JP4627908B2 - Screw kneader and method for producing resin composition using the same - Google Patents

Screw kneader and method for producing resin composition using the same Download PDF

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Publication number
JP4627908B2
JP4627908B2 JP2001072179A JP2001072179A JP4627908B2 JP 4627908 B2 JP4627908 B2 JP 4627908B2 JP 2001072179 A JP2001072179 A JP 2001072179A JP 2001072179 A JP2001072179 A JP 2001072179A JP 4627908 B2 JP4627908 B2 JP 4627908B2
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Japan
Prior art keywords
screw
kneading
resin composition
barrel
full flight
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JP2001072179A
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Japanese (ja)
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JP2002264126A (en
Inventor
敦弘 高田
竜磨 黒田
暁 花田
武 山田
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Sumitomo Chemical Co Ltd
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Sumitomo Chemical Co Ltd
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Priority to JP2001072179A priority Critical patent/JP4627908B2/en
Priority to US10/093,534 priority patent/US7049361B2/en
Priority to KR1020020013588A priority patent/KR100846648B1/en
Priority to TW091104737A priority patent/TWI228071B/en
Priority to CNB021056587A priority patent/CN100473516C/en
Priority to EP02005363A priority patent/EP1241220A3/en
Priority to CNA2005101370810A priority patent/CN1817949A/en
Priority to EP08100008A priority patent/EP1905798A3/en
Publication of JP2002264126A publication Critical patent/JP2002264126A/en
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Publication of JP4627908B2 publication Critical patent/JP4627908B2/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25Component parts, details or accessories; Auxiliary operations
    • B29C48/36Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/50Details of extruders
    • B29C48/505Screws
    • B29C48/625Screws characterised by the ratio of the threaded length of the screw to its outside diameter [L/D ratio]
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25Component parts, details or accessories; Auxiliary operations
    • B29C48/285Feeding the extrusion material to the extruder
    • B29C48/297Feeding the extrusion material to the extruder at several locations, e.g. using several hoppers or using a separate additive feeding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25Component parts, details or accessories; Auxiliary operations
    • B29C48/36Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/465Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using rollers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25Component parts, details or accessories; Auxiliary operations
