrusion molding machine, a calendar molding machine, an inflation molding machine, or the like, polyphenylene is used. Examples thereof include a method of laminating with a sulfide-based resin film, and extrusion lamination of a modified polyolefin-based resin to a polyphenylene sulfide-based resin film.

Moreover, when an adhesive film layer has surface adhesiveness, it is preferable to laminate | stack the adhesive release separator on the adhesive film side. The separator for releasing the pressure-sensitive adhesive to be used is not particularly limited, but paper and PET film which have been release-treated by fluorine coating, silicone coating, embossing, blending with talc, etc. are preferably used.
The metal member used in the insert molding using the laminated adhesive film for insert molding in the present invention is not particularly limited as long as the laminated adhesive film for insert molding of the present invention adheres, but for example, gold, silver, Examples include copper, tin, lead, steel, stainless steel, aluminum, aluminum alloy, galvalume steel, and galvanized steel. Of these, steel, stainless steel, aluminum, aluminum alloy, galvalume steel and galvanized steel are preferred. Note that two or more types of insert members made of metal may be used at the same time depending on the application.

  The polyphenylene sulfide resin used in the insert molding using the laminated adhesive film for insert molding in the present invention is not particularly limited, but is a polymer mainly composed of a unit in which a phenylene group and a sulfur atom are bonded. Examples thereof include polymers composed of structural units represented by 50 mol% or more (preferably 70 mol% or more) of units, and these contain fillers such as talc, kaolin, mica, montmorillonite, glass fiber, and carbon fiber. May be.

  Specific examples are shown below, but the present invention is not limited to the following examples. In the following examples and comparative examples, “parts” and “%” represent “parts by weight” and “% by weight”, respectively.

(Measurement of heat of fusion)
For the heat of fusion, the heat of fusion of the modified polyolefin resin composition was measured under the following conditions in accordance with JIS K7122 using a DSC-50 manufactured by Shimadzu Corporation. The same sample was scanned twice and calculated using the second scanning curve.
Temperature increase rate: 20 ° C / min
Target cell: Aluminum

(Measurement of melting point)
0.75 g of the modified polyolefin resin composition was added to 100 mL of o-dichlorobenzene, dissolved by heating at 130 ° C. for 3 hours, then gradually cooled and allowed to stand at 25 ° C. for 8 hours. By filtration, the precipitate was separated into a reprecipitate and a filtrate. The reprecipitate was dried under reduced pressure at 80 ° C. overnight, and the filtrate was concentrated to dryness and collected. About the re-precipitate and the concentrated dried product of the filtrate, the melting point was measured under the following conditions according to JIS K7121 using DSC-50 manufactured by Shimadzu Corporation. The same sample was scanned twice and calculated using the second scanning curve.
Temperature increase rate: 20 ° C / min
Target cell: Aluminum

(Shear strength evaluation)
Shear strength evaluation was performed using AG-2000D manufactured by Shimadzu Corporation at 23 ° C. and a tensile test speed of 50 mm / min. The shear strength was obtained by dividing the shear force (N) by the shear area (mm ² ) (MPa).

(Cross cut test)
The cross-cut test evaluation was performed according to JIS K5400 under the following conditions, and the evaluation score was calculated.
Clearance interval: 2mm
Number of squares: 25
Evaluation score: 10 points (no peeling), 8 points (within 5% defect), 6 points (5-15% defect), 4 (15-35% defect), 2 (35-65 defect) %), 0 points (over 65% defect)

