JP6424351B2 - 熱可塑性樹脂組成物 - Google Patents
熱可塑性樹脂組成物 Download PDFInfo
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- JP6424351B2 JP6424351B2 JP2016025267A JP2016025267A JP6424351B2 JP 6424351 B2 JP6424351 B2 JP 6424351B2 JP 2016025267 A JP2016025267 A JP 2016025267A JP 2016025267 A JP2016025267 A JP 2016025267A JP 6424351 B2 JP6424351 B2 JP 6424351B2
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- thermoplastic resin
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- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/03—Polymer mixtures characterised by other features containing three or more polymers in a blend
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2207/00—Properties characterising the ingredient of the composition
- C08L2207/53—Core-shell polymer
Description
樹脂の接合としては、例えばネジやボルトなどによる機械的接合、ホットメルトなど接着剤による接合、熱板溶着に代表される、熱を与えて溶融させることによる熱接合、接合部を振動させることにより発生する摩擦熱を利用した振動溶着、接合部にレーザー光を照射しその部位の吸収発熱を利用したレーザー溶着などが挙げられる。加工工程の削減や軽量化、環境負荷の低減などの観点から、最近では熱板溶着、振動溶着、レーザー溶着が、その有用性を高めている。
しかしながら特許文献1〜3に記載の樹脂組成物は、いずれも透過率をある数値以上に規定することで、十分なエネルギー量のレーザー光を溶着部まで到達させる、つまり「透過材」として用いられるものであり、「吸収材」として利用するには適した技術ではない。
[1] ゴム状重合体(a1)にビニル系重合体(a2)がグラフトされたグラフト共重合体(A)を含む熱可塑性樹脂組成物であって、
光線反射率(%R)、および下記式(1)で表される光線吸収率(%A)を、可視光領域から近赤外光領域において、波長間隔1nmで測定したとき、
380nm〜780nmの光線反射率の平均値(可視%R)が5%〜10%、
780nm〜1180nmの光線吸収率の平均値(近赤外%A)が25%〜93%、であることを満たす熱可塑性樹脂組成物。
光線吸収率(%A)=100−光線透過率(%T)−光線反射率(%R)・・・(1)
[2] 近赤外領域の光線吸収率の平均値と、可視光領域の光線反射率の平均値との比(近赤外%A/可視%R)が16.5〜4.5であることを特徴とする、[1]に記載の熱可塑性樹脂組成物。
[3] [1]または[2]に記載の熱可塑性樹脂組成物を成形した、成形品。
本発明の成形品は、色調とレーザー溶着後の外観に優れ、かつ樹脂部材として十分な耐衝撃性を有する。
なお、以下の説明において、「成形品」とは、本発明の熱可塑性樹脂組成物を成形してなるものである。また、以下の説明において特に断りがない限り、「色調が優れる」とは、成形品が濃色系の色調(ダークグレーや黒など)を示すことを意味する。また、「溶着外観が優れる」とは、レーザー溶着後の接合部において焦げや変色が抑制されていることを意味する。