    • B29C48/36Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/50Details of extruders
    • B29C48/505Screws
    • B29C48/535Screws with thread pitch varying along the longitudinal axis
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25Component parts, details or accessories; Auxiliary operations
    • B29C48/36Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/50Details of extruders
    • B29C48/505Screws
    • B29C48/57Screws provided with kneading disc-like elements, e.g. with oval-shaped elements
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25Component parts, details or accessories; Auxiliary operations
    • B29C48/36Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/395Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders
    • B29C48/40Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders using two or more parallel screws or at least two parallel non-intermeshing screws, e.g. twin screw extruders
    • B29C48/405Intermeshing co-rotating screws

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Processes Of Treating Macromolecular Substances (AREA)

Description

【0001】
【発明の属する技術分野】
本発明は、バレル、及び該バレル中に装填されており、少なくともフルフライトスクリューとニーディングブロックとを備えたスクリューを有するスクリュー混練装置及びこれを用いた樹脂組成物の製造方法に関する。
【0002】
【従来の技術】
高強度、高弾性のフィルムの材料として、超高分子量のポリオレフィンが知られている。しかし、超高分子量のポリオレフィンは強度が強すぎるため、薄膜化や延伸などの加工が困難であるという問題があった。
【0003】
【発明が解決しようとする課題】
しかしながら、超高分子量ポリオレフィンのような難加工性ポリオレフィンと、比較的低分子量のポリオレフィンワックスとは一般に相溶性が悪く、これらのブレンド物から製造したフィルムを延伸したときに、孔や破れ等の欠陥が生じやすく、適度な引張剛性を保てないという問題があった。
【0004】
本発明は上記実情に鑑みてなされたものであり、その課題は、フィルムに成形したものを延伸したときに、孔や破れ等の欠陥が生じにくい高弾性率を有する樹脂組成物を製造することのできるスクリュー混練装置及びこれを用いた樹脂組成物の製造方法を提供することである。
【0005】
【課題を解決するための手段】
上記課題を解決するため、本発明に係るスクリュー混練装置は、
バレル、及び該バレル中に装填されており、少なくともフルフライトスクリューとニーディングブロックとを備えたL/Dが30以上のスクリューを有するスクリュー混練装置であって、
前記ニーディングブロックはLn /Dが5以上、
前記フルフライトスクリューはLf /Dが3以上で、かつ、下記の両式を満たすことを特徴とするものである。
【0006】
35≦α≦60
0.15≦(M/D)≦0.25
ただし、αはフルフライトスクリューのフライト角(゜)、Mはフルフライトスクリューのスクリュー溝の深さ(mm)、Lはスクリュー全長(mm)、Ln はニーディングブロックの合計長さ(mm)、Lf はフルフライトスクリューの合計長さ(mm)、Dはバレルの直径(mm)である。
【0007】
本発明者らは、フィルムに成形したものを延伸したときに、孔や破れ等の欠陥が生じにくい高弾性率を有する樹脂組成物を製造する技術を開発すべく鋭意検討した結果、上記のような特定のスクリューデザインを有するスクリュー混練装置を用いることにより、上記課題を解決することができることを見出した。
【0008】
上記課題を解決するため、本発明に係る樹脂組成物の製造方法は、
下記条件を満たす混合樹脂100重量部と、無機充填剤10〜300重量部とを上記特徴を有するスクリュー混練装置を用いて混練することを特徴とするものである。
【0009】
(条件)重量平均分子鎖長が2850nm以上のポリオレフィン[A]の、重量平均分子量700〜6000のポリオレフィンワックス[B]に対する重量比
[A]/[B]は、50/50〜90/10である。
【0010】
熱可塑性樹脂を混練するのに使用される一般的な混練装置では、上記[A]ポリオレフィンと[B]ポリオレフィンワックスとを上記のような比率で均一に混練することが困難であった。しかし、本発明によるスクリュー混練装置を用いることにより、上記比率で配合された混合樹脂を均一に混練することができるようになった。
【0011】
かかる条件により混練を行うことで、高弾性率を有する樹脂組成物を得ることができ、これをフィルム化し、さらに延伸することにより所望の多孔性フィルムを得ることができる。
【0012】
本発明の好適な実施形態として、前記本発明に係る混練装置を使用して、下記式を満たす条件下に前記混合樹脂と前記無機充填剤とを混練する形態があげられる。
【0013】
5×104 ≦[E/(D/1000)3 ]≦3×105
ただし、Eは混練装置からの樹脂組成物の吐出量(kg/hr)、Dは混練装置のバレルの直径(mm)である。
【0014】
かかる条件下で混練することにより、高弾性率を有する樹脂組成物を得ることができる。なお、吐出量の測定は下記の通り行う。
【0015】
