JP7447235B2 - セルロース含有樹脂組成物 - Google Patents
セルロース含有樹脂組成物 Download PDFInfo
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- JP7447235B2 JP7447235B2 JP2022209542A JP2022209542A JP7447235B2 JP 7447235 B2 JP7447235 B2 JP 7447235B2 JP 2022209542 A JP2022209542 A JP 2022209542A JP 2022209542 A JP2022209542 A JP 2022209542A JP 7447235 B2 JP7447235 B2 JP 7447235B2
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- acid
- polyamide
- cellulose fibers
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- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 claims description 30
- 238000006116 polymerization reaction Methods 0.000 claims description 25
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- 125000000217 alkyl group Chemical group 0.000 description 6
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- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical compound OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 description 6
- XBDQKXXYIPTUBI-UHFFFAOYSA-N dimethylselenoniopropionate Natural products CCC(O)=O XBDQKXXYIPTUBI-UHFFFAOYSA-N 0.000 description 6
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- 239000004519 grease Substances 0.000 description 6
- FUZZWVXGSFPDMH-UHFFFAOYSA-N hexanoic acid Chemical compound CCCCCC(O)=O FUZZWVXGSFPDMH-UHFFFAOYSA-N 0.000 description 6
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- WWZKQHOCKIZLMA-UHFFFAOYSA-N octanoic acid Chemical compound CCCCCCCC(O)=O WWZKQHOCKIZLMA-UHFFFAOYSA-N 0.000 description 6
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 6
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Landscapes
- Compositions Of Macromolecular Compounds (AREA)
- Polyamides (AREA)
Description
熱可塑性樹脂をガラス繊維、炭素繊維、タルク、クレイなどの無機充填剤である強化材料で強化した樹脂組成物は、比重が高いため、得られる樹脂成形体の重量が大きくなるという課題がある。