本発明の熱可塑性樹脂組成物は、グラフト共重合体(A)を含有する。
グラフト共重合体(A)を構成するゴム状重合体(a1)としては特に制限されないが、例えばポリブタジエン、スチレン/ブタジエン共重合体、アクリロニトリル/ブタジエン共重合体、アクリル酸エステル/ブタジエン共重合体等のブタジエン系ゴム状重合体;イソプレン、クロロプレン、スチレン/イソプレン共重合体等の共役ジエン系ゴム状重合体;ポリアクリル酸ブチル等のアクリル系ゴム状重合体;エチレン/プロピレン共重合体等のオレフィン系ゴム状重合体;ポリオルガノシロキサン等のシリコーン系ゴム状重合体;天然ゴム、ブチルゴム、ウレタンゴム、塩素化ポリエチレン、エピクロルヒドリンゴム、フッ素ゴム、多硫化ゴムなどが挙げられる。これらは1種を単独で用いてもよいし、2種以上を組み合わせて用いてもよい。なお、これらゴム状重合体は、モノマーから使用することができ、ゴム状重合体の構造は複合ゴム構造やコア/シェル構造をとってもよい。
上述したゴム状重合体の中でも、得られる成形品の耐衝撃性や成形外観がブタジエン系ゴム状重合体、アクリル系ゴム状重合体、オレフィン系ゴム状重合体、シリコーン系ゴム状重合体、及びこれらゴム質重合体の複合ゴム構造やコア/シェル構造が好ましい。
秤量したゴム状重合体(a1)を、適当な溶剤に室温(23℃)で20時間かけて溶解させる。次いで遠心分離し、上澄みをデカンテーションして残存した不溶分を60℃で24時間乾燥した後、秤量する。最初に秤量したゴム状重合体(a1)に対する不溶分の割合(質量%)を求め、これをゴム状重合体(a1)のゲル含有量とする。
ゴム状重合体(a1)の溶解に用いる溶剤としては、例えばトルエン、アセトンなどが挙げられる。
ゴム状重合体(a1)の平均粒子径は、粒度分布測定器を用いて体積基準の粒子径分布を測定し、得られた粒子径分布より算出することができる。
ビニル系単量体としては特に制限されないが、例えば芳香族ビニル化合物、(メタ)アクリル酸アルキルエステル、シアン化ビニル化合物などが挙げられる。
(メタ)アクリル酸アルキルエステルとしては、例えばメタクリル酸メチル、メタクリル酸エチル、メタクリル酸2−エチルヘキシル、アクリル酸メチル、アクリル酸エチル、アクリル酸n−ブチル、アクリル酸イソブチル、アクリル酸t−ブチルなどが挙げられる。
シアン化ビニル化合物としては、例えばアクリロニトリル、メタクリロニトリルなどが挙げられる。
これらのビニル系単量体は、1種を単独で用いてもよいし、2種以上を組み合わせて用いてもよい。
上述したビニル系単量体の中でも、成形品の耐衝撃性がより向上することから、スチレンとアクリロニトリルとを併用することが好ましい。
グラフト重合を行う方法としては特に制限されないが、反応が安定して進行するように制御可能であることから乳化重合が好ましい。具体的には、ゴム状重合体(a1)にビニル系単量体を一括して仕込んだ後に重合する方法;ゴム状重合体(a1)にビニル系単量体の一部を先に仕込み、随時重合させながら残りを重合系に滴下する方法;ゴム状重合体(a1)にビニル系単量体の全量を滴下しながら随時重合する方法などが挙げられ、これらを1段ないしは2段以上に分けて行うことができる。また、各段におけるビニル系単量体の種類や組成比を変えて行うことも可能である。
ラジカル重合開始剤としては、過酸化物、アゾ系開始剤、酸化剤と還元剤とを組み合わせたレドックス系開始剤などが挙げられる。これらの中では、レドックス系開始剤が好ましく、特に硫酸第一鉄と、エチレンジアミン四酢酸二ナトリウム塩と、ナトリウムホルムアルデヒドスルホキシレートと、ハイドロパーオキサイドとを組み合わせたスルホキシレート系開始剤が好ましい。