Example 1
Polypropylene ethylene rubber (D340 Chemical V3401, MFR = 8, melting point 100 ° C.) 100 parts, 1,3-di (t-butylperoxyisopropyl) benzene (Nippon Yushi Co., Ltd .: Perbutyl P, 1 minute half-life 175 ° C.) 0 .5 parts were supplied from a hopper port to a twin-screw extruder (manufactured by Nippon Steel, product name LABOTEX30; φ30 mm, L / D = 28) set at a cylinder temperature of 200 ° C. and a screw rotation speed of 250 rpm, and then melt-kneaded, From the middle of the cylinder, 5 parts of styrene and 5 parts of glycidyl methacrylate were added and melt kneaded to obtain modified polyolefin resin pellets (A-1). The obtained resin pellet (A-1) is a hopper of a single screw extruder (product name: Labo plast mill; φ20 mm, L / D = 20) manufactured by a cylinder and a die temperature of 200 ° C. and a screw rotation speed of 100 rpm. The film (A-1T) having a surface adhesiveness of about 13 cm in width and 70 μm in thickness was obtained from a T-type die attached to the tip of the die. The obtained film was heat laminated at 200 ° C. to a polyphenylene sulfide resin film (press sheet, 50 μm thick) to obtain a laminated adhesive film (A-1L).

  The heat of fusion of the resin pellet (A-1) was 4 J / g, and the melting point was 97 ° C. (filtrate concentrated to dryness) because no reprecipitate was recovered.

  The obtained laminated adhesive film (A-1L) was cut out to 25 mm × 12.5 mm, stuck so that the adhesive film side was in contact with the end of the aluminum plate (25 mm × 100 mm), and in a hot air oven set at 200 ° C. Heating was performed for 3 minutes. Polyphenylene sulfide was insert-molded on the heat-treated aluminum plate to obtain a molded body laminated in the order of aluminum plate / laminated adhesive film / polyphenylene sulfide. When the adhesive strength was measured by a shear test, it was 3.0 MPa. The workability of attaching to the aluminum plate was good without sticking to the hand.

  Further, the obtained laminated adhesive film (A-1L) was cut out to 100 mm × 100 mm, stuck so that the adhesive film side was in contact with the aluminum sheet (100 mm × 100 mm), and heated in a hot air oven set at 200 ° C. for 3 minutes. Went. Polyphenylene sulfide was injection-molded on the heat-treated aluminum sheet to obtain a molded body laminated in the order of aluminum sheet / laminated adhesive film / polyphenylene sulfide. A cross cut was made with a cutter knife on the side of the aluminum sheet opposite to the gate, and a cross cut test was conducted.

(Example 2)
Polypropylene ethylene rubber (D340 Chemical V3401, MFR = 8, melting point 100 ° C.) 100 parts, 1,3-di (t-butylperoxyisopropyl) benzene (Nippon Yushi Co., Ltd .: Perbutyl P, 1 minute half-life 175 ° C) 0.1 part, maleic anhydride (manufactured by Wako Pure Chemical Industries, Ltd.) 10 parts with a cylinder temperature of 200 ° C. and a screw rotation speed of 250 rpm, a twin screw extruder with a vent (30 mmφ, L / D = 28, Inc.) Supplied to Nippon Steel Works, product name LABOTEX30) and melt-kneaded, then 5 parts of styrene was added from the middle of the cylinder and melt-kneaded to obtain a modified polyolefin resin pellet (A-2), as in Example 1. A film (A-2T) having a thickness of 70 μm was obtained, and a polyphenylene sulfide-based resin film (press sheet, 50 μm thickness) was formed at 200 ° C. A laminated adhesive film (A-2L) was obtained by heat lamination.

The heat of fusion of the resin pellet (A-2) was 4 J / g, and the melting point was 97 ° C. (filtrate concentrated to dryness) because no reprecipitate was recovered.
The obtained laminated adhesive film (A-2L) was cut out to 25 mm × 12.5 mm, stuck so that the adhesive film side was in contact with the end of the SUS304 plate (25 mm × 100 mm), and in a hot air oven set at 200 ° C. Heating was performed for 3 minutes. Polyphenylene sulfide was insert-molded on the heat-treated SUS304 plate to obtain a molded body laminated in the order of SUS304 plate / laminated adhesive film / polyphenylene sulfide. The adhesive strength was measured by a shear test and found to be 2.9 MPa. Also, the workability of attaching to the SUS304 plate was good without sticking to the hand.