セルロースは、その単体特性として、アラミド繊維に匹敵する高い弾性率と、ガラス繊維よりも低い線膨張係数を有することが知られている。また、真密度が1.56g/cm3と、低く、一般的な熱可塑性樹脂の補強材として使用されるガラス(密度2.4~2.6g/cm3)やタルク(密度2.7g/cm3)と比較し圧倒的に軽い材料である。
[1] (A)アミノ基末端濃度[-NH2]とカルボキシル基末端濃度[-COOH]とが下記式(1):
[-NH2] < [-COOH] ・・・(1)
を満たすポリアミドと、
(B)平均繊維径が500nm以下のセルロース繊維と
を含む、ポリアミド樹脂組成物。
[2] 前記セルロース繊維100質量部に対して、分散剤0.1~50質量部を更に含む、上記態様1に記載のポリアミド樹脂組成物。
[3] 前記ポリアミドのカルボキシル基末端濃度とアミノ基末端濃度との合計([-NH2]+[-COOH])が10μモル/g以上である、上記態様1又は2に記載のポリアミド樹脂組成物。
[4] 前記ポリアミドのカルボキシル基末端濃度とアミノ基末端濃度との合計([-NH2]+[-COOH])が500μモル/g以下である、上記態様1~3のいずれかに記載のポリアミド樹脂組成物。
[5] 前記セルロース繊維100質量部に対して、1~20質量部のヘミセルロース及び/又は0.1~10質量部のリグニンを含む、上記態様1~4のいずれかに記載のポリアミド樹脂組成物。
[6] 樹脂ペレット形状であり、かつ水分率が1200ppm以下である、上記態様1~5のいずれかに記載のポリアミド樹脂組成物。
[7] 水を含んだ状態の平均繊維径が500nm以下のセルロース繊維の存在下で、ポリアミド樹脂の原料モノマーを重合反応させることによって得られた、上記態様1~6のいずれかに記載のポリアミド樹脂組成物。
[8] 上記態様1~7のいずれかに記載のポリアミド樹脂組成物より形成された、成型品。
ポリアミドとしては、脂肪族、芳香族又はこれらの組合せの構造を有する種々のポリアミドを使用できる。好ましいポリアミドの例示としては、ラクタム類の重縮合反応により得られるポリアミド6、ポリアミド11、ポリアミド12や、1,6-ヘキサンジアミン、2-メチル-1,5-ペンタンジアミン、1,7-ヘプタンジアミン、2-メチル-1-6-ヘキサンジアミン、1,8-オクタンジアミン、2-メチル-1,7-ヘプタンジアミン、1,9-ノナンジアミン、2-メチル-1,8-オクタンジアミン、1,10-デカンジアミン、1,11-ウンデカンジアミン、1,12-ドデカンジアミン、m-キシリレンジアミンなどのジアミン類と、ブタン二酸、ペンタン二酸、ヘキサン二酸、ヘプタン二酸、オクタン二酸、ノナン二酸、デカン二酸、ベンゼン-1,2-ジカルボン酸、ベンゼン-1,3-ジカルボン酸、ベンゼン-1,4ジカルボン酸等、シクロヘキサン-1,3-ジカルボン酸、シクロヘキサン-1,4-ジカルボン酸などのジカルボン酸類との共重合体として得られる、ポリアミド6,6、ポリアミド6,10、ポリアミド6,11、ポリアミド6,12、ポリアミド6,T、ポリアミド6,I、ポリアミド9,T、ポリアミド10,T、ポリアミド2M5,T、ポリアミドMXD,6、ポリアミド6、C、ポリアミド2M5,C等;及び、これらがそれぞれ共重合された共重合体(一例としてポリアミド6,T/6,I)等の共重合体が挙げられる。
これら、末端調整剤を組成物に添加し末端官能基と反応させる方法は特に制限されないが、一態様として、重合時に任意の割合で末端調整剤を添加し反応させる方法が挙げられる。
次に本発明において用いることができるセルロース繊維について詳述する。
結晶化度(%)=([2θ/deg.=22.5の(200)面に起因する回折強度]-[2θ/deg.=18の非晶質に起因する回折強度])/[2θ/deg.=22.5の(200)面に起因する回折強度]×100
結晶化度(%) =h1 /h0 ×100
