WO2010143366A1 - ポリマー微粒子含有ビニルエステル系樹脂組成物、その製造方法、及びその硬化物 - Google Patents
ポリマー微粒子含有ビニルエステル系樹脂組成物、その製造方法、及びその硬化物 Download PDFInfo
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- WO2010143366A1 WO2010143366A1 PCT/JP2010/003547 JP2010003547W WO2010143366A1 WO 2010143366 A1 WO2010143366 A1 WO 2010143366A1 JP 2010003547 W JP2010003547 W JP 2010003547W WO 2010143366 A1 WO2010143366 A1 WO 2010143366A1
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- vinyl ester
- ester resin
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F290/00—Macromolecular compounds obtained by polymerising monomers on to polymers modified by introduction of aliphatic unsaturated end or side groups
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F283/00—Macromolecular compounds obtained by polymerising monomers on to polymers provided for in subclass C08G
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F290/00—Macromolecular compounds obtained by polymerising monomers on to polymers modified by introduction of aliphatic unsaturated end or side groups
- C08F290/02—Macromolecular compounds obtained by polymerising monomers on to polymers modified by introduction of aliphatic unsaturated end or side groups on to polymers modified by introduction of unsaturated end groups
- C08F290/06—Polymers provided for in subclass C08G
- C08F290/064—Polymers containing more than one epoxy group per molecule
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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
- C08L31/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an acyloxy radical of a saturated carboxylic acid, of carbonic acid or of a haloformic acid; Compositions of derivatives of such polymers
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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
- C08L33/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
- C08L33/04—Homopolymers or copolymers of esters
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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
- C08L51/00—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
- C08L51/04—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers grafted on to rubbers
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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
- C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
- C08L63/10—Epoxy resins modified by unsaturated compounds
Definitions
- the present invention relates to a vinyl ester resin composition containing fine polymer particles, a production method thereof, and a cured product thereof.
- Patent Document 1 Many attempts have been made to modify vinyl esters by adding various polymer components to vinyl ester resins conceptually containing such epoxy (meth) acrylate resins. Attempts to improve toughness by mixing these are disclosed in Patent Document 1 and Patent Document 2.
- Patent Document 1 a mixed resin composition liquid of vinyl ester and styrene using bisphenol A diglycidyl ether as a raw material, a core portion composed of a copolymer of styrene and butadiene, and a methacrylic acid-alkyl copolymer.
- the resin composition obtained by dispersing the core-shell structured polymer fine particle “Kureha Paraloid” EXL-2655 composed of the shell portion as described above with a homomixer manufactured by Tokushu Kika Kogyo Co., Ltd. is heated and stirred at 60 ° C.
- a resin composition solution is prepared.
- Patent Document 2 100 parts of vinyl ester resin, fine particles of rubber-containing core-shell structure polymer (average particle size: 0.3 ⁇ m, glass transition temperature of rubber part: ⁇ 50 ° C., trade name “F” -351 ”) 15 parts, curing agent (Nippon Yushi Co., Ltd., trade name" Percure HOT ”) 2 parts, aluminum hydroxide (Sumitomo Chemical Co., Ltd., trade name” CW-308B ”) 200 parts, oxidation Magnesium (manufactured by Kyowa Chemical Co., Ltd., trade name “Kyowamag # 150”) 1 part, zinc stearate (manufactured by Adeka Fine Chemical Co., Ltd., trade name “ZNS-P”), crosslinked polystyrene (Soken Chemical Co., Ltd.) 5 parts manufactured and trade name “SGP-70C”) is stirred and mixed with a planetary mixer and aged at room temperature for 24 hours to prepare BMC for artificial marble.
- a core-structure polymer fine particle-containing vinyl ester resin is obtained by mixing generally commercially available powdered powder into a vinyl ester.
- the powdery core-shell structure polymer fine particles are produced by coagulating / drying core-shell polymer particles in an aqueous latex state prepared by emulsion polymerization.
- Each of the core-shell polymer particles is typically produced with a primary particle size of 0.1 to 1 ⁇ m.
- a plurality of particles are aggregated to form a secondary particle. It becomes a powder as an aggregate having a secondary particle size of about 100 to 200 ⁇ m. This is because particles having a size of 0.1 to 1 ⁇ m have a very strong physical cohesive force, and it is difficult to achieve a powder form with each particle.
- the polymer fine particles having the core-shell structure was necessary for the polymer fine particles having the core-shell structure to set the glass transition temperature of the shell polymer to a temperature significantly higher than room temperature.
- a typical shell polymer has a glass transition temperature of 70 ° C. or higher.
- the secondary particle size mentioned above increases significantly, and a few centimeters to several millimeters are mixed at the same time. is there. Further, as the secondary particle diameter increases, much labor and energy are required to disperse in a dispersed state close to the primary particles.