(1)ダイスから出てくる樹脂を36秒間搾取する。
(2)電子秤で重量を測定する。
(3)1時間あたりの吐出量(kg/hr)に換算する。
【0016】
【発明の実施の形態】
図1は、多孔性フィルムを製造するための製造ラインを示す模式図である。本製造ラインは、工程順に混練工程1、圧延工程2、第1のスリット工程3、延伸工程4、第2のスリット工程5の各工程から成っている。
【0017】
混練工程1には、スクリュー混練装置10が使用され、この混練装置は、混合樹脂を供給する第1ホッパー11と無機充填剤を供給する第2ホッパー12とを備えている。スクリュー混練装置10は、二軸のスクリュー13を備えており、各ホッパー11,12から供給される混合樹脂と無機充填剤とを強混練して押し出す。混練して得られた樹脂組成物は、ペレット化される。
【0018】
圧延工程2には、スクリュー押し出し装置20が用いられる。この装置20には、混練工程1により得られた樹脂組成物のペレットを投入するホッパー21と、スクリュー22とを備えている。この装置20により、 樹脂組成物を混練しつつ前方に押し出し、ダイ23により棒状またはシート状にして排出し、圧延ロール機構24により圧延して圧延フィルムを得る。
【0019】
第1のスリット工程3では、圧延工程2で得られた圧延フィルムを幅方向で2つにカットし、例えば600mm幅の圧延フィルムから300mm幅のフィルムを2丁得る。
【0020】
延伸工程4では、所定の温度条件下で例えば300mm幅のフィルムを幅方向で4〜5倍に延伸する。これにより、サブミクロンオーダーの孔が形成された多孔性フィルムを得ることができる。
【0021】
第2のスリット工程5では、得られた多孔性フィルムを所望の幅寸法にカットする。
【0022】
<樹脂組成物>
混練装置10を用いて製造する樹脂組成物について説明する。この樹脂組成物は、混合樹脂100重量部と、無機充填剤10〜300重量部とを混練することにより得られる。
【0023】
混合樹脂としては、重量平均分子鎖長が2850nm以上のポリオレフィン[A]の、重量平均分子量700〜6000のポリオレフィンワックス[B]に対する重量比[A]/[B]が50/50〜90/10であるものを用いる。
【0024】
ポリオレフィンを構成するオレフィンとしては、エチレン、プロピレン、ブテン、ヘキセンなどが挙げられる。ポリオレフィンの具体例としては、低密度ポリエチレン、線状ポリエチレン(エチレン−α−オレフィン共重合体)、高密度ポリエチレン等のエチレン系樹脂、ポリプロピレン、エチレン−プロピレン共重合体等のプロピレン系樹脂、ポリ(4 −メチルペンテン−1)、ポリ(ブテン−1)およびエチレン−酢酸ビニル共重合体などが挙げられる。
【0025】
本発明のスクリュー混練装置を用いることにより、分子鎖長が2850nm以上のポリオレフィンを10重量%以上含有し、それから形成したフィルム状物を延伸したときに、孔や破れ等の生じにくい高弾性率を有する樹脂組成物を製造することができる。
【0026】
分子鎖長が2850nm以上のポリオレフィン(本発明において、長分子鎖ポリオレフィンという。)は特に強度に優れ、このような長分子鎖ポリオレフィンを樹脂成分全体の10重量%以上、より好ましくは20重量%以上含有している樹脂組成物は強度が顕著に優れるので、多用途に利用することができる。前記長分子鎖ポリオレフィンを樹脂成分全体の30重量%以上含有する樹脂組成物は、特に強度が高いので一層好ましい。尚、ポリオレフィンの分子鎖長、重量平均分子鎖長、分子量、および重量平均分子量はGPC(ゲルパーミエーションクロマトグラフィー)により測定し、特定分子鎖長範囲または特定分子量範囲のポリオレフィンの含有量(重量%)はGPC測定により得られる分子量分布曲線の積分により求めることができる。
【0027】
混合樹脂100重量部に対して無機充填剤を10〜300重量部添加すると、従来の加工方法では、メルトフラクチャー、あるいはスダレ状に孔が空く等の問題が発生して、膜厚精度の良いフィルムが得られなかったが、本発明方法によると膜厚精度が良好であるのみならず、剛性にも優れたフィルムが得られる。無機充填剤の添加量が10重量部未満では剛性を向上させるのに不十分であり、300重量部を越えて添加しても、添加量の割に剛性の向上効果が低い。
【0028】
無機充填剤としては炭酸カルシウム、タルク、クレー、カオリン、シリカ、ハイドロタルサイト、珪藻土、炭酸マグネシウム、炭酸バリウム、硫酸カルシウム、硫酸マグネシウム、硫酸バリウム、水酸化アルミニウム、水酸化マグネシウム、酸化カルシウム、酸化マグネシウム、酸化チタン、アルミナ、マイカ、ゼオライト、ガラス粉、酸化亜鉛などを使用できる。
【0029】
<スクリュー混練装置の構成>
次に、 スクリュー混練装置10のスクリュー13の構成の詳細を説明する。図2はスクリュー13の詳細を示す図である。
【0030】
スクリュー13は、エレメントと呼ばれる部品を、スクリュー軸と呼ばれる軸上に固定することにより構成される。
【0031】
図2において、符号Pで示されるエレメントはフルフライトスクリューである。フルフライトスクリューは、 その全長にわたって螺旋状に溝が形成されたスクリューエレメントである。符号DPで示されるエレメントは、符号Pで示されるフルフライトスクリューよりも深い溝が形成されたフルフライトスクリューを示す。このような深溝のフルフライトスクリューを使用することにより樹脂の滞留時間を長くすることができる。フルフライトスクリューは図3に示すような形状を有しており、混練材料を前方、すなわち混練装置の下流に向けて送り出す機能を有する。図3において、Dはバレルの直径(内径)(mm)、Dsはスクリューの直径(mm)、Mはスクリュー溝の深さ(mm)、αはスクリューのフライト角(゜)、Hはバレル内面とスクリュー溝の底部との距離、δfはスクリュー山とバレル内面との距離(mm)である。
【0032】
上記パラメータのうち、αは樹脂を送り出すスピードに関係し、αが小さくなるほど樹脂を送り出すスピードは遅くなり、その結果、樹脂の滞留時間は長くなり、樹脂の混練度は向上する。ただし、αをあまり小さくしすぎると生産効率が悪くなる。Mの大きさも樹脂を送り出すスピードと練りの強さに関係するパラメータである。
【0033】