一態様において、樹脂組成物は、ヘミセルロース及び/又はリグニンを更に含む。植物由来のセルロースには、ミクロフィブリル同士の間、及びミクロフィブリル束同士の間に、ヘミセルロースと総称される多糖類や、リグニンと総称される芳香族化合物が存在する。一態様においては、セルロース繊維の製造工程でこれらの成分を完全に除去するのではなく、好適な範囲内の含有量で含むことが好ましい。ヘミセルロースはマンナンやキシランなどの糖で構成される多糖類であり、セルロースと水素結合して、ミクロフィブリル間を結びつける役割を果たしている。また、ヘミセルロースの溶解度パラメータ(SP値)はセルロースよりも疎水性側にあることから、ヘミセルロースは、熱可塑性樹脂とセルロース繊維とのSP値差を緩和する効果を有すると考えられる。
なおヘミセルロース及びリグニンの上記含有量はそれぞれ本開示の[実施例]記載の方法で測定される値である。
本発明の樹脂組成物は、付加的成分として分散剤を含むことが可能である。一態様において、分散剤は、動的表面張力60mN/m以下を有する。また、一態様において、分散剤は、界面活性剤である。分散剤は、ポリアミドに対するセルロース繊維の分散性の向上に寄与する。その好ましい量は、セルロース繊維100質量部に対し、分散剤が50質量部以下の量の範囲内である。より好ましい上限量は45質量部であり、さらにより好ましくは40質量部、さらにより好ましくは35質量部、特に好ましくは30質量部である。付加的成分であるため、下限は特に限定されないが、セルロース繊維100質量部に対し、0.1質量部以上添加することで、取扱い性を高めることができる。下限量は、より好ましくは0.5質量部、最も好ましくは1質量部である。
γ=(P-mg+shρg)/Lcosθ
ここで、γ:静的表面張力、P:つりあう力、m:プレートの質量、g:重力定数、L:プレート周囲長、θ:プレートと液体の接触角、s:プレート断面積、h:(力が釣り合うところまで)液面から沈んだ深さ、ρ:液体の密度である。
σ=ΔP・r/2
ここで、σ:動的表面張力、ΔP:圧力差(最大圧力-最小圧力)、r:キャピラリー半径である。
本発明の樹脂組成物の製法として特に制限はないが、具体例としては以下の様な方法が挙げられる。
ポリアミド樹脂モノマーとセルロース繊維の水分散液とを混合し、重合反応を行い、得られた樹脂組成物をストランド状に押出し、水浴中で冷却固化させ、ペレット状成形体として得る方法、単軸又は、二軸押出機を用いて、樹脂とセルロース繊維との混合物を溶融混練し、ストランド状に押出し、水浴中で冷却固化させ、ペレット状成形体として得る方法、単軸又は、二軸押出機を用いて、樹脂とセルロース繊維との混合物を溶融混練し、棒状又は筒状に押出し冷却して押出成形体として得る方法、単軸又は、二軸押出機を用いて、樹脂とセルロース繊維との混合物を溶融混練し、Tダイより押出しシート、又はフィルム状の成形体を得る方法、単軸又は、二軸押出機を用いて、樹脂とセルロース繊維との混合物を溶融混練し、ストランド状に押出し、水浴中で冷却固化させ、ペレット状成形体として得る方法等が挙げられる。好ましい態様においては、水を含んだ状態のセルロース繊維の存在下で、ポリアミドの原料モノマーの重合反応を行う。
以下に、使用した原料及び、評価方法について説明する。
・「UBEナイロン 1013B」宇部興産株式会社製
ポリアミド6(以下、PAと称す。)
カルボキシル末端基比率が、([COOH]/[全末端基])=0.58
・「ε-カプロラクタム」 宇部興産株式会社製
・「アジピン酸」 東京化成工業株式会社製(以下、末端調整剤-Aと称す。)
・「安息香酸」 東京化成工業株式会社製(以下、末端調整剤-Bと称す。)
・「ヘキサメチレンジアミン」 東京化成工業株式会社製(以下、末端調整剤-Cと称す。)
・セルロース繊維A(以下、CF-Aと略すことがある)