- vinyl esters generally contain a large amount of styrene monomer. From the viewpoint of odor, safety, or prevention of quality deterioration due to unnecessary polymerization, it is industrially easy to mix powder core-shell structure polymer fine particles. However, for this reason, the technology of modifying the vinyl ester with the core-shell structure polymer fine particles has been used only for a very limited amount of applications.
- the present invention is to provide an improved method for producing a fine particle-containing vinyl ester resin and an improved vinyl ester resin composition obtained by this production method. Specifically, to provide a vinyl ester resin modified with a core-shell polymer while avoiding all the troublesome problems that were unavoidable in the prior art when modifying vinyl ester resins with core-shell fine particles. It is in.
- the present invention has a specific vinyl ester resin composition and polymer fine particle structure, so that the polymer fine particles can be handled even when the polarity and viscosity change within the viscosity range that can be handled and the stability is maintained. It has been found that the primary dispersion state can be maintained without aggregation.
- the present invention is a polymer ester-containing vinyl ester resin composition
- a polymer ester-containing vinyl ester resin composition comprising 100 parts by weight of vinyl ester resin, 1 to 100 parts by weight of polymer particles, and 0 to 100 parts by weight of vinyl monomer,
- the polymer fine particles have a primary particle size of 0.05 to 1 ⁇ m
- the present invention relates to a polymer fine particle-containing vinyl ester resin composition, wherein the polymer fine particles are dispersed in a primary particle state in the polymer fine particle-containing vinyl ester resin composition.
- the vinyl ester resin is a polymer epoxide-containing polyepoxide, comprising 100 parts by weight of polyepoxide and 1 to 100 parts by weight of the polymer particles, and the polymer particles are primary particles in the polyepoxide.
- the polymer fine particle-containing vinyl ester resin composition which is a reaction product of the polymer fine particle-containing polyepoxide dispersed in the above state and an ethylenically unsaturated double bond-containing monocarboxylic acid.
- the polymer fine particle-containing vinyl ester resin composition is characterized in that a (meth) acrylate group is graft-bonded to the polymer fine particle.
- the (meth) acrylate group is graft-bonded means that the polymer chain has a (meth) acrylate group on the polymer chain, and the (meth) acrylate group is polymerized. It does not mean that a polymer is present. That is, it means that a (meth) acrylate group that can be a starting point of polymerization is grafted to the polymer fine particles, and does not mean that it contains a (meth) acrylate residue after polymerization. Of course, as long as it contains the grafted (meth) acrylate groups, those containing (meth) acrylate residues after polymerization are also the polymer fine particles.
- the (meth) acrylate group is graft-bonded means that the (meth) acrylate group is graft-bonded (hanging) by an ester bond on the polymer chain constituting the polymer fine particle. It does not mean that it is graft-bonded to the polymer chain constituting the polymer fine particle by the reaction of the unsaturated double bond part of the (meth) acrylate group. That is, it means that the (meth) acrylate group is grafted to the polymer fine particles by forming an ester bond, and does not mean that it is contained in the polymer chain via a carbon-carbon bond. Therefore, the (meth) acrylate group is a reactive point capable of radical polymerization possessed by the polymer fine particles.
- the polymer fine particle-containing polyepoxide contains a polymer fine particle having an epoxy equivalent increased from less than 500 g / eq to 25 g / eq or more in the presence of the polymer fine particles dispersed in a primary particle state.
- the polymer fine particle-containing vinyl ester resin composition is a reaction product of polyepoxide and an ethylenically unsaturated double bond-containing monocarboxylic acid.
- the polymer fine particles have a core-shell structure, and the shell polymer contains 30 to 95% by weight of an aromatic vinyl monomer, 5 to 70% by weight of a vinylcyan monomer, and contains an epoxy group.
- Copolymer of shell-forming monomer (A) 100% by weight comprising (meth) acrylate monomer 0-55% by weight, multifunctional vinyl monomer 0-30% by weight, and other vinyl monomers 0-50% by weight
- the polymer fine particle-containing vinyl ester resin composition 100% by weight comprising (meth) acrylate monomer 0-55% by weight, multifunctional vinyl monomer 0-30% by weight, and other vinyl monomers 0-50% by weight
- the polymer fine particle-containing vinyl ester resin composition 100% by weight comprising (meth) acrylate monomer 0-55% by weight, multifunctional vinyl monomer 0-30% by weight, and other vinyl monomers 0-50% by weight
- the polymer fine particle-containing vinyl ester resin composition 100% by weight comprising (meth) acrylate monomer
- a further object of the present invention is to provide a vinyl ester resin composition of the present invention described above, and in particular, a vinyl ester resin composition in which the toughness of the cured product is greatly improved. Specifically, it is an object of the present invention to provide a vinyl ester resin modified with a core-shell type polymer which has not been attempted due to technical problems.
