JPWO2008069182A1 - オキシメチレン系重合体を含む樹脂材料の接着方法および構造体 - Google Patents

オキシメチレン系重合体を含む樹脂材料の接着方法および構造体 Download PDF

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JPWO2008069182A1
JPWO2008069182A1 JP2008548280A JP2008548280A JPWO2008069182A1 JP WO2008069182 A1 JPWO2008069182 A1 JP WO2008069182A1 JP 2008548280 A JP2008548280 A JP 2008548280A JP 2008548280 A JP2008548280 A JP 2008548280A JP WO2008069182 A1 JPWO2008069182 A1 JP WO2008069182A1
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resin material
oxymethylene polymer
melting point
oxymethylene
polymer
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岡村 顕
顕 岡村
聡 長井
聡 長井
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Mitsubishi Gas Chemical Co Inc
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Mitsubishi Gas Chemical Co Inc
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    • B29K2105/0005Condition, form or state of moulded material or of the material to be shaped containing compounding ingredients
    • B29K2105/0044Stabilisers, e.g. against oxydation, light or heat
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
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    • B29K2105/126Whiskers, i.e. reinforcement in the form of monocrystals
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/16Fillers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2309/00Use of inorganic materials not provided for in groups B29K2303/00 - B29K2307/00, as reinforcement
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

オキシメチレン系重合体(A)を含む樹脂材料(X)と、樹脂材料(Y)とを接着する樹脂材料の接着方法であって、前記樹脂材料(Y)を、前記オキシメチレン系重合体(A)に対して融点が5〜50℃低い低融点オキシメチレン系重合体(B)とし、あるいは、前記樹脂材料(Y)を、前記樹脂材料(X)もしくは他種の樹脂材料とし、当該樹脂材料(Y)と樹脂材料(X)との間に前記低融点オキシメチレン系重合体(B)を介在させて、加熱処理を施す樹脂材料の接着方法、および当該接着方法により得られる構造体である。

