JP6655529B2 - 耐候性及び耐熱性に優れた低光沢asa系樹脂組成物 - Google Patents
耐候性及び耐熱性に優れた低光沢asa系樹脂組成物 Download PDFInfo
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Description
具体的に本発明の目的は、耐熱性に優れ、成形物の表面全体に光沢ムラの少ない熱可塑性のアクリロニトリル−スチレン−アクリレート(ASA)樹脂組成物を提供することにある。
(a)平均粒径が3,000〜5,000Åの大口径アクリル系ゴムをコアとして含むASAグラフト共重合体10〜40重量%と、
(b)平均粒径が0.5〜1.5μmの超大口径アクリル系ゴムをコアとして含むASAグラフト共重合体1〜20重量%と、
(c)SAN共重合体20〜60重量%と、
(d)耐熱SAN共重合体10〜40重量%と、
(e)架橋された芳香族ビニル化合物−シアン化ビニル化合物共重合体1〜10重量%と、
(f)非晶質無機物0.1〜5重量%と、を含む。
本発明で用いられる大口径ASAグラフト共重合体は、アクリル系ゴムをコアとし、前記コア表面にビニル系単量体がグラフト重合してシェル(shell)を形成するコア−シェル構造の物質である。具体的に、ASAグラフト共重合体は、コアを構成するアクリル系ゴム30〜80重量%とシェルを構成するビニル系グラフト共重合体20〜70重量%の含量比を有する。前記ASAグラフト共重合体の重合方法は、当業界に公知の通常の方法を使用できるが、例えば、乳化重合、懸濁重合などが可能で、好ましくは乳化重合法を使用することができる。コアを構成するアクリル系ゴムの平均粒径を大きく増大するためには乳化重合法を使用することがより効果的である。
本発明で用いられる超大口径ASAグラフト共重合体は、アクリル系ゴムをコアとし、前記コア表面にビニル系単量体がグラフト重合してシェル(shell)を形成するコア−シェル構造の物質である。具体的に、ASAグラフト共重合体はコアを構成するアクリル系ゴム30〜80重量%とシェルを構成するビニル系グラフト共重合体20〜70重量%の含量比を有する。前記ASAグラフト共重合体の重合方法は、当業界に公知の通常の方法を使用できるが、例えば、乳化重合、懸濁重合などが可能で、好ましくは乳化重合法を使用することができる。特に、超大口径アクリル系ゴムを製造するためには乳化重合法を使用することがさらに効果的である。
本発明のSAN共重合体は、芳香族ビニル系単量体50〜90重量%とシアン化ビニル系単量体10〜50重量%からなる二元共重合体であり、重量平均分子量(Mw)が100,000〜200,000範囲である。前記SAN共重合体は、通常の重合方法の塊状重合、溶液重合、乳化重合、懸濁重合などの方法で製造することができる。前記芳香族ビニル系単量体は、スチレン、α−メチルスチレン、パラメチルスチレン、エチルスチレン、プロピルスチレン、ブチルスチレンなどから選択された単独または2種以上が混合使用できるが、必ずしもこれに制限されることはない。前記芳香族ビニル系単量体として好ましくはスチレンが挙げられる。前記シアン化ビニル系単量体は、アクリロニトリル、メタクリロニトリル、エタクリロニトリルなどから選択された単独または2種以上が混合使用できるが、必ずしもこれに制限されることはない。前記シアン化ビニル系単量体として好ましくはアクリロニトリルが挙げられる。