- the present invention includes core-shell type polymer fine particles having a shell polymer which is difficult to handle and has a shell polymer which is a soft polymer, and has a glass transition temperature of less than 20 ° C., preferably less than 0 ° C.
- the present invention also relates to a vinyl ester resin composition and a method for producing the same.
- the present inventors added such polymer fine particles having a shell polymer layer that is a soft polymer that has not been attempted in the past and that can be dispersed in primary particles, to the vinyl ester resin, It has also been found that the toughness of the cured product of the composition is greatly improved.
- the inventors of the present invention have made it possible to handle a vinyl ester resin composition containing polymer fine particles having such a soft polymer as a shell polymer layer in a viscosity range that can be handled and in a state where stability is maintained.
- the inventors have also found a method for producing a composition capable of maintaining the primary dispersion state without causing the polymer fine particles to aggregate even if the change occurs.
- the polymer fine particles have a core-shell type structure, and the glass transition temperature (Tg) of the shell polymer is less than 20 ° C.
- Tg glass transition temperature
- a preferred embodiment in this case is to provide a polymer fine particle-containing vinyl ester resin composition, wherein the shell polymer has a glass transition temperature (Tg) of less than 0 ° C.
- the shell polymer is a copolymer of the shell-forming monomer (B), and 100% by weight of the shell-forming monomer is an alkoxyalkyl (meth) acrylate.
- Polymeric fine particle-containing vinyl ester comprising 5 to 95% by weight, glycidyl (meth) acrylate 0 to 40% by weight, functional vinyl monomer 0 to 20% by weight, and other vinyl monomers 5 to 70% by weight It is made into a system resin composition.
- the present invention also provides a cured product obtained by radical polymerization of a curable composition containing the above-described polymer fine particle-containing vinyl ester resin composition of the present invention, wherein the polymer fine particles are primary.
- the present invention relates to a cured product that is dispersed in a state of particles.
- this invention is a manufacturing method of the polymer fine particle containing vinyl ester-type resin composition of the said invention, Comprising: In order, Obtaining the polymer fine particle-containing polyepoxide, A step of reacting the polyepoxide containing polymer fine particles with a monocarboxylic acid containing an ethylenically unsaturated double bond to obtain a vinyl ester resin containing polymer fine particles, and a step of adding the vinyl monomer to the vinyl ester resin. And a method for producing a polymer fine particle-containing vinyl ester resin composition.
- the polymer fine particle-containing vinyl ester resin composition of the present invention comprises 100 parts by weight of vinyl ester resin, 1 to 100 parts by weight of polymer fine particles, and 0 to 100 parts by weight of vinyl monomer, and the primary particle size of the polymer fine particles is 0.
- the polymer fine particles have a core-shell structure, and the glass transition temperature (Tg) of the shell polymer is less than 20 ° C., preferably less than 0 ° C., that is, a polymer fine particle-containing vinyl which is a soft polymer.
- Tg glass transition temperature
- the cured product is particularly excellent in mechanical properties.
- the polymer fine particles are particularly preferably dispersed in the form of primary particles in the polymer fine particle-containing vinyl ester resin composition.
- the curable composition of the present invention needs to contain 1 to 100 parts by weight of the polymer fine particles with respect to 100 parts by weight of the vinyl ester resin. From the viewpoint of the balance of the effect of improving toughness, it is preferable. More preferably, the composition of the present invention is prepared so that the content of polymer fine particles is 11 to 80 parts by weight, and this is used by diluting with the vinyl monomer according to the present invention as necessary. To do. Alternatively, it is industrially preferable to use it by mixing with a commercially available vinyl ester resin and adjusting the concentration to the desired polymer fine particle concentration.
- the amount of vinyl monomer contained in the composition of the present invention is 0 to 100 parts by weight. As the vinyl monomer content increases, the viscosity of the composition of the present invention decreases and becomes easier to handle. However, the amount of the vinyl monomer may be appropriately determined so as to achieve a desirable balance with the physical properties of the cured product.
- the primary particle diameter of the polymer fine particles has a volume average particle diameter in the range of 0.05 to 1 ⁇ m.
- the polymer fine particles are dispersed as primary particles in a continuous layer consisting essentially of 100 parts by weight of vinyl ester resin and 0 to 100 parts by weight of vinyl monomer. Dispersed with a particle size of 05-1 ⁇ .
- the polymer fine particles preferably swell to other components according to the present invention, that is, vinyl ester resin or vinyl monomer component, it is preferable that the polymer fine particles do not dissolve.
- the polymer layer is preferably a polymer having a crosslinked structure.
- the polymer fine particles according to the present invention are considered as good solvents, for example, with respect to solvents such as toluene, acetone, MEK, ethyl acetate, THF, methylene chloride and the like. Even if it swells, it does not dissolve, that is, it does not lose the form of the fine particles.