また、ラジカル重合を行う際には、得られるグラフト共重合体(A)の分子量やグラフト率を制御するため、各種公知の連鎖移動剤を添加してもよい。
なお、圧搾脱水機や押出機から排出されたグラフト共重合体(A)を回収せず、直接、熱可塑性樹脂組成物を製造する押出機や成形機に送って成形品としてもよい。
熱可塑性樹脂組成物は、上述したグラフト共重合体(A)のみを含むものでもよいが、得られる熱可塑性樹脂組成物の成形性や、成形品の成形外観の観点から、グラフト共重合体(A)以外の熱可塑性樹脂(他の熱可塑性樹脂(B))をさらに含むことが好ましい。
これら他の熱可塑性樹脂(B)は、1種を単独で用いてもよいし、2種以上を組み合わせて用いてもよい。
本発明の熱可塑性樹脂組成物は、上述したグラフト共重合体(A)、他の熱可塑性樹脂(B)の他にも、光の吸収性や反射性を阻害しない範囲で、必要に応じて任意成分を含有してもよい。
任意成分としては、例えば酸化防止剤や光安定剤等の各種安定剤、滑剤、可塑剤、離型剤、染料、顔料、帯電防止剤、難燃剤、金属粉末、無機充填剤など添加剤が挙げられる。
熱可塑性樹脂組成物は、グラフト共重合体(A)と、必要に応じて他の熱可塑性樹脂(B)と、任意成分とをV型ブレンダやヘンシェルミキサー等により混合分散させ、これにより得られた混合物をスクリュー式押出機、バンバリーミキサ、加圧ニーダ、ミキシングロール等の溶融混練機等を用いて溶融混練することにより製造される。また、必要に応じてペレタイザー等を用いて溶融混練物をペレット化してもよい。
本発明の熱可塑性樹脂組成物は、波長380nm〜780nmの範囲の光線反射率の平均値(可視%R)が5%〜10%であることが必要である。ここで光線反射率とは、熱可塑性樹脂組成物を2mmの厚さに成形して得られる試験片についての測定値である。光線反射率が10%以下では、可視光領域の光の反射量が少なく、成形品の色調が好ましい。
本発明の熱可塑性樹脂組成物は、波長780nm〜1180nmの範囲の光線吸収率の平均値(近赤外%A)が25%〜93%であることが必要である。ここで光線吸収率(%A)とは、光線反射率(%R)と光線透過率(%T)の測定値を用い、次式(1)により算出される。光線反射率は、熱可塑性樹脂組成物を2mmの厚さに成形して得られる試験片についての測定値である。光線透過率は、熱可塑性樹脂組成物を0.1mmの厚さに成形して得られる試験片についての測定値である。光線吸収率が93%以下であれば、近赤外領域の光の吸収量が過剰にならず、成形品を吸収材として用い、前記吸収材と透過材とをレーザー溶着した際に焦げや変色が発生せず、溶着外観が低下することを防ぐことができる。光線吸収率が25%以上であると、近赤外領域の光の吸収量が多くなるため、レーザー溶着後に十分な接合強度が得られる。
本発明の熱可塑性樹脂組成物は、近赤外領域の光線吸収率の平均値と、可視光領域の光線反射率の平均値との比(近赤外%A/可視%R)が16.5〜4.5であることが好ましく、10.0〜5.0であることが更に好ましい。16.5以下であれば、近赤外領域の光の吸収が制御され、レーザー溶着後の外観の焦げや変色がより抑制される傾向にある。一方、4.5以上であれば、レーザー溶着後に十分な接合強度が得られやすくなり、成形品の色調もより優れる傾向にある。
以上説明した本発明の熱可塑性樹脂組成物は、グラフト共重合体(A)を含有し、試験片の可視光領域の光線反射率および近赤外光領域の光線吸収率が特定の数値を有するので、色調とレーザー溶着後の外観に優れ、かつ樹脂部材として十分な耐衝撃性を有した成形品を得ることができる。
本発明の成形品は、上述した本発明の熱可塑性樹脂組成物を公知の成形方法によって成形してなるものである。
成形方法としては、例えば射出成形法、プレス成形法、押出成形法、真空成形法、ブロー成形法等が挙げられる。