本発明の耐熱SAN共重合体は、スチレン単量体とビニルシアン系単量体にα-メチルスチレン単量体及びフェニルマレイミド単量体から選択された1種または2種を含んで共重合した三元共重合体または四元共重合体が使用されることができる。前記耐熱SAN共重合体の重量平均分子量(Mw)が80,000〜120,000範囲のものが使用されることができる。自動車の内外装用品として要求される耐熱性を備えるためには、スチレン単量体、ビニルシアン系単量体、α-メチルスチレン単量体、及びフェニルマレイミド単量体を共重合した四元共重合体を使用することが良い。より好ましくは耐熱SAN共重合体としてスチレン単量体5〜10重量%、ビニルシアン系単量体15〜25重量%、α-メチルスチレン単量体40〜50重量%、及びフェニルマレイミド単量体15〜25重量%を共重合した四元共重合体を使用する。前記三元共重合体または四元共重合体は、公知の重合方法[韓国登録特許10−0922700号、10−0915114号]を参考して製造されることができる。
本発明の架橋された芳香族ビニル化合物−シアン化ビニル化合物共重合体は、低光沢特性を得るために使用される。前記架橋された芳香族ビニル化合物−シアン化ビニル化合物共重合体の全体的な架橋化度は30〜70重量%、好ましくは40〜65重量%である。架橋化度が30重量%よりも低いか、または70重量%を超える場合は、樹脂組成物の光沢度を減少させる役割をすることができなく、加工過程で微細ゲル(gel)が発生して外観不良の問題を引き起こすことがある。
前記架橋された芳香族ビニル化合物−シアン化ビニル化合物共重合体を構成するシアン化ビニル化合物は、アクリロニトリル、メタクリロニトリルなどから選択された単独または2種以上が混合使用できるが、必ずしもこれに制限されることはない。
前記架橋されたビニル化合物−シアン化ビニル化合物共重合体は、商業的に購入して使用することができる。例えば、韓国のHan Nanotech社で購入でき、好ましい実施例としてはAM−7グレードを使用することができる。
本発明で用いられる非晶質無機物は、一定の形を持たない非晶質の無機物である。
理論的に限定されたことはないが、前記超大口径ASAグラフト共重合体と共に樹脂内に分散して光を散乱して光沢を低下させる効果を示す。
本発明の低光沢ASA系樹脂組成物は、前記成分以外にも通常の添加剤をさらに加えるこ とができる。例えば、染料、顔料、抗菌剤、滑剤、熱安定剤、酸化防止剤、離型剤、光安定剤、無機物添加剤、紫外線吸収剤、紫外線遮断剤、難燃剤、充填剤、核形成剤、静電気防止剤、発泡剤、可塑剤などの添加剤を付加でき、これらは単独または2種以上混合して付加することができる。前記通常の添加剤は、低光沢ASA系樹脂組成物に0.01〜5重量%範囲で含まれる。前記通常の添加剤の含量が0.01重量%未満であれば熱安定性の不足による加工過程での変色と混錬性の問題が発生することがあり、5重量%を超えると添加剤の熱分解及び揮発による気体の発生などの問題がある。
実施例1〜5、比較例1〜4.低光沢熱可塑性樹脂組成物の製造
下記表1に示す組成成分及び含量比で混合し、250℃のツイン押出機を用いて射出成形して試片を製作した。下記実施例と比較例で使用された各成分の仕様は次の通りである。
(a)大口径グラフト共重合体
(a−1)平均粒径が3500〜4000Åの大口径アクリル系ゴムコアが含まれ、アクリル系ゴムコアの含量が60重量%のASAグラフト共重合体
(a−2)平均粒径が3,000〜4000Åの大口径ブタジエン系ゴムコアが含まれ、ブタジエン系ゴムコアの含量が6重量%のABSグラフト共重合体
(b)超大口径グラフト共重合体
(b−1)平均粒径が0.5〜1.0μmの超大口径アクリル系ゴムコアが含まれ、アクリル系ゴムコアの含量が60重量%のASAグラフト共重合体
(b−2)平均粒径が2.5〜3.0μmの超大口径ブタジエン系ゴムコアが含まれ、ブタジエン系ゴムの含量が13.5重量%のABSグラフト共重合体(LG化学のMA221、バルク重合体)
(c)SAN共重合体
重量平均分子量180,000、スチレン単量体72重量%とアクリロニトリル28重量%の二元SAN共重合体