Description

本発明は、オキシメチレン系重合体を含む樹脂材料間を接着させるために、特定の融点を有するオキシメチレン系重合体を用いる樹脂材料の接着方法および該接着方法によって得られる構造体に関する。
近年、地球規模での環境問題に対して、産業廃棄物が環境を汚染することを防止するために、焼却処理の際に必要な熱量やCO2発生量の削減が注目されている。その結果、材料の回収、リサイクルについての関心が益々高まっている。
オキシメチレン系重合体は、脂肪族エーテル型、もしくは脂肪族エーテルを主成分としたポリマーであり、主として石油に依存しない原料であるメタノールから誘導され、環境負荷の低い材料と考えられている。剛性などの機械的特性も高く、エンジニアリングプラスチックスとして現在、広く使用される優れた材料である。
オキシメチレン系重合体を含む樹脂材料同士を接着させる方法としては、その表面が化学的に不活性なため、超音波融着を行う方法や、オキシメチレン重合体表面を予め粗化したり、電子線やプラズマ処理で改質したりした上で、シアノアクリレート系接着剤、エポキシ系接着剤を用いる方法が知られている。前者はその工程や設備が複雑であるうえ、適用できる対象も一部の射出成形体に限られている。また、後者は十分な接着効果が得られないだけでなく、リサイクル性の点で、オキシメチレン系重合体とは別の成分を使用することになるために好ましくないといった問題があった。そのため、オキシメチレン系重合体を含む樹脂材料同士を同種のオキシメチレン系重合体の材料で接着する技術が望まれていた。
オキシメチレン系重合体同士の接着においては、同系の非晶性共重合体(特許文献1参照)、低融点の共重合体(特許文献2参照)の適用が提案されている。前者についてはその接着強度が十分でない上に、非晶性共重合体の融点が低く、接着後の耐熱性が劣り、実用性は不十分なものであった。一方、後者は、前者よりも接着強度が大幅に改良され、接着成分の耐熱性が上がっているものの、接着後に従来のオキシメチレン系重合体と同じ環境で使用するには未だ耐熱性に劣っている。
また、オキシメチレン系重合体は、結晶性の高い樹脂であり、これを含む射出成形品や押出成形品、延伸材料間の接着に際して、接着のために高温または長時間での熱履歴を経ると熱収縮が予想以上に大きく、更には材料側の溶融が無視できなくなり、形状を正確に維持した構造体が製造できないという問題がある。
本発明者らは、既にコモノマー含有量の大きいオキシメチレン共重合体を開発している。これは、融点が従来のオキシメチレン重合体と比べて適度に低いが、接着剤としての有効性についてはなんら言及されていない(特許文献3参照)。
特開平1−132638号公報 特開平8−60125号公報 国際公開2002−077049号公報
本発明は、オキシメチレン系重合体を含む樹脂材料同士の接着性を向上させ、構造体の熱収縮や熱変形を抑制することが可能な樹脂材料の接着方法、および当該接着方法により得られる構造体を提供することを目的とする。
本発明者らは、前記課題を解決すべく鋭意検討した結果、オキシメチレン系重合体を含む樹脂材料同士を接着させるに際し、一方の樹脂材料に含まれるオキシメチレン系重合体の融点に対し、特定の融点差をもったオキシメチレン系重合体を含む樹脂材料を、(1)他方の材料として、または(2)接着層として用いて、加熱処理を行なう本発明に想到した。そして、これにより、熱収縮や熱変形といった問題もなく材料間の接着性を向上させることができることを見出した。
すなわち、本発明は、オキシメチレン系重合体(A)を含む樹脂材料(X)と、樹脂材料(Y)とを接着する樹脂材料の接着方法であって、前記樹脂材料(Y)を、前記オキシメチレン系重合体(A)に対して融点が5〜50℃低い低融点オキシメチレン系重合体(B)とし、あるいは、前記樹脂材料(Y)を、前記樹脂材料(X)もしくは他種の樹脂材料とし、当該樹脂材料(Y)と樹脂材料(X)との間に前記低融点オキシメチレン系重合体(B)を介在させて、加熱処理を施す樹脂材料の接着方法である。
また、本発明は、上記接着方法で得られる構造体である。
本発明によれば、オキシメチレン系重合体を含む樹脂材料同士の接着性を向上させ、構造体の熱収縮や熱変形を抑制することが可能な樹脂材料の接着方法、および当該接着方法により得られる構造体を提供することができる。
[樹脂材料の接着方法]
本発明の樹脂材料の接着方法は、オキシメチレン系重合体(A)を含む樹脂材料(X)と、樹脂材料(Y)とを加熱処理にて接着する方法である。以下、各種材料および加熱処理の条件について説明する。
(オキシメチレン系重合体(A)を含む樹脂材料(X))
オキシメチレン系重合体(A)としては、一般に市販されているオキシメチレンホモポリマーやオキシメチレンブロック共重合体などが挙げられる。なかでも、下記一般式(1)で示される繰り返し単位を含み、かつ、トリオキサンと該トリオキサン100質量部に対し0.5〜30.0質量部の1種以上のコモノマーとの共重合物が好ましい。トリオキサン100質量部に対するコモノマーは、0.5〜10.0質量部であることがより好ましい。
Figure 2008069182
上記式(1)中、R1、R2はそれぞれ独立に、水素原子、アルキル基、アルキル基を有する有機基、フェニル基、フェニル基を有する有機基を表す。mは1〜6の整数を表す。アルキル基としては、炭素数1〜8のアルキル基が挙げられる。
上記コモノマーとしては、環状ホルマールや環状エーテルなどが挙げられる。具体的には、1,3−ジオキソランおよびその誘導体;1,3−ジオキセパンおよびその誘導体;1,3,5−トリオキセパン及びその誘導体;1,3,6−トリオキソカンおよびその誘導体;および単官能グリシジルエーテル;が好ましい。
樹脂材料(X)中のオキシメチレン系重合体(A)は、50vol%以上であることが好ましく、樹脂材料(X)がオキシメチレン系重合体(A)からなることがより好ましい。
(樹脂材料(Y))
樹脂材料(Y)に含まれる低融点オキシメチレン系重合体(B)の融点は、オキシメチレン系重合体(A)に対して5〜50℃低く、10〜30℃低いことが好ましい。これより融点差が小さい場合には、接着させるための温度がオキシメチレン系重合体(A)の融点に極めて近くなるため、オキシメチレン系重合体(A)を含む材料の熱収縮が大きくなるばかりでなく、熱変形、更には溶融して形状を損なうおそれがある。逆に融点差が大きい場合には前述のように接着後の耐熱性が劣ったり、十分な接着強度が得られなかったりする。
低融点オキシメチレン系重合体(B)としては、同じく前述の一般式(1)で示されるものであるが、トリオキサンと該トリオキサン100重量部に対し10.0〜50.0重量部の1種以上のコモノマーとの共重合物であることが好ましい。