成形品の用途としては、灯具・内装・外装等の車両用部品、OA機器や家電部品、医療用器具、各種工業用材料などが挙げられ、車両用灯具が好適である。
透過材の材料としては、レーザー光を透過できるものであれば特に制限されないが、例えばアクリル樹脂、ポリカーボネート樹脂などが挙げられる。
本発明により得られる樹脂接合体は、接合部において焦げや変色が抑制され、外観に優れる。しかも、十分な接合強度を発現できる。
以下の実施例及び比較例における各種測定及び評価方法は、以下の通りである。
尚、実施例4、5は参考例である。
<光線反射率(%R)の測定>
4オンス射出成形機(株式会社日本製鋼所製)を用い、シリンダー設定温度260℃、金型温度60℃、射出率20g/秒の条件で、ペレット状の熱可塑性樹脂組成物から、長さ100mm、幅100mm、厚み2mmの板状の試験片(成形品)を作製した。次いで標準白板(BaSO4)の全反射率を100%として、波長380nm〜1180nmの光の全反射率を、分光光度計(株式会社日本分光製、「V−770」)を用いて、波長間隔1nmで測定した。
設定温度250℃で、ペレット状の熱可塑性樹脂組成物から、厚み0.1mmのフィルム状の試験片を作製した。次いで波長380nm〜1180nmの光の透過率を、分光光度計(株式会社日本分光製、「V−770」)を用いて、波長間隔1nmで測定した。
測定した光線反射率(%R)および光線透過率(%T)を用い、式(1)に従って、波長380nm〜1180nmの光の吸収率を、波長間隔1nmで算出した。
ISO 3167に準拠して、射出成形機(東芝機械株式会社製、「IS55FP−1.5A」)を用い、ペレット状の熱可塑性樹脂組成物から、試験片(成形品)を作製した。得られた試験片のシャルピー衝撃強度をISO 179に準拠して、23℃雰囲気下で測定した。
4オンス射出成形機(株式会社日本製鋼所製)を用い、シリンダー設定温度260℃、金型温度60℃、射出率20g/秒の条件で、ペレット状のアクリル樹脂から、長さ100mm、幅100mm、厚み2mmの板状の試験片(成形品)を作製し、これを透過材として用いた。
一方、吸収材としては、ペレット状の本発明の熱可塑性樹脂組成物を用い、前記アクリル樹脂と同等の条件で作製した試験片を用いた。
吸収材と透過材を重ね合わせ、レーザー樹脂溶着装置(株式会社ファインディバイス社製)を用い、下記条件でレーザー光を透過材側から照射して吸収材と溶着させ、樹脂接合体を得た。得られた樹脂接合体の接合部における溶着外観を目視で評価した。
(溶着条件)
・出力:6W
・焦点径:3mm
・走査速度:5mm/秒
・溶着長:20mm
・圧力:0.5MPa
光線反射率の測定に使用したものと同じ試験片を用い、測色計により明度(L値)を測定した。L値が低いほど濃色となり、色調に優れる。
試薬注入容器、冷却管、ジャケット加熱機及び攪拌装置を備えた反応器内に、イオン交換水150部、ポリブタジエンラテックス(体積平均粒子径0.2μm)を固形分換算で50部、不均化ロジン酸カリウム1部、水酸化カリウム0.03部を仕込み、60℃に加熱後、硫酸第一鉄七水塩0.007部、ピロリン酸ナトリウム0.1部、結晶ブドウ糖0.3部を添加した。次いで、アクリロニトリル15部、スチレン35部、クメンハイドロパーオキサイド0.4部、t−ドデシルメルカプタン0.5部からなる混合液を120分間にわたって滴下し、重合した。滴下終了後、温度70℃の状態を60分保持した後、クメンハイドロパーオキサイド0.05部を添加し、さらに温度70℃の状態を30分保持した後、冷却し、ポリブタジエンに、アクリロニトリルとスチレンをグラフト重合させたポリブタジエン系のグラフト共重合体(A−1)のラテックスを得た。
次いで、ラテックスに酸化防止剤を添加し、1%硫酸水溶液150部を60℃に加熱し、この中へグラフト共重合体(A−1)のラテックス100部を徐々に滴下して凝固した。そして、析出物を分離し、脱水、洗浄した後に乾燥して、グラフト共重合体(A−1)を得た。