  Further, the obtained laminated adhesive film (A-2L) was cut out to 100 mm × 100 mm, stuck so that the adhesive film side was in contact with the aluminum sheet (100 mm × 100 mm), and heated in a hot air oven set at 200 ° C. for 3 minutes. Went. Polyphenylene sulfide was injection-molded on the heat-treated aluminum sheet to obtain a molded body laminated in the order of aluminum sheet / laminated adhesive film / polyphenylene sulfide. When a cross cut was made on the aluminum sheet side opposite to the gate with a cutter knife and a cross cut test was conducted, the score was 8 points.

(Example 3)
Biaxial shaft with vent in which 90% of the resin pellet (A-1) of Example 1 and 10% of homopolypropylene (Prime Polymer J106G, MFR = 15, melting point 164 ° C.) were set to a cylinder temperature of 200 ° C. and a screw rotation speed of 250 rpm. It is supplied to an extruder (30 mmφ, L / D = 28, manufactured by Nippon Steel Works, product name LABOTEX30) and melt-kneaded to obtain a modified polyolefin resin pellet (A-3). A film (A-3T) having a thickness of 70 μm was obtained, and a laminated adhesive film (A-3L) was obtained by heat laminating at 200 ° C. to a polyphenylene sulfide resin film (press sheet, 50 μm thickness).

  The heat of fusion of the resin pellet (A-3) was 13 J / g, and the melting points were 163 ° C. (reprecipitate) and 97 ° C. (filtrate concentrated to dryness).

  The obtained laminated adhesive film (A-3L) was cut out to 25 mm × 12.5 mm, stuck so that the adhesive film side was in contact with the end of the SUS304 plate (25 mm × 100 mm), and in a hot air oven set at 200 ° C. Heating was performed for 3 minutes. Polyphenylene sulfide was insert-molded on the heat-treated SUS304 plate to obtain a molded body laminated in the order of SUS304 plate / laminated adhesive film / polyphenylene sulfide. When the adhesive strength was measured by a shear test, it was 3.3 MPa. Also, the workability of attaching to the SUS304 plate was good without sticking to the hand.

  Further, the obtained laminated adhesive film (A-3L) was cut out to 100 mm × 100 mm, stuck so that the adhesive film side was in contact with the aluminum sheet (100 mm × 100 mm), and heated in a hot air oven set at 200 ° C. for 3 minutes. Went. Polyphenylene sulfide was injection-molded on the heat-treated aluminum sheet to obtain a molded body laminated in the order of aluminum sheet / laminated adhesive film / polyphenylene sulfide. A cross cut was made with a cutter knife on the side of the aluminum sheet opposite to the gate, and a cross cut test was conducted.

Example 4
Biaxial shaft with vent in which 80% of the resin pellet (A-1) of Example 1 and 20% of homopolypropylene (Prime Polymer S119, MFR = 60, melting point 164 ° C.) were set to a cylinder temperature of 200 ° C. and a screw rotation speed of 250 rpm. It is supplied to an extruder (30 mmφ, L / D = 28, manufactured by Nippon Steel Works, product name LABOTEX30) and melt-kneaded to obtain a modified polyolefin resin pellet (A-4). A film (A-4T) having a thickness of 70 μm was obtained, and a laminated adhesive film (A-4L) was obtained by heat laminating at 200 ° C. to a polyphenylene sulfide resin film (press sheet, 50 μm thickness).

  The heat of fusion of the resin pellet (A-4) was 18 J / g, and the melting points were 164 ° C. (reprecipitation) and 97 ° C. (filtrate concentrated to dryness).

  The obtained laminated adhesive film (A-4L) was cut out to 25 mm × 12.5 mm, stuck so that the adhesive film side was in contact with the end of the SUS304 plate (25 mm × 100 mm), and in a hot air oven set at 200 ° C. Heating was performed for 3 minutes. Polyphenylene sulfide was insert-molded on the heat-treated SUS304 plate to obtain a molded body laminated in the order of SUS304 plate / laminated adhesive film / polyphenylene sulfide. When the adhesive strength was measured by a shear test, it was 3.1 MPa. Also, the workability of attaching to the SUS304 plate was good without sticking to the hand.