- polymer fine particles are dispersed in the form of primary particles (hereinafter also referred to as primary dispersion) in the polymer fine particle-containing vinyl ester resin composition and polyepoxide (hereinafter also referred to as a continuous layer).
- primary dispersion means that the polymer fine particles having a primary particle diameter of 0.05 to 1 ⁇ m according to the present invention are dispersed substantially independently (without contact), and the dispersion state is, for example, the above-mentioned polymer fine particle containing A part of the polyepoxide can be dissolved in a solvent such as methyl ethyl ketone, and this can be confirmed by measuring the particle size with a particle size measuring device by laser light scattering.
- stable dispersion of polymer fine particles means that the polymer fine particles are not aggregated, separated, or precipitated in the continuous layer, and are constantly under normal conditions over a long period of time. Mean that the distribution of the polymer fine particles in the continuous layer does not substantially change, and the viscosity is lowered by heating these compositions in a range that is not dangerous. It is preferable that “stable dispersion” can be maintained even if stirring is performed.
- the polymer fine particle-containing vinyl ester resin composition of the present invention is obtained by dispersing polymer fine particles having a primary particle diameter of 0.05 to 1 ⁇ m obtained in the step of obtaining a polymer fine particle-containing polyepoxide described later in a primary particle state.
- the polymer fine particle-containing polyepoxide is obtained by reacting an ethylenically unsaturated double bond-containing monocarboxylic acid.
- composition obtained by mixing 0 to 100 parts by weight of a vinyl monomer with 100 parts by weight of the polymer fine particle-containing vinyl ester resin and adding a vinyl monomer. .
- a vinyl monomer can be present in the step of reacting the polyepoxide and the ethylenically unsaturated double bond-containing monocarboxylic acid.
- (meth) acrylate means acrylate and / or methacrylate.
- the polymer fine particle-containing polyepoxide is reacted with an ethylenically unsaturated double bond-containing monocarboxylic acid to obtain a polymer fine particle-containing vinyl ester resin.
- the (meth) acryloyloxy group addition reaction is performed at a reaction temperature of 60 to 150 ° C.
- the reaction is preferably performed within 8 hours, and from the viewpoint of avoiding gelation during the reaction, the reaction is more preferably completed within 5 hours at a reaction temperature of 70 to 135 ° C.
- the end point of the reaction is determined by tracking the acid value of the reaction product, but the acid value of the polymer fine particle-containing polyepoxide according to the present invention or the polymer fine particle-containing vinyl ester resin composition of the present invention after the reaction is completed.
- the acid value is in the same category as a general vinyl ester.
- it is 20 mgKOH / g or less, but if it is necessary to lower the residual acid component from the viewpoint of corrosivity, hot water resistance, etc., it can be made less than 10 mgKOH / g, and conversely, from the viewpoint of adhesiveness, etc.
- this reaction can be carried out in the presence of oxygen in an inert gas atmosphere such as nitrogen gas or carbon dioxide, or in the presence of oxygen such as an air atmosphere or a nitrogen-oxygen mixed gas atmosphere with a lower oxygen content than air. As long as such problems do not occur, it can be implemented.
- an inert gas atmosphere such as nitrogen gas or carbon dioxide
- oxygen such as an air atmosphere or a nitrogen-oxygen mixed gas atmosphere with a lower oxygen content than air.
- the amount of the epoxy group of the polyepoxide in the polymer fine particle-containing polyepoxide to be subjected to the addition reaction of the (meth) acryloyloxy group and the amount of the carboxylic acid group in the ethylenically unsaturated double bond-containing monocarboxylic acid are in molar ratio.
- the upper limit of the amount of the carboxylic acid group is centered around the equivalent of the epoxy group and the carboxylic acid group contained only in the polyepoxide, ie, the total amount of the epoxy groups of both the polyepoxide and the polymer fine particles.
- the addition reaction of the (meth) acryloyloxy group is preferably carried out in the presence of a catalyst.
- a catalyst examples include tertiary amines such as dimethylbenzylamine and tributylamine, quaternary ammonium salts such as trimethylbenzylammonium chloride, primary amine and secondary amine salts, lithium chloride and the like.
- N-substituted aromatic amines such as N, N-dimethylaniline, imidazole compounds such as 2-ethyl-4-methylimidazole, trisubstituted phosphines such as triphenylphosphine, quaternary compounds such as tetrabutylphosphonium salt Phosphonium salts can be used.
- the amount of the catalyst is 0.01 to 1 part by weight with respect to 100 parts by weight of the total amount of the polyepoxide in the polymer fine particle-containing polyepoxide and the ethylenically unsaturated double bond-containing monocarboxylic acid. Is preferable from the viewpoints of reactivity and cost.
- the addition reaction of the (meth) acryloyloxy group is preferably carried out in the presence of a polymerization inhibitor.