リンターパルプを裁断後、オートクレーブを用いて、120℃以上の熱水中で3時間加熱し、ヘミセルロース部分を除去した精製パルプを、圧搾し、純水中に固形分率が1.5質量%になるように叩解処理により高度に短繊維化及びフィブリル化させた後、そのままの濃度で高圧ホモジナイザー(操作圧:85MPaにて10回処理)により解繊することにより解繊セルロースを得た。ここで、叩解処理においては、ディスクリファイナーを用い、カット機能の高い叩解刃(以下カット刃と称す)で4時間処理した後に解繊機能の高い叩解刃(以下解繊刃と称す)を用いてさらに1.5時間叩解を実施し、セルロース繊維Aを得た。得られたセルロース繊維の特性を後述の方法で評価した。結果を下記に示す。
平均L/D=300
平均繊維径=90nm
結晶化度=80%
重合度=600
解繊処理の条件を、操作圧:85MPaにて5回処理とする以外は、CF-Aと同じ条件とし、以下のセルロースファイバーBを得た。
平均L/D=450
平均繊維径=400nm
結晶化度=82%
重合度=700
特許第5885658号の製造例1、実施例8に記載の方法に従ってバクテリアセルロースを製造し、以下のセルロース繊維Cの分散液を得た。
平均L/D=1000
平均繊維径=40nm
結晶化度=95%
重合度=650
CF-Cに市販のリグニン(ナカライテスク株式会社製)を加えて、セルロース繊維Dの分散液を得た。
CF-Cに、「木材研究」第34号(1965)第100頁に記載の竹ヘミセルロース製造法によって製造したヘミセルロースを加えて、セルロース繊維Eの分散液を得た。
原料を、アバカパルプとする以外は、CF-Aと同じ条件とし、以下のセルロース繊維Dを得た。
平均L/D=500
平均繊維径=30nm
結晶化度=80%
重合度=600
「第14改正日本薬局方」(廣川書店発行)の結晶セルロース確認試験(3)に規定される銅エチレンジアミン溶液による還元比粘度法により測定した。
<セルロース繊維の結晶形、結晶化度>
X線回折装置(株式会社リガク製、多目的X線回折装置)を用いて粉末法にて回折像を測定(常温)し、Segal法で結晶化度を算出した。また、得られたX線回折像から結晶形についても測定した。
セルロース繊維を、1質量%濃度で純水懸濁液とし、高剪断ホモジナイザー(日本精機(株)製、商品名「エクセルオートホモジナイザーED-7」、処理条件:回転数15,000rpm×5分間)で分散させた水分散体を、0.1~0.5質量%まで純水で希釈し、マイカ上にキャストし、風乾したものを、原子間力顕微鏡(AFM)で測定した。測定は、少なくとも100本のセルロース繊維が観測されるように倍率を調整して行い、無作為に選んだ100本のセルロース繊維の長径(L)、短径(D)及びこれらの比(L/D)を求め、100本のセルロース繊維の加算平均を算出した。
ホロセルロース(%)=ホロセルロース画分(g)/試料(無水ベース)(g)×100
αセルロース(%)=αセルロース画分(g)/試料(無水ベース)(g)×100
ヘミセルロース(%)=ホロセルロース(%)-αセルロース(%)
酸不溶性リグニン(%) = 酸不溶性リグニン画分(g)/試料量(無水ベース)(g)×100
酸可溶性リグニン(%)=((d × v ×(As-Ab))/(a × w))×100
リグニン(%)=酸不溶性リグニン(%)+酸可溶性リグニン(%)
d : 希釈倍率
v : ろ液定容量(L)
As: 試料溶液の吸光度
Ab: ブランク溶液の吸光度
a : リグニンの吸光係数(110 L/g・cm)
w : 試料量(無水ベース)(g)
分散剤としては以下のものを用いた。
・「ブラウノンN-515」青木油脂工業株式会社製
ポリオキシエチレンアルキルフェニルエーテル:以下、単に界面活性剤と称する。
静的表面張力34.8mN/m、動的表面張力40.9mN/m、常圧下沸点100℃超
各分散剤を用い、自動表面張力測定装置(協和界面科学株式会社製、商品名「CBVP-Z型」、付属のガラス製セル)を用い、ウィルヘルミー法により静的表面張力を測定した。各分散剤は常温で液体であったので、装置に付属のステンレス製シャーレに底から液面までの高さを7mm~9mmとなるように仕込み、25℃±1℃に調温した後に測定し、以下の式により求めた。γ=(P-mg+shρg)/Lcosθ。ここで、P:つりあう力、m:プレートの質量、g:重力定数、L:プレート周囲長、θ:プレートと液体の接触角、s:プレート断面積、h:(力が釣り合うところまで)液面から沈んだ深さ、ρ:液体の密度(分散剤は密度が1±0.4g/mLであったので、1を用いた。)、である。