符号NDで示されるエレメントは、ニーディングブロックである。ニーディングブロックは、通常は図4に示されるように、同一の断面形状を有する複数のニーディングディスクが、それぞれのディスクの幾何学的中心が共通の直線上に位置し、該直線の周りに一定方向に互いに所定の角度のずれを持って順次ずらされて重ねられた形状を有している。なお、各ニーディングディスクの厚さは同じでもよいし、異なっていてもよい。
【0034】
スクリューがバレル内に装填された状態において、ニーディングブロックを構成するニーディングディスクとバレルの間隔には分布があり、その間隔が最も小さくなるところで、最も強く混練材料にせん断応力が作用する。
【0035】
符号LNDで示されるエレメントは、符号NDのニーディングブロックにおけるニーディングディスクの積み重ねのねじれとは逆方向にねじれるようにニーディングディスクが重ねられた形状を有するニーディングブロックである。二種類のニーディングブロックNDおよびLNDを組み合わせて使用することにより、一種類のニーディングブロックの場合よりも混練材料の滞留時間を長くすることができ、より強いせん断応力を与えることができる。
【0036】
符号SNDで示されるエレメントもニーディングブロックであるが、その特徴は、隣接するニーディングディスクを比較したときに、混練装置の下流側のニーディングディスクが上流側のニーディングディスクよりも薄いことである。このようなニーディングブロックSNDを使用することにより、混練材料の下流側への流れ速度を調整することができ、混練材料によりよく圧縮・伸長作用を与えることができる。
【0037】
なお、図4は二軸押出機に装填された状態のニーディングブロックを示す図であるが、スクリュー軸は描かれていない。
【0038】
本発明のスクリュー混練装置では、スクリュー全体のL/Dは30以上、フルフライトスクリューのLf /Dは3以上、ニーディングブロックのLn /Dは5以上に設定する。さらに、フルフライトスクリューにおいては、35≦α≦60かつ、0.15≦(M/D)≦0.25となるようにパラメータを設計する。L/Dが大きいほど滞留時間は長くなる。ここで、Ln はニーディングブロックのエレメント長(mm)(ただし、スクリューに二以上のニーディングブロックが含まれる場合には、それらのエレメント長の合計値)、Lf はフルフライトスクリューのエレメント長(mm)(ただし、スクリューに二以上のフルフライトスクリューが含まれる場合には、それらのエレメント長の合計値)である。上記のようにパラメーターを選択することにより、フィルムやシートに成形したときに高弾性率を有する樹脂組成物を得ることができる。
【0039】
上記構成を有するスクリュー混練装置を用いて、混合樹脂と前記無機充填剤とを混練する場合、下記式を満たす条件下で行うことが好ましい。
【0040】
5×104 ≦[E/(D/1000)3 ]≦3×105
ただし、Eは混練装置からの樹脂組成物の吐出量(kg/hr)、Dは混練装置のバレルの直径(mm)である。これにより、高弾性を有する樹脂組成物を得ることができる。吐出量Eとは、混練装置内のバレル内部でどれだけの量の樹脂を前方に押し出すかを示すパラメータである。
【0041】
本発明に係る混練装置は、全く同一のスクリューエレメントから構成される2本のスクリューからなる二軸スクリューのものが最も好ましいが、本発明の要件を満たしていれば、単軸式であっても、3本以上のスクリューを有していてもかまわない。
【0042】
また、2本以上のスクリューから構成される混練装置においては、スクリューの回転方向は同じで、軸中心間の距離がスクリューエレメントの最も大きい径の和よりも短く、図4(a)のように各スクリューエレメントの凸部と凹部が噛み合う形式のいわゆる噛み合い型のものが最も好ましいが、2本以上のスクリューの回転方向が同じで軸中心間の距離がスクリューエレメントの最も大きい径の和よりも大きい、いわゆる非噛み合い型のスクリュー形式のものでもよいし、2本以上のスクリューの回転方向が異なり、かつ非噛み合い型のスクリュー形式のものでもかまわない。
【図面の簡単な説明】
【図1】多孔性フィルムの製造工程を示す模式図
【図2】スクリュー混練装置のスクリューの詳細を示す図
【図3】フルフライトディスクの構成を示す図
【図4】ニーディングディスクの構成を示す図
【符号の説明】
10 スクリュー混練装置
13 スクリュー
ND ニーディングディスク
P フルフライトディスク
α フライト角
M スクリュー溝
D バレル直径
[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a barrel, a screw kneading apparatus having a screw provided in the barrel and having at least a full flight screw and a kneading block, and a method for producing a resin composition using the screw kneading apparatus.
[0002]
[Prior art]
Ultrahigh molecular weight polyolefin is known as a material for high-strength and high-elasticity films. However, since ultra-high molecular weight polyolefin is too strong, there is a problem that processing such as thinning and stretching is difficult.
[0003]
[Problems to be solved by the invention]
However, difficult-to-process polyolefins such as ultra-high molecular weight polyolefins and polyolefin waxes of relatively low molecular weight are generally poorly compatible, and defects such as holes and tears occur when films made from these blends are stretched. There is a problem that an appropriate tensile rigidity cannot be maintained.