- a polymerization inhibitor examples include hydroquinones such as hydroquinone, hydroquinone monomethyl ether (MEHQ), t-butylhydroquinone and t-butylcatechol (TBC), quinones such as benzoquinone, anthraquinone, naphthoquinone and toluquinone, phenyl- ⁇ -Amines such as naphthylamine and parabenzylaminophenol, nitro compounds such as dinitrobenzene, nitroxy compounds such as 4-hydroxy-2,2,6,6-tetramethylpiperidine-1-oxy (OH-TEMPO), phenothiazine, etc.
- hydroquinones such as hydroquinone, hydroquinone monomethyl ether (MEHQ), t-butylhydroquinone and t-butylcatechol (TBC)
- quinones
- Examples thereof include sulfur-containing compounds, oxygen molecules (dissolved oxygen), and copper naphthenate.
- the amount of these inhibitors may be used in the range of 2 to 1,000 ppm with respect to the total amount of polyepoxide and ethylenically unsaturated double bond-containing monocarboxylic acid.
- the polymer fine particle-containing polyepoxide according to the present invention is a composition in which polymer fine particles are dispersed in the state of primary particles in the polyepoxide.
- Various methods can be used to obtain such a polymer fine particle-containing polyepoxide. For example, after bringing polymer fine particles obtained in an aqueous latex state into contact with the polyepoxide, a method of removing unnecessary components such as water, polymer Examples include a method in which the fine particles are once extracted into an organic solvent and then mixed with the polyepoxide, and then the organic solvent is removed. The method described in International Publication WO2005 / 28546 is preferably used, and the specific invention is concerned.
- the method for producing the polymer fine particle-containing polyepoxide may be prepared by sequentially including a first step of obtaining a polymer fine particle loose aggregate, a second step of obtaining a polymer fine particle dispersion, and a third step of obtaining a polymer fine particle-containing polyepoxide. preferable.
- the composition of the present invention includes a hand lay-up method, a spray-up method, a pultrusion method, a filament winding method, a matched die method, a prepreg method, a centrifugal molding method, a resin transfer molding (RTM) method, a vacuum bag molding method, and a cold press method. It can be molded by known molding methods such as glass fiber and carbon fiber, BMC (bulk molding compound) and SMC (sheet molding compound) raw materials, gel coat, lining material, paint, adhesive, paste, In addition to putty, epoxy acrylate is preferably used for applications such as adhesives, paints, and inks that are cured by ultraviolet rays or electron beams, which are generally used.
- the cured product of the present invention is preferably obtained by curing such a curable composition of the present invention by radical polymerization.
- curing agent examples include ketone peroxides such as methyl ethyl ketone peroxide, diacyl peroxides such as benzoyl peroxide, hydroperoxides such as cumene hydroperoxide, peroxyketals, dialkyl peroxides, peroxydicarbonates, peroxyesters. Etc., and 0.1 to 3 parts by weight are preferably added to 100 parts by weight of the vinyl ester resin according to the present invention.
- organic acid metal salts such as cobalt naphthenate, N-substituted aromatic amines such as N, N-dimethylaniline and N, N-dimethylparatoluidine, and the like can be preferably used. It is preferable to add 0.01 to 1 part by weight with respect to 100 parts by weight of the vinyl ester resin.
- UV rays including ultraviolet rays by sunlight
- examples of such a photo-curing agent include p-tert-butyltrichloroacetophenone, diethoxyacetophenone (DEAP), benzophenone, Michler's ketone (4,4-bisdimethylaminobenzophenone) and other aromatic ketones, benzyl, benzyldimethyl ketal, etc.
- TMS tetramethylthiuram monosulfide
- thioxanthone 2-chlorothioxanthone
- these photoinitiators can be used together with a sensitizer, and as such a sensitizer, n-butylamine, triethylamine, N-methyldiethanolamine, piperidine, N, N-dimethylaniline, triethylenetetramine, Amines such as diethylaminoethyl (meth) acrylate, urea compounds such as O-tolylthiourea, sulfur compounds such as s-benzyl-isothuronium-p-toluenesulfinate, N, N-dimethyl-p-aminobenzonitrile Nitriles such as sodium, phosphorus compounds such as sodium diethyl thiophosphate and the like are exemplified, and it is preferable to add 0 to 6 parts by weight.
- a sensitizer n-butylamine, triethylamine, N-methyldiethanolamine, piperidine, N, N-dimethylaniline, triethylenetetramine,
- an irradiation amount of 10 to 3,000 mJ / cm 2 at a wavelength of 200 to 600 nm can be exemplified as typical curing conditions.
- the temperature at the time of curing with the radical initiator as described above, and it is appropriately selected so that the type necessary for the initiator and the cured product can be obtained in the range of ⁇ 20 ° C. to 150 ° C. can do.