樹脂材料(Y)が低融点オキシメチレン系重合体(B)を含有する場合、当該重合体(B)は、50vol%以上であることが好ましく、当該重合体(B)のみで構成されていることが好ましい。
また、樹脂材料(Y)が低融点オキシメチレン系重合体(B)を含有しない場合、すなわち、低融点オキシメチレン系重合体(B)が樹脂材料(X)と樹脂材料(Y)とを接着する接着層となる場合は、当該重合体(B)を主成分とすれば、他の材料を併用してもよい。
なお、低融点オキシメチレン系重合体(B)を接着層とする場合の樹脂材料(Y)は、樹脂材料(X)と同一の材質としてもよく、他種の材質としてもよい。他種の材質としては、オキシメチレン系重合物(A)の含有量が異なる材質、またはオキシメチレン系重合物(A)以外の成分が異なる材質などが挙げられる。
(加熱処理条件)
加熱処理条件(接着条件)は、オキシメチレン系重合体(A)の融点未満で、かつ、低融点オキシメチレン系重合体(B)の融点より20℃低い温度以上の範囲とすることが好ましい。上記融点未満とすることで、オキシメチレン系重合体(A)を含む材料の熱収縮が抑えられ、熱変形、さらには溶融して形状が損なわれることを防ぐことができる。また、低融点オキシメチレン系重合体(B)の融点より20℃低い温度以上で処理することで、十分な接着強度を付与することができる。
なお、本発明のオキシメチレン系重合体を含む材料は、主として上記のオキシメチレン系重合体を含有するものであるが、本発明の本来の目的を損なわない範囲内で公知の添加剤や充填剤を添加することが可能である。
添加剤としては、例えば結晶核剤、酸化防止剤、可塑剤、艶消し剤、発泡剤、潤滑剤、離型剤、帯電防止剤、紫外線吸収剤、光安定剤、熱安定剤、消臭剤、難燃剤、摺動剤、香料、抗菌剤等が挙げられる。また、充填剤としては、ガラス繊維、タルク、マイカ、炭酸カルシウム、チタン酸カリウムウィスカー等が挙げられる。さらに、顔料、染料を加えて所望の色目に仕上げることも可能である。また、各種モノマー、カップリング剤、末端処理剤、その他の樹脂、木粉、でんぷんなどを加えて変性することも可能である。
さらに、本発明に係る樹脂材料(X)および樹脂材料(Y)の形態には限定はないが、射出成形品、押出成形品、延伸成形、またはそれらを2次加工した成形品が好ましい。その他に、ブロー成形品、フィルム、シート、繊維、マルチフィラメント、モノフィラメント、ロープ、網、織物、編物、不織布、フィルター、更にはそれらを2次加工した材料が例示されるが、それらに限定されるものではない。これらの材料間にオキシメチレン系重合体(B)を介在させ熱接着させる場合、介在の形態としては、例えば、樹脂材料(A)の表面に、予め前記低融点オキシメチレン系重合体(B)を層状、又はドメインとして存在させることが好ましい。
また、連続(層状、棒状、波打ち状)、もしくは不連続(ドメイン状、ドット状)を問わず、オキシメチレン系重合体(A)を含む材料の1次加工時に同時に、または逐次的に表面へ予め介在させてもよいし、オキシメチレン系重合体(A)を含む材料の1次加工の以後、構造体を形成させるまでの間の工程で介在させてもよい。
[構造体]
本発明の構造体は、既述の本発明の樹脂材料の接着方法により得られる。この構造体は、オキシメチレン系重合体を含む樹脂材料同士の接着性が良好であり、熱収縮や熱変形が抑制されている。
かかる構造体は、そのまま用いてもよいし、さらに加工を施してもしてもよい。例えば、同じような接着作業をくり返して、もしくは同時に行なうことで、オキシメチレン系重合体(A)を含む少なくとも1種以上の樹脂材料が多層で構成される構造体とすることもできる。また、一度接着させた構造体を新たに形状の異なる別のオキシメチレン系重合体(A)を含む樹脂材料と接着させて更に高度な構造体を形成していくことができる。
例えば、構造体が多層繊維である場合の層構造としては、同一繊維中、その断面に、何れも繊維表面に露出した2つ以上の層を有し、その層を構成する成分が、少なくとも上記の樹脂材料(X)および(Y)の2成分からなる。表面への露出割合は、特に限定されないが、融点が低く、2次加工時に接着層として機能する樹脂材料(Y)(特に、オキシメチレン系重合体(B)成分)の露出割合が高いほど接着強度は良好なものとなる。そのため、樹脂材料(Y)を各々分かれた複数層として形成させてもよい。
以下に、実施例を挙げて本発明をさらに具体的に説明するが、本発明は以下に示す具体例に制限されるものではない。
なお、実施例で使用した材料、融点の測定方法、および接着方法と判断基準とを以下に示す。
(樹脂材料)
実施例の樹脂材料(X)として、172℃および168℃の融点を有する三菱エンジニアリングプラスチック株式会社製のユピタールA40(以下、オキシメチレン系重合体(a)という)およびユピタールF40(以下、オキシメチレン系重合体(b)という)を使用した。オキシメチレン系重合体(a)および(b)のそれぞれを、溶融紡糸し、延伸倍率4、単繊度で5dtexのマルチフィラメントに加工した。
実施例の樹脂材料(Y)として、155℃の融点を有する三菱エンジニアリングプラスチックス株式会社製ユピタールV40(以下、オキシメチレン系重合体(c)という)を使用した。このオキシメチレン系重合体(c)溶融紡糸し、延伸倍率1倍、単繊度で5dtexのマルチフィラメントに加工した。
なお、比較例の場合は、オキシメチレン系重合体(a)および(b)が樹脂材料(Y)となったり、オキシメチレン系重合体(c)が樹脂材料(X)となったりすることがある。
(融点の測定方法)
10℃/分の速度で、30℃から210℃まで昇温し、示差走査熱量計(セイコーインスツルメンツ(株)製DSC6200)を用い、溶融ピーク温度を測定し、融点とした。
(接着方法及び判定基準)
樹脂材料(X)のマルチフィラメントを10cm長に切断したものを鉄板の上に直線状に配置し、次に樹脂材料(Y)のマルチフィラメントを3cm長に切断したものを、樹脂材料(X)と交差するように上に配置し、更にもう1つの鉄板で挟みこんだ。これを下記表1に記載の温度に予め加熱した油圧式ホットプレス装置によって、所定時間の加熱、加圧条件下で熱接着処理(加熱処理)を施した。
処理後、樹脂材料(X)と樹脂材料(Y)との接着状態を目視で確認し、各々の溶融、未溶融の確認を行った。また、樹脂材料(X)の処理後の長さを測定し、処理前後での熱収縮率を測定した。
[実施例1〜7]
既述の接着方法、および下記表1に記載の条件で、樹脂材料(X)と樹脂材料(Y)とを接着した。評価結果も表1に示した。
[比較例1〜12]
既述の接着方法、および下記表1に記載の条件で、樹脂材料(X)と樹脂材料(Y)とを接着した。評価結果も表1に示した。
Figure 2008069182