[0004]
The present invention has been made in view of the above circumstances, and its object is to produce a resin composition having a high elastic modulus that is less prone to defects such as holes and tears when stretched into a film. It is providing the manufacturing method of the screw kneading apparatus which can be used, and a resin composition using the same.
[0005]
[Means for Solving the Problems]
In order to solve the above problems, the screw kneading apparatus according to the present invention is:
A screw kneading apparatus having a barrel and a screw having an L / D of 30 or more, which is loaded in the barrel and includes at least a full flight screw and a kneading block,
The kneading block L n / D is 5 or more,
The full flight screw is characterized in that L f / D is 3 or more and satisfies both the following formulas.
[0006]
35 ≦ α ≦ 60
0.15 ≦ (M / D) ≦ 0.25
Where α is the flight angle of the full flight screw (°), M is the depth of the screw groove of the full flight screw (mm), L is the total length of the screw (mm), and L n is the total length of the kneading block (mm) , L f is the total length (mm) of the full flight screw, and D is the diameter (mm) of the barrel.
[0007]
As a result of intensive investigations to develop a technique for producing a resin composition having a high elastic modulus that is less likely to cause defects such as holes and tears when the film-formed one is stretched, It has been found that the above problem can be solved by using a screw kneading apparatus having a specific screw design.
[0008]
In order to solve the above problems, a method for producing a resin composition according to the present invention comprises:
100 parts by weight of a mixed resin satisfying the following conditions and 10 to 300 parts by weight of an inorganic filler are kneaded using a screw kneader having the above characteristics.
[0009]
(Condition) The weight ratio [A] / [B] of the polyolefin [A] having a weight average molecular chain length of 2850 nm or more to the polyolefin wax [B] having a weight average molecular weight of 700 to 6000 is 50/50 to 90/10. is there.
[0010]
In a general kneading apparatus used for kneading a thermoplastic resin, it has been difficult to uniformly knead the [A] polyolefin and the [B] polyolefin wax at the above ratio. However, by using the screw kneader according to the present invention, the mixed resin blended at the above ratio can be uniformly kneaded.
[0011]
By kneading under such conditions, a resin composition having a high elastic modulus can be obtained, and a desired porous film can be obtained by forming the resin composition into a film and further stretching.
[0012]
As a preferred embodiment of the present invention, there is an embodiment in which the mixed resin and the inorganic filler are kneaded under the conditions satisfying the following formula using the kneading apparatus according to the present invention.
[0013]
5 × 10 4 ≦ [E / (D / 1000) 3 ] ≦ 3 × 10 5
However, E is the discharge amount (kg / hr) of the resin composition from a kneading apparatus, D is the diameter (mm) of the barrel of a kneading apparatus.
[0014]
By kneading under such conditions, a resin composition having a high elastic modulus can be obtained. The discharge amount is measured as follows.
[0015]
(1) The resin coming out of the die is squeezed for 36 seconds.
(2) Measure the weight with an electronic balance.
(3) Convert to the discharge rate per hour (kg / hr).
[0016]
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a schematic view showing a production line for producing a porous film. This production line is composed of a kneading step 1, a rolling step 2, a first slit step 3, a stretching step 4, and a second slit step 5 in the order of steps.
[0017]
In the kneading step 1, a screw kneading apparatus 10 is used, and this kneading apparatus includes a first hopper 11 that supplies a mixed resin and a second hopper 12 that supplies an inorganic filler. The screw kneading apparatus 10 includes a biaxial screw 13 and strongly mixes and extrudes the mixed resin and the inorganic filler supplied from the hoppers 11 and 12. The resin composition obtained by kneading is pelletized.
[0018]
In the rolling step 2, a screw extruder 20 is used. The apparatus 20 includes a hopper 21 into which pellets of the resin composition obtained in the kneading step 1 are charged, and a screw 22. With this apparatus 20, the resin composition is extruded forward while being kneaded, discharged in the form of a rod or sheet with a die 23, and rolled with a rolling roll mechanism 24 to obtain a rolled film.
[0019]
In the first slitting process 3, the rolled film obtained in the rolling process 2 is cut into two in the width direction, and for example, two 300mm wide films are obtained from the 600mm wide rolled film.
[0020]
In the stretching step 4, for example, a film having a width of 300 mm is stretched 4 to 5 times in the width direction under a predetermined temperature condition. Thereby, the porous film in which the hole of the submicron order was formed can be obtained.
[0021]
In the second slitting step 5, the obtained porous film is cut into a desired width dimension.