  Further, the obtained laminated adhesive film (A-4L) was cut out to 100 mm × 100 mm, stuck so that the adhesive film side was in contact with the aluminum sheet (100 mm × 100 mm), and heated in a hot air oven set at 200 ° C. for 3 minutes. Went. Polyphenylene sulfide was injection-molded on the heat-treated aluminum sheet to obtain a molded body laminated in the order of aluminum sheet / laminated adhesive film / polyphenylene sulfide. A cross cut was made with a cutter knife on the side of the aluminum sheet opposite to the gate, and a cross cut test was conducted.

(Example 5)
Homopolypropylene (Prime Polymer S119, MFR = 60, melting point 164 ° C.) 100 parts, 1,3-di (t-butylperoxyisopropyl) benzene (Nippon Yushi Co., Ltd .: Perbutyl P, 1 minute half-life 175 ° C.) After supplying 5 parts from a hopper port to a twin screw extruder (manufactured by Nippon Steel Works, product name LABOTEX30; φ30 mm, L / D = 28) set to a cylinder temperature of 200 ° C. and a screw rotation speed of 250 rpm, From the middle of the cylinder, 5 parts of styrene and 5 parts of glycidyl methacrylate were added and melt-kneaded to obtain modified polyolefin resin pellets (A-5). The obtained resin pellet (A-5) is a hopper of a single-screw extruder (product name: Labo plast mill; φ20 mm, L / D = 20) manufactured by a cylinder and a die temperature of 200 ° C. and a screw speed of 100 rpm. The film (A-5T) having a surface adhesiveness of about 13 cm in width and 70 μm in thickness was obtained from a T-type die attached to the tip of the die. The obtained film was heat laminated at 200 ° C. to a polyphenylene sulfide resin film (press sheet, 50 μm thick) to obtain a laminated adhesive film (A-5L).

  The amount of heat of fusion of the resin pellet (A-5) was 80 J / g, and the melting point was 164 ° C. (re-precipitate) because the filtrate concentrated dried product was not recovered.

  The obtained laminated adhesive film (A-5L) was cut out to 25 mm × 12.5 mm, and grounded so that the adhesive film side was in contact with the end of the aluminum plate (25 mm × 100 mm). In the heat treatment at 200 ° C. for 3 minutes, peeling portions were recognized and insufficient, so the heat treatment was further applied for 3 minutes for pasting. Polyphenylene sulfide was insert-molded on the heat-treated aluminum plate to obtain a molded body laminated in the order of aluminum plate / laminated adhesive film / polyphenylene sulfide. When the adhesive strength was measured by a shear test, it was 3.0 MPa. The workability of attaching to the aluminum plate was good without sticking to the hand.

  Moreover, the obtained laminated adhesive film (A-5L) was cut out to 100 mm x 100 mm, and grounded so that the adhesive film side might contact an aluminum sheet (100 mm x 100 mm). In the heat treatment at 200 ° C. for 3 minutes, peeling portions were recognized and insufficient, so the heat treatment was further applied for 3 minutes for pasting. Polyphenylene sulfide was injection-molded on the heat-treated aluminum sheet to obtain a molded body laminated in the order of aluminum sheet / laminated adhesive film / polyphenylene sulfide. A cross cut was made with a cutter knife on the side of the aluminum sheet opposite to the gate, and a cross cut test was conducted.

(Comparative Example 1)
The adhesive film (A-1T) before laminating the polyphenylene sulfide resin film of Example 1 was applied to an aluminum plate in the same manner as in Example 1, and heated for 3 minutes in a hot air oven set at 200 ° C. As a result, the adhesive film was slightly yellowed and reduced in viscosity. Polyphenylene sulfide was insert-molded to obtain a molded body laminated in the order of aluminum plate / laminated adhesive film / polyphenylene sulfide, and the adhesive strength measured by a shear test was 0.4 MPa. Also, when this adhesive film was stuck on an aluminum plate, it was sticky to the hand, so workability was poor.

