JP2018501326A - 熱可塑性複合材料、熱可塑性複合材料を調製するための方法、及び射出成形品 - Google Patents
熱可塑性複合材料、熱可塑性複合材料を調製するための方法、及び射出成形品 Download PDFInfo
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- JP2018501326A JP2018501326A JP2017523265A JP2017523265A JP2018501326A JP 2018501326 A JP2018501326 A JP 2018501326A JP 2017523265 A JP2017523265 A JP 2017523265A JP 2017523265 A JP2017523265 A JP 2017523265A JP 2018501326 A JP2018501326 A JP 2018501326A
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Abstract
Description
(a)熱可塑性樹脂と中空ガラス微小球とを溶融混合して溶融混合物を得る工程と、
(b)非セルロース系有機繊維を溶融混合物と混合して溶融混合物を含浸させ、熱可塑性樹脂、中空ガラス微小球、及び非セルロース系有機繊維を含有する熱可塑性複合材料を得る工程と、を含む。
一実施形態において、本明細書に記載の熱可塑性複合材料は、熱可塑性複合材料の総重量を100重量%として、熱可塑性樹脂35〜75重量%、非セルロース系有機繊維5〜45重量%、及び中空ガラス微小球5〜20重量%を含み得る。
本開示の他の一態様によると、熱可塑性複合材料を調製するための方法を提供し、この方法は、
(a)熱可塑性樹脂と中空ガラス微小球とを溶融混合して溶融混合物を得る工程と、
(b)非セルロース系有機繊維を溶融混合物と混合して溶融混合物を含浸させ、熱可塑性樹脂、中空ガラス微小球、及び非セルロース系有機繊維を含有する熱可塑性複合材料を得る工程と、を含む。
本開示の他の一態様は、射出成形品である。本開示の更なる態様は、超臨界発泡射出成形工程に付された射出成形品である。
本開示のいくつかの実施形態によると、従来技術における既存の射出成形プロセスを用い、本開示によって提供される熱可塑性複合材料に射出成形工程を実施してもよい。例えば、3つの加熱領域を含む、Chen Hsong Machinery Co.LtdのMJ−20Hプラスチック射出成形機を用い、本開示によって提供される熱可塑性複合材料に射出成形工程を実施してもよい。本開示のいくつかの実施形態によると、超臨界発泡プロセスを更に取り入れ、本開示によって提供される熱可塑性複合材料に超臨界発泡射出成形工程を実施してもよい。
3つの加熱領域を有する、Chen Hsong Machinery Co.LtdのMJ−20Hプラスチック射出成形機を用い、実施例1〜11及び比較例1〜3の熱可塑性複合材料に射出成形工程を実施した。プロセスパラメーターを表2に示す。
射出ポートに3つの加熱領域及び2つの射出ノズル領域を有するMucell(登録商標)対応のEngel ES200/100TL射出成形機を使用し、実施例12〜15並びに比較例5及び6の熱可塑性複合材料に射出成形工程を実施した。プロセスパラメーターを表5に示す。
射出成形品について様々な特性試験を実施し、曲げ弾性率、破断伸び、ノッチ付き衝撃強度、及び密度を含む物理的特性を評価した。曲げ弾性率はASTM D−790に従って評価し、破断伸びはASTM D−638に従って評価し、かつノッチ付き衝撃強度はASTM D−256に従って評価した。具体的には、各ASTMについての厚さ3.2mmの標準射出成形試料バーを、20℃及び湿度50%の環境に48時間定置した。次に、曲げ弾性率及び破断伸びについて、Instron 5969(Norwood,MA)万能試験機において試験を実施した。ノッチ付き衝撃試験は、Model PIT550A−2振り子衝撃試験機(Shenzhen Wance Testing Machine Co.,Ltd.)において、インパクトハンマー2.75Jで実施した。