[0022]
<Resin composition>
The resin composition produced using the kneading apparatus 10 will be described. This resin composition is obtained by kneading 100 parts by weight of a mixed resin and 10 to 300 parts by weight of an inorganic filler.
[0023]
As the mixed resin, the weight ratio [A] / [B] of the polyolefin [A] having a weight average molecular chain length of 2850 nm or more to the polyolefin wax [B] having a weight average molecular weight of 700 to 6000 is 50/50 to 90/10. Use what is.
[0024]
Examples of the olefin constituting the polyolefin include ethylene, propylene, butene, hexene and the like. Specific examples of the polyolefin include ethylene resins such as low density polyethylene, linear polyethylene (ethylene-α-olefin copolymer) and high density polyethylene, propylene resins such as polypropylene and ethylene-propylene copolymer, poly ( 4-methylpentene-1), poly (butene-1), ethylene-vinyl acetate copolymer and the like.
[0025]
By using the screw kneading apparatus of the present invention, a polyolefin having a molecular chain length of 2850 nm or more is contained in an amount of 10% by weight or more, and when a film-like product formed therefrom is stretched, a high elastic modulus that is less likely to cause pores or breakage is obtained. The resin composition which has can be manufactured.
[0026]
Polyolefin having a molecular chain length of 2850 nm or more (in the present invention, referred to as a long molecular chain polyolefin) is particularly excellent in strength, and such a long molecular chain polyolefin is at least 10% by weight, more preferably at least 20% by weight of the total resin component. Since the contained resin composition is remarkably excellent in strength, it can be used for many purposes. A resin composition containing the long molecular chain polyolefin in an amount of 30% by weight or more based on the entire resin component is particularly preferable because of its high strength. The molecular chain length, weight average molecular chain length, molecular weight, and weight average molecular weight of the polyolefin are measured by GPC (gel permeation chromatography), and the content of polyolefin in a specific molecular chain length range or a specific molecular weight range (% by weight). ) Can be obtained by integration of a molecular weight distribution curve obtained by GPC measurement.
[0027]
When 10 to 300 parts by weight of the inorganic filler is added to 100 parts by weight of the mixed resin, the conventional processing method causes problems such as melt fracture or sag-like perforations, resulting in a film with good film thickness accuracy. However, according to the method of the present invention, a film having not only good film thickness accuracy but also excellent rigidity can be obtained. If the added amount of the inorganic filler is less than 10 parts by weight, it is insufficient for improving the rigidity, and even if added over 300 parts by weight, the effect of improving the rigidity is low for the added amount.
[0028]
Inorganic fillers include calcium carbonate, talc, clay, kaolin, silica, hydrotalcite, diatomaceous earth, magnesium carbonate, barium carbonate, calcium sulfate, magnesium sulfate, barium sulfate, aluminum hydroxide, magnesium hydroxide, calcium oxide, magnesium oxide Titanium oxide, alumina, mica, zeolite, glass powder, zinc oxide and the like can be used.
[0029]
<Configuration of screw kneader>
Next, the detail of the structure of the screw 13 of the screw kneading apparatus 10 is demonstrated. FIG. 2 is a diagram showing details of the screw 13.
[0030]
The screw 13 is configured by fixing a component called an element on a shaft called a screw shaft.
[0031]
In FIG. 2, the element indicated by the symbol P is a full flight screw. A full flight screw is a screw element in which a groove is spirally formed over its entire length. The element indicated by reference sign DP represents a full flight screw in which a groove deeper than the full flight screw indicated by reference sign P is formed. By using such a deep groove full flight screw, the residence time of the resin can be lengthened. The full flight screw has a shape as shown in FIG. 3, and has a function of feeding the kneaded material forward, that is, downstream of the kneading apparatus. In FIG. 3, D is the diameter (inner diameter) of the barrel (mm), Ds is the diameter of the screw (mm), M is the depth of the screw groove (mm), α is the flight angle of the screw (°), and H is the inner surface of the barrel. And δf is the distance (mm) between the screw crest and the barrel inner surface.
[0032]
Of the above parameters, α is related to the speed at which the resin is sent out, and as α decreases, the speed at which the resin is sent out becomes slower. As a result, the residence time of the resin becomes longer and the kneading degree of the resin improves. However, if α is too small, the production efficiency is deteriorated. The size of M is also a parameter related to the speed at which the resin is sent out and the strength of the kneading.
[0033]
An element indicated by a symbol ND is a kneading block. As shown in FIG. 4, a kneading block generally includes a plurality of kneading discs having the same cross-sectional shape, and the geometric centers of the discs are located on a common straight line. It has a shape in which they are sequentially shifted and overlapped with each other at a predetermined angle in a certain direction. The thickness of each kneading disk may be the same or different.