Claims (9)

  1. オキシメチレン系重合体(A)を含む樹脂材料(X)と、樹脂材料(Y)とを接着する樹脂材料の接着方法であって、
    前記樹脂材料(Y)を、前記オキシメチレン系重合体(A)に対して融点が5〜50℃低い低融点オキシメチレン系重合体(B)とし、あるいは、
    前記樹脂材料(Y)を、前記樹脂材料(X)もしくは他種の樹脂材料とし、当該樹脂材料(Y)と樹脂材料(X)との間に前記低融点オキシメチレン系重合体(B)を介在させて、加熱処理を施す樹脂材料の接着方法。
  2. 低融点オキシメチレン系重合体(B)が、前記オキシメチレン系重合体(A)に対して融点が10〜30℃低い請求項1に記載の樹脂材料の接着方法。
  3. 加熱処理の温度を、前記オキシメチレン系重合体(A)の融点未満で、かつ、前記低融点オキシメチレン系重合体(B)の融点より20℃低い温度以上とする請求項1に記載の樹脂材料の接着方法。
  4. オキシメチレン系重合体(A)が、下記一般式(1)で表される繰り返し単位を含み、かつ、
    トリオキサンと、該トリオキサン100質量部に対し0.5〜30.0質量部の1種以上のコモノマーとの共重合物である請求項1に記載の樹脂材料の接着方法。
    Figure 2008069182
    (式中、R1、R2はそれぞれ独立に、水素原子、アルキル基、アルキル基を有する有機基、フェニル基、フェニル基を有する有機基を表す。mは1〜6の整数を表す。)
  5. オキシメチレン系重合体(B)が、下記一般式(1)で表される繰り返し単位を含み、かつ、
    トリオキサンと、該トリオキサン100質量部に対し5.0〜50.0質量部の1種以上のコモノマーとの共重合物である請求項1に記載の樹脂材料の接着方法。
    Figure 2008069182
    (式中、R1、R2はそれぞれ独立に、水素原子、アルキル基、アルキル基を有する有機基、フェニル基、フェニル基を有する有機基を表す。mは1〜6の整数を表す。)
  6. コモノマーが、1,3−ジオキソランおよびその誘導体、1,3−ジオキセパンおよびその誘導体、1,3,5−トリオキセパン及びその誘導体、1,3,6−トリオキソカンおよびその誘導体、および単官能グリシジルエーテルからなる群から選ばれる少なくとも1種である請求項4または5に記載の樹脂材料の接着方法。
  7. 樹脂材料(X)が、射出成形品、押出成形品、延伸成形品、またはそれらを2次加工した成形品であることを特徴とする請求項1に記載の樹脂材料の接着方法。
  8. 樹脂材料(X)の表面に、予め前記低融点オキシメチレン系重合体(B)を層状、又はドメインとして存在させる請求項1に記載の樹脂材料の接着方法。
  9. 請求項1に記載の接着方法で得られる構造体。
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JPH0860125A (ja) * 1994-08-25 1996-03-05 Polyplastics Co ポリアセタール樹脂用接着剤、接合方法およびその接合物
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