- the vinyl ester resin according to the present invention is generally a reaction product resin obtained by reacting a polyepoxide (eg, epoxy resin) with an ethylenically unsaturated double bond-containing monocarboxylic acid (eg: (meth) acrylic acid). Yes, it has the same skeleton as the polyepoxide in the main chain, and is curable by an unsaturated double bond in the molecule.
- a polyepoxide eg, epoxy resin
- an ethylenically unsaturated double bond-containing monocarboxylic acid eg: (meth) acrylic acid
- one or more skeletons selected from the group consisting of aromatic ester types are preferred, and bisphenol A type and phenol novolac type skeletons are more preferred.
- such vinyl esters have excellent properties such as excellent acid resistance and high curing speed, but have the disadvantage of low toughness.
- the present invention was made to compensate for the drawbacks while maintaining the excellent properties of such vinyl ester resin, and the polymer fine particle-containing vinyl ester resin composition is a polymer fine particle according to the present invention. Is dispersed in the form of primary particles, so that the maintenance and compensation are effectively performed.
- the polymer fine particles according to the present invention preferably have a rubber core, a cured product having improved mechanical strength can be obtained.
- the polyepoxide according to the present invention is an epoxy compound having an epoxy group in the molecule, and from the viewpoint of ensuring the primary dispersibility, a preferred number average molecular weight is 50 or more and 4,000 or less, and a more preferred number average molecular weight is 100 or more and 2,500 or less.
- the effect of the present invention is particularly effective and particularly preferable for vinyl ester resins using polyepoxides having a number average molecular weight of 1,000 or less, which has been difficult to improve toughness with the prior art.
- Examples of the epoxide include bisphenol A type epoxy resin, bisphenol F type epoxy resin, novolac type epoxy resin, brominated glycidyl ether type epoxy resin represented by brominated bisphenol A type epoxy resin, glycidyl ester type epoxy resin, hydrogenated bisphenol.
- Examples include A (or F) type epoxy resins, glycidyl ether type epoxy resins, aminoglycidyl ether-containing resins and epoxy compounds obtained by adding bisphenol A (or F), polybasic acids and the like to these epoxy resins.
- bisphenol A type epoxy resin and phenol novolac type epoxy resin are preferable.
- an operation of increasing the epoxy equivalent by 25 or more to the polymer fine particle-containing polyepoxide having an epoxy equivalent of less than 500 g / eq in a state of containing the polymer fine particles dispersed in a primary particle state can also be used.
- phenolic compounds such as bisphenol A, bisphenol F, resorcin, and dibasic acids (anhydrides) such as adipic acid, tetrahydrophthalic anhydride, dimer acid, and carboxylated nitrile rubber at both ends
- anhydrides such as adipic acid, tetrahydrophthalic anhydride, dimer acid, and carboxylated nitrile rubber at both ends
- Such a denaturing operation can be preferably carried out by stirring at a temperature of 70 to 180 ° C.
- catalysts include tertiary amines such as dimethylbenzylamine, tributylamine and triethylamine, quaternary ammonium salts such as trimethylbenzylammonium chloride, primary amine and secondary amine salts, and lithium chloride.
- Inorganic salts such as N, N-substituted aromatic amines such as N, N-dimethylaniline, imidazole compounds such as 2-ethyl-4-methylimidazole, trisubstituted phosphines such as triphenylphosphine, and tetrabutylphosphonium salts.
- Quaternary phosphonium salts can be used.
- the amount of the catalyst is preferably in the range of 0.01 to 1 part by weight with respect to 100 parts by weight of the total amount of polyepoxide in the polymer fine particle-containing polyepoxide, from the viewpoint of reaction degree control.
- (Ethylenically unsaturated double bond-containing monocarboxylic acid) examples include (meth) acrylic acid, crotonic acid, cinnamic acid, sorbic acid, HE (M) A malate (hydroxyethyl (meth) acrylate and maleic anhydride). Reaction products), half esters of maleic acid and itaconic acid, etc., (meth) acrylic acid is preferred from the viewpoint of reactivity and cost.
- the polymer fine particles according to the present invention require a volume average primary particle diameter of 0.05 to 1 ⁇ m, and preferably 0.1 to 1 in terms of obtaining a preferable viscosity and a highly stable vinyl ester resin.
- 0.8 ⁇ m preferably a core-shell type polymer fine particle comprising at least two layers of a core polymer layer present inside thereof and a shell polymer layer present outside thereof, and the core polymer layer However, it consists of an elastic body whose glass transition temperature is less than 0 degreeC.
- the polymer fine particle according to the present invention is a polymer fine particle in which a shell polymer layer is formed by graft polymerization of a monomer component capable of graft copolymerization in the presence of an elastic core layer made of such an elastic body,
- the structure has an elastic core layer existing inside thereof and at least one shell polymer layer that is graft-polymerized on the surface and covers the periphery or part of the elastic core layer.