[0034]
In the state where the screw is loaded in the barrel, there is a distribution in the distance between the kneading disk and the barrel constituting the kneading block, and the shear stress acts on the kneaded material most strongly when the distance is the smallest.
[0035]
The element indicated by the reference symbol LND is a kneading block having a shape in which the kneading discs are stacked so as to twist in the direction opposite to the twisting of the stacking of the kneading discs in the kneading block of the reference symbol ND. By using a combination of two types of kneading blocks ND and LND, the residence time of the kneaded material can be made longer than in the case of one type of kneading block, and a stronger shear stress can be applied.
[0036]
The element indicated by the symbol SND is also a kneading block, but the feature is that when the adjacent kneading disks are compared, the kneading disk on the downstream side of the kneading apparatus is thinner than the kneading disk on the upstream side. is there. By using such a kneading block SND, the flow speed of the kneaded material to the downstream side can be adjusted, and the kneaded material can be given a compression / extension action better.
[0037]
FIG. 4 is a diagram showing the kneading block loaded in the twin-screw extruder, but the screw shaft is not drawn.
[0038]
In the screw kneading apparatus of the present invention, L / D of the entire screw is set to 30 or more, L f / D of the full flight screw is set to 3 or more, and L n / D of the kneading block is set to 5 or more. Furthermore, in a full flight screw, parameters are designed so that 35 ≦ α ≦ 60 and 0.15 ≦ (M / D) ≦ 0.25. The larger the L / D, the longer the residence time. Here, L n is the element length of the kneading block (mm) (however, if the screw contains two or more kneading blocks, the total length of those elements), L f is the element of the full flight screw It is a length (mm) (however, when two or more full flight screws are included in the screw, the total element length thereof). By selecting the parameters as described above, it is possible to obtain a resin composition having a high elastic modulus when formed into a film or sheet.
[0039]
When the mixed resin and the inorganic filler are kneaded using the screw kneading apparatus having the above-described configuration, it is preferably performed under the conditions satisfying the following formula.
[0040]
5 × 10 4 ≦ [E / (D / 1000) 3 ] ≦ 3 × 10 5
However, E is the discharge amount (kg / hr) of the resin composition from a kneading apparatus, D is the diameter (mm) of the barrel of a kneading apparatus. Thereby, a resin composition having high elasticity can be obtained. The discharge amount E is a parameter indicating how much resin is pushed forward inside the barrel in the kneading apparatus.
[0041]
The kneading apparatus according to the present invention is most preferably a biaxial screw composed of two screws composed of exactly the same screw elements. However, as long as the requirements of the present invention are satisfied, a single screw type may be used. You may have three or more screws.
[0042]
In the kneading apparatus composed of two or more screws, the rotation direction of the screws is the same, and the distance between the shaft centers is shorter than the sum of the largest diameters of the screw elements, as shown in FIG. A so-called meshing type in which the convex portion and the concave portion of each screw element mesh is most preferable, but the rotation direction of two or more screws is the same, and the distance between the shaft centers is larger than the sum of the largest diameters of the screw elements. A so-called non-meshing screw type may be used, or two or more screws may have different rotation directions and may be a non-meshing screw type.
[Brief description of the drawings]
FIG. 1 is a schematic view showing a manufacturing process of a porous film. FIG. 2 is a view showing details of a screw of a screw kneading apparatus. FIG. 3 is a view showing a configuration of a full flight disc. Figure [Explanation of symbols]
10 Screw kneading device 13 Screw ND Kneading disk P Full flight disk α Flight angle M Screw groove D Barrel diameter

Claims (3)

バレル、及び該バレル中に装填されており、少なくともフルフライトスクリューとニーディングブロックとを備えたL/Dが30以上のスクリューを有するスクリュー混練装置であって、
前記ニーディングブロックはLn /Dが5以上、
前記フルフライトスクリューはLf /Dが3以上で、かつ、下記の両式を満たすことを特徴とするスクリュー混練装置。
35≦α≦60
0.15≦(M/D)≦0.25
ただし、αはフルフライトスクリューのフライト角(゜)、Mはフルフライトスクリューのスクリュー溝の深さ(mm)、Lはスクリュー全長(mm)、Ln はニーディングブロックの合計長さ(mm)、Lf はフルフライトスクリューの合計長さ(mm)、Dはバレルの直径(mm)である。
A screw kneading apparatus having a barrel and a screw having an L / D of 30 or more, which is loaded in the barrel and includes at least a full flight screw and a kneading block,
The kneading block L n / D is 5 or more,
A screw kneading apparatus, wherein the full flight screw has L f / D of 3 or more and satisfies both the following formulas.