(d)耐熱SAN共重合体
重量平均分子量100,000、スチレン単量体15重量%、ビニルシアン系単量体25重量%、α-メチルスチレン40重量%、及びフェニルマレイミド20重量%の四元SAN共重合体
(e)架橋された芳香族ビニル化合物−シアン化ビニル化合物共重合体
架橋化度50重量%、Han Nanotech社のAM−7製品
(f)非晶質無機物
平均粒径が4μmのタルク(Talc)、KOCHONE社のKCM−6300製品
g)その他の添加剤
滑剤:エチレンビスステアラミド
酸化防止剤:ソンウォン産業SN147BF
前記実施例1〜5及び比較例1〜4で製造した各試片は下記の物性評価方法により物性を測定した。
(1)アイゾッド(Izod)衝撃強度:ASTM D256により測定した。
(2)流動指数:220℃、10kg条件でASTM D1238により測定した。
(3)引張強度:ASTM D638により測定した。
(4)耐熱性(HDT):ASTM D648により測定した。
(5)光沢測定:ASTM D523により測定した。
(6)光沢ムラ:ASTM D523により測定した。図1の金型で射出された試片を10つの領域で表面光沢ムラを測定して最大値と最小値の差をΔGlossで計算した。
(7)耐候性:SAE J2527によりΔEで評価した。
Claims (8)
- (a)平均粒径が3,000〜5,000Åの大口径アクリル系ゴムをコアとして含むASAグラフト共重合体30〜40重量%と、
(b)平均粒径が0.5〜1.5μmの超大口径アクリル系ゴムをコアとして含むASAグラフト共重合体1〜20重量%と、
(c)SAN共重合体20〜40重量%と、
(d)耐熱SAN共重合体10〜40重量%と、
(e)架橋された芳香族ビニル化合物−シアン化ビニル化合物共重合体1〜10重量%と、
(f)非晶質無機物0.1〜5重量%と、
を含み、
前記前記(e)架橋された芳香族ビニル化合物−シアン化ビニル化合物共重合体は、架橋度が30〜70重量%であることを特徴とする低光沢ASA系樹脂組成物。 - 前記(a)大口径ASAグラフト共重合体または(b)超大口径ASAグラフト共重合体は乳化重合法によって製造されたもので、アクリル系ゴムをコアとし、前記コア表面にビニル系単量体がグラフト重合してシェル(shell)を形成することを特徴とする請求項1に記載の低光沢ASA系樹脂組成物。
- 前記(a)大口径ASAグラフト共重合体または(b)超大口径ASAグラフト共重合体はアクリル系ゴムコアの含量が30〜80重量%で、ビニル系グラフト共重合体シェルの含量が20〜70重量%であることを特徴とする請求項1に記載の低光沢ASA系樹脂組成物。
- 前記(c)SAN共重合体は、芳香族ビニル系単量体50〜90重量%とシアン化ビニル系単量体10〜50重量%を共重合した二元共重合体であることを特徴とする請求項1に記載の低光沢ASA系樹脂組成物。
- 前記(d)耐熱SAN共重合体は、スチレン単量体5〜10重量%、ビニルシアン系単量体15〜25重量%、α-メチルスチレン単量体40〜50重量%及びフェニルマレイミド単量体15〜25重量%を共重合した四元共重合体であることを特徴とする請求項1に記載の低光沢ASA系樹脂組成物。
- 前記(f)非晶質無機物は、平均粒径が1〜10μmのタルク(Talc)であることを特徴とする請求項1に記載の低光沢ASA系樹脂組成物。
- 滑剤及び酸化防止剤をさらに含むことを特徴とする請求項1に記載の低光沢ASA系樹脂組成物。
- 請求項1から7のうち何れか1項に記載の低光沢ASA系樹脂組成物を射出成形して製造されることを特徴とする成形品。
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