- the shell polymer layer of the present invention has a core polymer layer / shell polymer layer ratio (mass ratio of monomers forming each polymer) in the range of 40/60 to 99/1 with respect to the core polymer layer.
- the polymer fine particles The amount of the shell polymer layer occupying is more preferably 60/40 to 90/10, and still more preferably 70/30 to 90/10.
- the polymer constituting the core polymer layer (which may have a multilayer structure) existing inside the polymer fine particle has a glass transition temperature (Tg) of preferably less than 0 ° C., more preferably ⁇ 20 ° C. or less, and further preferably A rubber having elasticity of ⁇ 45 ° C. or lower, that is, a rubber core is preferable.
- Tg glass transition temperature
- Such a core polymer layer usually has a spherical shape.
- the volume average particle diameter of the core portion in the polymer fine particles is as long as the volume average particle diameter of the polymer fine particles is in the range of 0.05 to 1 ⁇ m. Is preferably 0.05 to 1 ⁇ m, more preferably 0.05 to 0.6 ⁇ m.
- the particle diameter of the core polymer layer can be easily confirmed by, for example, preparing a cured product containing the composition of the present invention and observing it using a transmission electron microscope (TEM).
- TEM transmission electron microscope
- Such a core polymer layer preferably has a crosslinked structure.
- the crosslinked core polymer is dissolved in the vinyl ester resin or vinyl monomer component according to the present invention. In addition, it does not dissolve even if it swells even in the good solvent.
- Such a rubber core is obtained by polymerizing a monomer for forming a rubber core.
- the first monomer examples include diene rubber obtained by polymerizing conjugated diene monomers, acrylic rubber obtained by polymerizing (meth) acrylate monomers, and polysiloxane rubber. Although it can be used, diene rubber or acrylic rubber is preferred from the viewpoint of cost.
- the rubbery polymer-forming monomer may further contain an aromatic vinyl monomer and a vinyl cyanomer.
- a preferred first monomer for the acrylic rubber is butyl acrylate or 2-ethylhexyl acrylate, and a preferred first monomer for the diene rubber is butadiene, isoprene, or the like.
- a crosslinked structure is introduced into a polymer component obtained by polymerizing the monomer.
- the method for introducing the crosslinked structure is not particularly limited, and a generally used method can be employed.
- a crosslinkable monomer such as a polyfunctional monomer described later is added to the monomer component for rubber core formation, and then polymerization is performed.
- the rubber core preferably has a gel content of 60% by mass or more, more preferably 80% by mass or more, further preferably 90% by mass or more, and 95% by mass or more. It is particularly preferred.
- the gel content refers to when about 1.2 g of crumb obtained by coagulation and drying is immersed in 100 g of toluene and left at 23 ° C. for 24 hours, and then insoluble and soluble components are separated. Means the ratio of the insoluble content to the total amount of the insoluble content and the soluble content.
- polyfunctional monomer As the polyfunctional monomer, butadiene is not included, and allyl alkyl (meth) acrylates such as allyl (meth) acrylate and allylalkyl (meth) acrylate; allyloxyalkyl (meth) acrylates; (poly) ethylene 2 (meth) acryl groups such as glycol di (meth) acrylate, butanediol di (meth) acrylate, ethylene glycol di (meth) acrylate, triethylene glycol di (meth) acrylate, tetraethylene glycol di (meth) acrylate Polyfunctional (meth) acrylates having the above; diallyl phthalate, triallyl cyanurate, triallyl isocyanurate, divinylbenzene and the like. Particularly preferred are allyl methacrylate, triallyl isocyanurate, butanediol di (meth) acrylate, and divinylbenzene.
- the outermost shell polymer layer of the polymer fine particles is a layer composed of a shell polymer obtained by polymerizing a shell-forming monomer, and this improves the compatibility between the polymer fine particles and the vinyl ester resin according to the present invention. It plays the role which makes it possible to disperse
- a polymer having a glass transition temperature (Tg) of less than 20 ° C. may be preferable. More preferably, it may be preferable to use a polymer in which the glass transition temperature (Tg) of the shell polymer is less than 0 ° C.
- Such a shell polymer is preferably grafted on the rubber core. More precisely, it is preferable that the monomer component used for forming the shell polymer layer is graft-polymerized to the core polymer forming the rubber core, and the shell polymer layer and the rubber core are substantially chemically bonded. That is, the shell polymer is preferably formed by graft polymerization of the monomer for shell formation in the presence of the core polymer, and is preferably graft-polymerized covering a part or the whole of the core polymer. . This polymerization operation can be carried out by adding a monomer, which is a constituent of the shell polymer, to the core polymer latex prepared and present in the form of an aqueous polymer latex.
- a preferable shell-forming monomer (A) is 30 to 95% by weight of an aromatic vinyl monomer, 5 to 70% by weight of a vinylcyan monomer, and an epoxy group.