35 ≦ α ≦ 60
0.15 ≦ (M / D) ≦ 0.25
Where α is the flight angle of the full flight screw (°), M is the depth of the screw groove of the full flight screw (mm), L is the total length of the screw (mm), and L n is the total length of the kneading block (mm) , L f is the total length (mm) of the full flight screw, and D is the diameter (mm) of the barrel.
下記条件を満たす混合樹脂100重量部と、無機充填剤10〜300重量部とを請求項1に記載のスクリュー混練装置を用いて混練することを特徴とする樹脂組成物の製造方法。
(条件)重量平均分子鎖長が2850nm以上のポリオレフィン[A]の、重量平均分子量700〜6000のポリオレフィンワックス[B]に対する重量比
[A]/[B]は、50/50〜90/10である。
The manufacturing method of the resin composition characterized by knead | mixing 100 weight part of mixed resin which satisfy | fills the following conditions, and 10-300 weight part of inorganic fillers using the screw kneading apparatus of Claim 1.
(Condition) The weight ratio [A] / [B] of the polyolefin [A] having a weight average molecular chain length of 2850 nm or more to the polyolefin wax [B] having a weight average molecular weight of 700 to 6000 is 50/50 to 90/10. is there.
下記式を満たす条件下に前記混合樹脂と前記無機充填剤とを混練することを特徴とする請求項2に記載の樹脂組成物の製造方法。
5×104 ≦[E/(D/1000)3 ]≦3×105
ただし、Eは混練装置からの樹脂組成物の吐出量(kg/hr)、Dは混練装置のバレルの直径(mm)である。
The method for producing a resin composition according to claim 2, wherein the mixed resin and the inorganic filler are kneaded under a condition satisfying the following formula.
5 × 10 4 ≦ [E / (D / 1000) 3 ] ≦ 3 × 10 5
However, E is the discharge amount (kg / hr) of the resin composition from a kneading apparatus, D is the diameter (mm) of the barrel of a kneading apparatus.
JP2001072179A 2001-03-14 2001-03-14 Screw kneader and method for producing resin composition using the same Expired - Fee Related JP4627908B2 (en)

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JP2001072179A JP4627908B2 (en) 2001-03-14 2001-03-14 Screw kneader and method for producing resin composition using the same
US10/093,534 US7049361B2 (en) 2001-03-14 2002-03-11 Polyolefin series resinfilm, composition for preparing the same, process for preparing the composition for preparing the same, and apparatus for preparing the same
TW091104737A TWI228071B (en) 2001-03-14 2002-03-13 Polyolefin series resin film, composition for preparing the same, process for preparing the composition for preparing the same, and apparatus for preparing the same
KR1020020013588A KR100846648B1 (en) 2001-03-14 2002-03-13 Polyolefin series resin film, composition for preparing the same, process for preparing the composition for preparing the same, and apparatus for preparing the same
CNB021056587A CN100473516C (en) 2001-03-14 2002-03-14 Polyolefine series resin film, composition for preparation, preparing method for composition and device for preparation
EP02005363A EP1241220A3 (en) 2001-03-14 2002-03-14 Polyolefin series resin film, composition for preparing the same and process and apparatus for preparing the film and the composition
CNA2005101370810A CN1817949A (en) 2001-03-14 2002-03-14 Polyolefin series resin film, composition for preparing the same and process and apparatus for preparing the film and the composition
EP08100008A EP1905798A3 (en) 2001-03-14 2002-03-14 Process for preparing a composition for preparing a polyolefin series resin film and process for preparing the film

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JP4572516B2 (en) * 2003-07-18 2010-11-04 東レ株式会社 Method for producing resin composition
EP2017306B1 (en) 2006-03-23 2013-08-21 Toray Industries, Inc. Thermoplastic resin composition, process for producing the same and molding
JP4720567B2 (en) * 2006-03-23 2011-07-13 東レ株式会社 Thermoplastic resin composition and method for producing the same
CN101905536A (en) * 2009-06-08 2010-12-08 王广武 Preparation method of hot-extruded high molecular material by means of rolling and forming and assembly equipment thereof
EP3450489A4 (en) * 2016-08-18 2019-12-18 Japan Polypropylene Corporation Polypropylene resin composition for microporous film and use of polypropylene resin composition

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JPS59194824A (en) * 1983-04-19 1984-11-05 Ube Ind Ltd Resin molding machine
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JPH10180841A (en) * 1996-12-25 1998-07-07 Asahi Chem Ind Co Ltd Side feed extruder of powder and extrusion method using the extruder
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