<製造例2:酸基含有共重合体ラテックス(K)の製造>
試薬注入容器、冷却管、ジャケット加熱機および撹拌装置を備えた反応器内に、イオン交換水200部、オレイン酸カリウム2部、ジオクチルスルホコハク酸ナトリウム4部、硫酸第一鉄七水塩0.003部、エチレンジアミン四酢酸二ナトリウム塩0.009部、ナトリウムホルムアルデヒドスルホキシレート0.3部を窒素気流下で仕込み、60℃に昇温した。60℃になった時点から、アクリル酸n−ブチル85部、メタクリル酸15部、クメンヒドロパーオキサイド0.5部からなる混合物を120分かけて連続的に滴下した。滴下終了後、さらに2時間、60℃を維持した状態で熟成を行い、固形分が33%、重合転化率が96%、酸基含有共重合体の体積平均粒子径が120nmである酸基含有共重合体ラテックス(K)を得た。
試薬注入容器、冷却管、ジャケット加熱機及び攪拌装置を備えた反応器内に、イオン交換水190部、アルケニルコハク酸ジカリウム0.6部、アクリル酸n−ブチル50部、アリルメタクリレート0.6部、t−ブチルハイドロパーオキサイド0.1部からなる混合物を添加した。この反応器に窒素気流を通じることによって雰囲気の窒素置換を行い、内温を55℃まで昇温した。内温が55℃に達した時点で、硫酸第一鉄七水塩0.0001部、エチレンジアミン四酢酸二ナトリウム塩0.0003部、ナトリウムホルムアルデヒドスルホキシレート0.2部、イオン交換水10部からなる水溶液を添加し、ラジカル重合を開始させた。重合発熱が確認された後、ジャケット温度を75℃とし、重合発熱が確認されなくなるまで重合を継続し、さらに1時間この状態を維持した。得られたゴム状重合体の体積平均粒子径は100nmであった。
反応器内部の液温が70℃に低下した後、5%ピロリン酸ナトリウム水溶液を固形分として0.6部添加した。内温70℃で制御した後、酸基含有共重合体ラテックス(K)を固形分として1.2部添加し、30分撹拌、肥大化を行い、ゴム状重合体のラテックスを得た。
得られたラテックス状のゴム状重合体の体積平均粒子径は285nmであった。
次いで、1.5%硫酸水溶液100部を80℃に加熱し、この中へグラフト共重合体(A−2)のラテックス100部を徐々に滴下して凝固した。そして、析出物を分離し、脱水、洗浄した後に乾燥して、グラフト共重合体(A−2)を得た。
試薬注入容器、冷却管、ジャケット加熱機及び攪拌装置を備えた反応器内に、イオン交換水160部、ポリブタジエンラテックス(体積平均粒子径0.2μm)を固形分換算で10部、アクリル酸n−ブチル40部、アルケニルコハク酸ジカリウム0.2部、アリルメタクリレート0.2部、ブチレングリコールジメタクリレート0.1部、t−ブチルハイドロパーオキサイド0.1部からなる混合物を添加した。この反応器に窒素気流を通じることによって雰囲気の窒素置換を行い、内温を60℃まで昇温した。内温が60℃に達した時点で、硫酸第一鉄七水塩0.0002部、エチレンジアミン四酢酸二ナトリウム塩0.0006部、ナトリウムホルムアルデヒドスルホキシレート0.25部、イオン交換水3部からなる水溶液を添加し、ラジカル重合を開始させた。重合発熱が確認された後、ジャケット温度を75℃とし、重合発熱が確認されなくなるまで重合を継続し、さらに1時間この状態を維持してシード重合を行い、複合ゴム状重合体を得た。
次いで、1.5%硫酸水溶液100部を50℃に加熱し、この中へグラフト共重合体(A−3)のラテックス100部を徐々に滴下して凝固した。そして、析出物を分離し、脱水、洗浄した後に乾燥して、グラフト共重合体(A−3)を得た。
<製造例3:他の熱可塑性樹脂(B−1)の製造>
アクリロニトリル27部及びスチレン73部を公知の懸濁重合により重合し、N,N−ジメチルホルムアミド溶液から25℃で測定した還元粘度が0.61dl/gであるアクリロニトリル−スチレン共重合体を得た。これを他の熱可塑性樹脂(B−1)として用いた。