各分散剤を用い、動的表面張力計(英弘精機株式会社製 製品名シータサイエンスt-60型、プローブ(キャピラリーTYPE I(ピーク樹脂製)、シングルモード)を使用し、最大泡圧法により気泡発生周期を10Hzで動的表面張力を測定した。各分散剤を5質量%としてイオン交換水に溶解又は分散し測定液を調製し、その溶液又は分散液100mLを、100mL容量のガラス製ビーカーに仕込み、25℃±1℃に調温された後、測定された値を用いた。動的表面張力は、以下の式により求められた。σ=ΔP・r/2。ここで、σ:動的表面張力、ΔP:圧力差(最大圧力-最小圧力)、r:キャピラリー半径、である。
SP値は、各サンプル1mLをSP値が既知の下表の溶剤10mLに室温で滴下し、スターラーで1時間撹拌した後、相分離なく溶解した溶剤のSP値の範囲から求めた。
最大型締圧力75トンの射出成形機を用いて、ISO294-3に準拠した多目的試験片を成形し、JIS K6920-2に準拠した条件で実施した。なお、ポリアミド樹脂は、吸湿による変化が起きるため、成形直後にアルミ防湿袋に保管し、吸湿を抑制した。
多目的試験片の中央部から、精密カットソーにて縦4mm、横4mm、長さ10mmの立方体サンプルを切り出し、測定温度範囲-20~80℃で、ISO11359-2に準拠して測定し、0℃~60℃の間での膨張係数を算出した。この際、測定に先立ち、120℃環境下で5時間静置してアニーリングを実施した。
後述する実施例及び比較例で製造したポリアミド樹脂組成物のペレットを用い、ISO 15512に準拠した方法でカールフィッシャー水分計(三菱化学アナリテック社製 電量滴定方式微量水分測定装置CA-200型)を用いてペレット中の水分率(ppm)を測定した。
秤量した試料を、90質量%フェノール水溶液に溶解し、25℃にて1/50N塩酸で電位滴定して算出した。
秤量した試料を、160℃のベンジルアルコールに溶解し、指示薬に25℃にて1/50N塩酸で電位滴定して算出した。
実施例及び比較例で得られたペレットを用いて、最大型締圧力4000トンの射出成形機のシリンダー温度を250℃に設定し、該ペレットを用いて10回パージ作業を行った後、成型を行い、成型片の着色状態を、以下の4段階で評価した。
◎ 軽微な着色(薄黄色)
○ 軽度の着色(黄色)
△ 中程度の着色(茶色)
× 激しい着色(こげ茶色~黒)
着色性と同様に、成型中の臭気発生を、以下の4段階で評価した。
◎ かすかな臭気(樹脂由来臭)
○ かすかな臭気(糖由来臭)
△ 成型機周辺で感知できる臭気(糖由来臭)
× 室内全域で感知できるほどの臭気(糖由来臭)
表1に記載のセルロース繊維含有量が3質量%となるよう水分散液を調製した。このセルロース繊維の水分散液70質量部と、ε-カプロラクタム100質量部と、表1に記載の質量部の末端調整剤と分散剤とを、均一な分散液となるまでミキサーで撹拌、混合した。続いて、この分散液を撹拌し、徐々に水蒸気を放出しながら240℃まで加熱し、240℃で1時間重合反応を行った。重合が終了した時点で得られた樹脂組成物を払い出し、これを切断してペレットとした。得られたペレットを95℃の熱水で処理し、精練を行い、乾燥させた。多目的試験片を得る際の射出成形条件は、シリンダー温度250℃、金型温度70℃とした。
末端調整剤-Aを0.16質量部、重合反応時間を5時間とした以外は、実施例1と同様に行った。
セルロース繊維の水分散液(3質量%)と、表1に記載の質量部の分散剤とをミキサーにて混合した後、この分散液を、遠心分離機を用いてセルロース繊維20質量部になるまで濃縮した。濃縮した分散液を乾燥処理した後、粉砕処理を実施して、粉末状セルロース繊維を得た。