射出成形部品の密度を、試料の体積で除した、既知の重量の射出成形部品から測定した。試料の体積は、LyondellBasellの無充填ホモポリマーポリプロピレン「Profax」6523の既知の成形重量と、置換媒体としてヘリウムガスを用い、Micromeritics AccuPyc 1330 Gas Pycnometerによって10ccのカップ内で測定したその既知の密度(0.9g/cc)と、から測定した。50kNロードセル及び引張グリップ、及び三点曲げグリップを有するInstronフレームを、引張伸び特性及び曲げ弾性率特性に対してそれぞれ使用した。引張試験モードにおいてはASTM D−638規格に記載の試験手順に従ったが、歪みゲージは使用せず、代わりにグリップ分離距離を使用して試料の伸び率を求めた。曲げ弾性率は、ASTM D−638において典型的に使用されるASTM type 1試験片が使用試験片である、ASTM D−790三点曲げ試験の修正版を用いて測定した。Tinius Olsen model IT503衝撃テスターとその標本ノッチャーを使用し、ASTM D−256に従って、成型部品の室温ノッチ付きアイゾット衝撃強度を測定した。
iM16k中空ガラス微小球及びPA(ナイロン)66繊維の両方を、120℃で2時間乾燥した。
実施例2〜5は実施例1と同様に作製し、試験した。ただし、表6に示すように、PA(ナイロン)66繊維は増量し、PPブレンド1は減量した。
実施例6及び7は実施例1〜5と同様に作製し、試験した。ただし、中空ガラス微小球の量は変更した(また、表6に示すように、PPブレンド1によって補正した)。
この実施例は、中空ガラス微小球を含むペレットと含まないペレットをブレンドする代替プロセスを実証するものである。iM16k中空ガラス微小球及びPA(ナイロン)66繊維の両方を、120℃で2時間乾燥した。
この実施例は、実施例1〜5と同様に作製し、試験した。ただし、988Aガラス繊維は、表6に示した量で、PA(ナイロン)66繊維と共にダイに供給した。
この実施例は、実施例1〜5と同様に作製し、試験した。ただし、表6に示すように、より多くのPOE強靭化剤を使用し、異なる熱可塑性樹脂を使用した(Dowlex IP_41)。
この実施例は、実施例1〜5と同様に作製し、試験した。ただし、PA(ナイロン)66繊維の代わりに、異なる非セルロース系有機繊維LS 056を表6に示した量で使用した。
この比較例は、実施例1〜5と同様に実施した。ただし、繊維を使用せず、中空ガラス微小球を表6に示した配合量でシランを用いて前処理した。KBM−903シランカップラーを使用してiM16k中空ガラス微小球を表面処理し、次いで撹拌した。
この比較例は、実施例1〜5と同様に表6に示した配合量で実施した。ただし、非セルロース系有機繊維を使用せず、代わりに988Aガラス繊維を使用した。
これらの実施例は、表6に示した量である以外は実施例1〜5と同様に作製され、表6に示したように、わずかに異なる熱可塑性樹脂PPブレンドを用いた。
射出成形試験試料バーを、PPブレンドの代わりにHostacom TRC 787N E熱可塑性複合材料を使用し、繊維及び中空ガラス微小球は使用せず、表4のパラメーター及び表6の量で調製した。
射出成形試験試料バーを、PPブレンドの代わりにHostacom TRC 787N E熱可塑性複合材料を使用し、繊維及び中空ガラス微小球は使用せず、表5のパラメーター及び表6の量で調製した。超臨界CO2発泡の量は、11.7重量%に調節した。配合量を表6に示す。
Claims (15)
- 熱可塑性複合材料であって、前記熱可塑性複合材料の総重量を100重量%として、熱可塑性樹脂35〜75重量%、非セルロース系有機繊維5〜45重量%、及び中空ガラス微小球5〜20重量%を含む、熱可塑性複合材料。
- 前記熱可塑性樹脂が、ポリプロピレン、ポリエチレン、ポリ塩化ビニル、ポリスチレン、エチレン−酢酸ビニルコポリマー、アクリロニトリル−スチレン−ブタジエンコポリマー、及びナイロン6から選択される1つ以上である、請求項1に記載の熱可塑性複合材料。
- 前記非セルロース系有機繊維が、ナイロン66繊維、ポリエチレンテレフタレート繊維、ポリプロピレンテレフタレート繊維、ポリフェニレンサルファイド繊維、ポリエーテルエーテルケトン繊維、及びアラミド繊維から選択される1つ以上である、請求項1に記載の熱可塑性複合材料。
- 前記非セルロース系有機繊維の高温側の融解ピークが、前記熱可塑性樹脂の融解ピークより60℃以上高い、請求項1に記載の熱可塑性複合材料。
- 前記非セルロース系有機繊維の直径が5〜70μmである、請求項1に記載の熱可塑性複合材料。
- 前記中空ガラス微小球が、粒径5〜100μm、密度0.3〜0.8g/cm3、及び耐圧強度37.9MPa超である、請求項1に記載の熱可塑性複合材料。