  Further, the adhesive film (A-1T) was cut out to 100 mm × 100 mm, stuck so as to contact an aluminum sheet (100 mm × 100 mm), and heated in a hot air oven set at 200 ° C. for 3 minutes. Polyphenylene sulfide was injection-molded on the heat-treated aluminum sheet to obtain a molded body laminated in the order of aluminum sheet / laminated adhesive film / polyphenylene sulfide. When a cross cut was made on the aluminum sheet side opposite to the gate with a cutter knife and a cross cut test was conducted, most of the film was peeled off and scored 0 points.

(Comparative Example 2)
A film (B) having a thickness of 70 μm was used in the same manner as in Example 1 using unmodified polypropylene ethylene rubber (D340 Chemical V3401, MFR = 8, melting point 100 ° C.) instead of the modified polyolefin resin pellet (A-1). -2T), heat-laminated with a polyphenylene sulfide-based resin film at 200 ° C., and polyphenylene sulfide was insert-molded, but peeled off easily, and the adhesive strength could not be measured by a shear test. Similarly, the cross cut test could not be measured.

The heat of fusion was 5 J / g, and the melting point was 100 ° C. (filtrate concentrated to dryness) because no reprecipitate was recovered.
The laminated adhesive films shown in Examples 1 and 2 could easily form a state in which the polyphenylene sulfide-based resin film was firmly adhered to the metal surface by being laminated with metal and heating. On the other hand, it can be seen that the adhesive film in which the polyphenylene sulfide-based resin film of Comparative Example 1 is not laminated is difficult to set conditions for expressing a strong adhesive force without deteriorating the resin when heat-bonded. In Comparative Example 2, it can be seen that since the polyolefin resin is not modified, the polyphenylene sulfide resin is not adhesive.

Claims (8)

A laminated adhesive film for insert molding in which an adhesive is laminated on a polyphenylene sulfide-based resin film. The laminated adhesive film for insert molding is laminated so that the adhesive surface is in contact with a metal member, and then heated to form an adhesive. The adhesive film laminated metal member for insert molding is placed in the mold so that the surface of the polyphenylene sulfide-based resin film is on the void side in the mold, and the polyphenylene sulfide-based resin is bonded. A laminated adhesive film for insert molding characterized by injection molding. The laminated adhesive for insert molding according to claim 1, wherein the adhesive contains a modified polyolefin resin graft-modified using a monomer containing an ethylenic double bond and a polar group in the same molecule. the film. 3. The adhesive contains a modified polyolefin resin graft-modified with an aromatic vinyl monomer and a monomer containing an ethylenic double bond and a polar group in the same molecule. The laminated adhesive film for insert molding as described. The monomer containing the ethylenic double bond and the polar group in the same molecule is at least one selected from (meth) acrylic acid, maleic anhydride, and glycidyl (meth) acrylate. Laminated adhesive film for insert molding. The laminated adhesive film for insert molding according to claim 2, wherein the heat of fusion of the modified polyolefin resin is in the range of 1 to 50 J / g. The modified polyolefin resin composition according to any one of claims 2 to 5 has two or more melting points, and has at least one melting point exceeding 150 ° C and melting point not exceeding 150 ° C. A laminated adhesive film for insert molding. The laminated adhesive film for insert molding according to claim 1, which has a thickness of 30 to 300 μm. The laminated adhesive film for insert molding according to claim 1 is laminated so that the adhesive surface is in contact with the metal member, and then heated to melt the adhesive part and adhere to the metal member, and the adhesive for insert molding An insert molding method in which a film-laminated metal member is placed in a mold such that the polyphenylene sulfide-based resin film surface is on the inner cavity side, and the polyphenylene sulfide-based resin is injection-molded.