PAと粉末状セルロース繊維を表1に記載の質量部で混合し、東芝機械(株)製のTEM48SS押出機で、スクリュー回転数350rpm、吐出量140kg/hrで溶融混練し、真空脱揮した後、ダイからストランド状に押出し、水浴で冷却し、ペレタイズした。
精錬後の乾燥を実施しないこと以外は、実施例2と同様に行った。
本発明のポリアミド樹脂組成物は、特に、大型射出成型機を用いたサイクル時間の長い成型において、優れた特性を有する。
Claims (8)
- ポリアミド樹脂組成物の製造方法であって、
リンターパルプを解繊しセルロース繊維を得る解繊工程と、
前記セルロース繊維とポリアミド樹脂モノマーとを混合し重合する重合工程と、
を有し、
前記ポリアミド樹脂組成物は、
(A)アミノ基末端濃度[-NH2]とカルボキシル基末端濃度[-COOH]とが下記式(1):
[-NH2] < [-COOH] ・・・(1)
を満たすポリアミド(但し、全末端基濃度[全末端基]に対するカルボキシル基末端濃度[-COOH]の比[-COOH]/[全末端基]が0.6であるものを除く。)と、
(B)平均繊維径が1nm以上500nm以下のセルロース繊維と
を含み、
前記ポリアミドのカルボキシル基末端濃度とアミノ基末端濃度との合計([-NH2]+[-COOH])が50μモル/g以上300μモル/g未満であり、
前記ポリアミド樹脂組成物中の前記ポリアミド100質量部に対する前記セルロース繊維の量が0.1質量部~100質量部である、ポリアミド樹脂組成物の製造方法。 - ポリアミド樹脂組成物の製造方法であって、
リンターパルプを解繊しセルロース繊維を得る解繊工程と、
前記セルロース繊維とポリアミド樹脂とを混合する混合工程と、
を有し、
前記ポリアミド樹脂組成物は、
(A)アミノ基末端濃度[-NH2]とカルボキシル基末端濃度[-COOH]とが下記式(1):
[-NH2] < [-COOH] ・・・(1)
を満たすポリアミド(但し、全末端基濃度[全末端基]に対するカルボキシル基末端濃度[-COOH]の比[-COOH]/[全末端基]が0.6であるものを除く。)と、
(B)平均繊維径が1nm以上500nm以下のセルロース繊維と
を含み、
前記ポリアミドのカルボキシル基末端濃度とアミノ基末端濃度との合計([-NH2]+[-COOH])が50μモル/g以上300μモル/g未満であり、
前記ポリアミド樹脂組成物中の前記ポリアミド100質量部に対する前記セルロース繊維の量が0.1質量部~100質量部である、ポリアミド樹脂組成物の製造方法。 - 前記ポリアミド樹脂組成物が、前記セルロース繊維100質量部に対して、分散剤0.1~50質量部を更に含む、請求項1又は2に記載の方法。
- 前記ポリアミド樹脂組成物が、樹脂ペレット形状であり、かつ水分率が1200ppm以下である、請求項1~3のいずれか一項に記載の方法。
- (A)アミノ基末端濃度[-NH2]とカルボキシル基末端濃度[-COOH]とが下記式(1):
[-NH2] < [-COOH] ・・・(1)
を満たすポリアミド(但し、全末端基濃度[全末端基]に対するカルボキシル基末端濃度[-COOH]の比[-COOH]/[全末端基]が0.6であるものを除く。)と、
(B)平均繊維径が1nm以上500nm以下のセルロース繊維と
を含み、
前記ポリアミドのカルボキシル基末端濃度とアミノ基末端濃度との合計([-NH2]+[-COOH])が50μモル/g以上300μモル/g未満であり、
前記ポリアミド100質量部に対する前記セルロース繊維の量が0.1質量部~100質量部であり、
前記セルロース繊維が、リンターパルプ由来である、ポリアミド樹脂組成物。 - 前記セルロース繊維100質量部に対して、分散剤0.1~50質量部を更に含む、請求項5に記載のポリアミド樹脂組成物。
- 樹脂ペレット形状であり、かつ水分率が1200ppm以下である、請求項5又は6に記載のポリアミド樹脂組成物。
- 請求項5~7のいずれか一項に記載のポリアミド樹脂組成物より形成された、成型品。
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