- 前記熱可塑性複合材料が、無機充填剤、相溶化剤、強靭化剤、及び抗酸化剤のうちの1つ以上を更に含む、請求項1に記載の熱可塑性複合材料。
- 前記無機充填剤が、ガラス繊維、炭素繊維、玄武岩繊維、タルク、及びモンモリロナイトから選択される1つ以上である、請求項7に記載の熱可塑性複合材料。
- 前記非セルロース系有機繊維がペレットの長さ方向に伸長し、前記非セルロース系有機繊維の長さが5〜25mmである、請求項1に記載の熱可塑性複合材料。
- 前記熱可塑性複合材料が、前記熱可塑性複合材料の総重量を100重量%として、前記非セルロース系有機繊維15〜30重量%、及び前記中空ガラス微小球5〜10重量%を含む、請求項1に記載の熱可塑性複合材料。
- 熱可塑性複合材料を調製するための方法であって、
(a)熱可塑性樹脂と中空ガラス微小球とを溶融混合して溶融混合物を得る工程と、
(b)非セルロース系有機繊維を前記溶融混合物と混合して前記溶融混合物を含浸させ、前記熱可塑性樹脂、前記中空ガラス微小球、及び前記非セルロース系有機繊維を含有する熱可塑性複合材料を得る工程と、を含む方法。 - 前記工程(a)において、熱可塑性樹脂と中空ガラス微小球とを、無機充填剤、相溶化剤、強靭化剤、及び抗酸化剤のうちの1つ以上を含む補助剤と共に溶融混合して溶融混合物を得て、前記工程(b)において、前記溶融混合物と非セルロース系有機繊維とを混合して前記溶融混合物を前記非セルロース系有機繊維に含浸させ、前記熱可塑性樹脂、前記中空ガラス微小球、前記補助剤、及び前記非セルロース系有機繊維を含有する熱可塑性複合材料を得る、請求項11に記載の熱可塑性複合材料を調製するための方法。
- 前記工程(a)が二軸押出機において実施される、請求項11に記載の熱可塑性複合材料を調製するための方法。
- 射出成形工程に付された、請求項1〜10のいずれか一項に記載の熱可塑性複合材料を含む、射出成形品。
- 超臨界発泡射出成形工程に付された、請求項14に記載の射出成形品。
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- 2014-10-31 US US15/523,122 patent/US10400091B2/en not_active Expired - Fee Related
- 2014-10-31 CA CA2965841A patent/CA2965841A1/en not_active Abandoned
- 2014-10-31 WO PCT/CN2014/090028 patent/WO2016065614A1/en active Application Filing
- 2014-10-31 BR BR112017008785A patent/BR112017008785A2/pt not_active Application Discontinuation
- 2014-10-31 CN CN201480083091.8A patent/CN107207781A/zh active Pending
- 2014-10-31 EP EP14905017.1A patent/EP3212706B1/en active Active
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EP3212706A1 (en) | 2017-09-06 |
BR112017008785A2 (pt) | 2017-12-26 |
CN107207781A (zh) | 2017-09-26 |
JP6667518B2 (ja) | 2020-03-18 |
EP3212706B1 (en) | 2020-09-02 |
KR20170077189A (ko) | 2017-07-05 |
EP3212706A4 (en) | 2018-06-06 |
US20170321038A1 (en) | 2017-11-09 |
ES2828676T3 (es) | 2021-05-27 |
MX2017005391A (es) | 2017-08-16 |
US10400091B2 (en) | 2019-09-03 |
CA2965841A1 (en) | 2016-05-06 |
WO2016065614A1 (en) | 2016-05-06 |
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