アクリロニトリル19部、スチレン53部及びN−フェニルマレイミド28部を公知の連続溶液重合により重合し、N,N−ジメチルホルムアミド溶液から25℃で測定した還元粘度が0.65dl/gであるアクリロニトリル−スチレン−N−フェニルマレイミド三元共重合体を得た。これを他の熱可塑性樹脂(B−2)として用いた。
顔料として、以下を用いた。
・カーボンブラック:三菱化学株式会社製「#960」
・酸化鉄:戸田工業株式会社製「KN−320」
・酸化チタン:テイカ株式会社製「JR−407」
染料として、以下を用いた。
・ペリノン系染料:ランクセス株式会社「MACROLEX Orange 3G」
・アンスラキノン系染料:ランクセス株式会社「MACROLEX Red Violet R」
・アンスラキノン系染料:ランクセス株式会社「MACROLEX Green 5B」
表1〜2に示す量のグラフト共重合体(A)、他の熱可塑性樹脂(B)、カーボンブラック、酸化チタン、酸化鉄、及び染料と、エチレンビスステアリルアミド1部と、シリコーンオイルSH200(東レ・ダウコーニング株式会社製)0.2部と、アデカスタブAO−60(株式会社ADEKA製)0.2部と、アデカスタブLA−57(株式会社ADEKA製)0.4部とをヘンシェルミキサーを用いて混合した。スクリュー式押出機(株式会社日本製鋼所製、「TEX−30α型二軸押出機」)を用いて、得られた混合物を250℃にて溶融混練した後、ペレタイザーにてペレット化した熱可塑性樹脂組成物を得た。
得られたペレット状の熱可塑性樹脂組成物を用いて試験片(成形品)を作製し、光線反射率および光線透過率を測定し、光線吸収率を算出し、耐衝撃性、レーザー溶着外観及び色調を評価した。これらの結果を表1〜2に示す。
一方、各比較例の場合、成形品の耐衝撃性、レーザー溶着外観、色調のいずれかの項目に劣る結果となった。
具体的には、比較例1の場合、可視%Rが10%以上であったため、色調に劣っていた。
比較例2の場合、近赤外%Aが93%以上であったため、レーザー溶着外観が劣っていた。
比較例3の場合、近赤外%Aが25%未満であったため、透過材と吸収材とが十分に接合していなかった。
比較例4の場合、グラフト共重合体(A)を含有しなかったため、耐衝撃性に劣っていた。
Claims (2)
- ゴム状重合体(a1)にビニル系重合体(a2)がグラフトされたグラフト共重合体(A)と他の熱可塑性樹脂(B)とを含み、
グラフト共重合体(A)と他の熱可塑性樹脂(B)の合計に対して、グラフト共重合体(A)の含有量が20〜60質量%、他の熱可塑性樹脂(B)の含有量が40〜80質量%であり、
下記要件(ア)〜(ウ)を満たす、レーザー溶着における吸収材用熱可塑性樹脂組成物。
(ア)2mmの厚さに成形した板状の試験片について波長380nm〜780nmの範囲で波長間隔1nmで測定したときの光線反射率の平均値(可視%R)が5%〜10%である。
(イ)2mmの厚さに成形した板状の試験片についての光線反射率(%R)と、0.1mmの厚さに成形したフィルム状の試験片についての光線透過率(%T)とを波長780nm〜1180nmの範囲で波長間隔1nmでそれぞれ測定し、次式(1)により算出した光線吸収率の平均値(近赤外%A)が25%〜93%である。
光線吸収率(%A)=100−光線透過率(%T)−光線反射率(%R)・・・(1)
(ウ)前記近赤外領域の光線吸収率の平均値(近赤外%A)と、前記可視光領域の光線反射率の平均値(可視%R)との比(近赤外%A/可視%R)が16.5〜4.5である。 - 請求項1に記載の熱可塑性樹脂組成物を成形した、成形品。
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