- a shell-forming monomer comprising 0 to 55% by weight of (meth) acrylate monomer, 0 to 30% by weight of a polyfunctional vinyl monomer, and 0 to 50% by weight of other vinyl monomers, more preferably Styrene 40 to 84.5 wt%, acrylonitrile 10 to 40 wt%, glycidyl methacrylate 5 to 35 wt%, polyfunctional vinyl monomer 0.5 to 5 wt%, and other vinyl monomers 0 to 20 wt% is there.
- a preferable shell-forming monomer (B) is an alkoxyalkyl (meth) acrylate.
- the content of alkoxyalkyl (meth) acrylate is preferably 5 to 95% by weight (relative to 100% by weight of the shell polymer), more preferably 30 to 50% by weight.
- a more preferred embodiment as the shell-forming monomer (B) is that it comprises an alkoxyalkyl (meth) acrylate and glycidyl (meth) acrylate, and further comprises a polyfunctional vinyl monomer. You can also.
- a polyfunctional vinyl monomer is included as a constituent component of the shell polymer, it tends to be easy to lower the viscosity of the vinyl ester resin composition of the present invention.
- 100% by weight of the shell-forming monomer comprises 5 to 50% by weight of alkoxyalkyl (meth) acrylate and 1 to 40% by weight of glycidyl (meth) acrylate.
- the medium in which polymer fine particles are dispersed is accompanied by a chemical change of polyepoxide ⁇ vinyl ester. Further, even in the process of curing the vinyl ester to obtain a cured product, the chemical dispersion is further accompanied by another chemical change in the medium in which the polymer fine particles are dispersed.
- the polymer fine particles disclosed in the prior art can only be dispersed in a state where a large number of primary particles are aggregated, the volume of the polymer fine particles increases, and therefore the polymer fine particles tend to float with respect to the vinyl ester resin. It was a cause of lowering instability.
- the present invention has a specific polymer fine particle structure or shell composition, so that the primary particles can be dispersed without agglomeration of the polymer fine particles even when the above-described large changes in polarity and viscosity occur.
- the above-mentioned chemistry while stably containing polymer fine particles in an amount exceeding 10 parts by weight with respect to 100 parts by weight of vinyl ester, which has been found to be able to be retained and difficult with the prior art, It has also been found that a distributed state that does not change before and after the change can be realized.
- the shell forming monomer (A) will be described below.
- the aromatic vinyl monomer is a shell-forming monomer for imparting a certain non-polarity to the shell polymer from the viewpoint of the compatibility of the shell polymer with the vinyl ester resin because of the primary dispersibility according to the present invention.
- the monomer used as a part of the monomer is preferably 30 to 95% by weight, more preferably 40 to 84.5% by weight in 100% by weight of the shell-forming monomer (A).
- Styrene, vinyltoluene and the like are exemplified, and styrene is preferable.
- the vinylcyan monomer is considered as a monomer used as a part of the shell-forming monomer (A) in order to impart a certain polarity to the shell polymer. It is preferable that 5-70% by weight is contained in 100% by weight of the monomer (A), more preferably 10-40% by weight, and (meth) acrylonitrile and the like are exemplified, but preferably acrylonitrile is used. is there.
- the epoxy group-containing (meth) acrylate monomer is considered as a monomer used as a part of the shell-forming monomer (A) in order to introduce an epoxy group into the shell polymer, and the above-described (meth) acryloyloxy It is used to generate a (meth) acrylate group grafted to the polymer fine particles according to the present invention through a group addition reaction, and is 0 to 55% by weight based on 100% by weight of the shell-forming monomer (A). It is preferably contained, more preferably 5 to 35% by weight, and glycidyl (meth) acrylate and the like are exemplified, but glycidyl methacrylate is preferred.
- the polyfunctional vinyl monomer is a part of the monomer (A) for forming the shell in order to prevent the polymer fine particles from swelling and to facilitate the polymerization of the shell polymer. And is preferably contained in an amount of 0 to 30% by weight, more preferably 0.5 to 5% by weight in 100% by weight of the shell-forming monomer (A).
- Acrymethacrylate and triallyl isocyanurate are preferable.
- the other vinyl monomer is a vinyl monomer other than the aromatic vinyl monomer, the vinyl cyan monomer, the epoxy group-containing (meth) acrylate monomer, and the polyfunctional vinyl monomer, and having 1 to 8 carbon atoms.
- examples thereof include alkyl (meth) acrylates having an alkyl group, and (meth) acrylates having a functional group other than an epoxy group such as 2-hydroxyethyl methacrylate, 2-hydroxypropyl methacrylate, and 4-hydroxybutyl methacrylate.
- the shell forming monomer (B) will be described below.
- the alkoxyalkyl (meth) acrylate is a single monomer for shell formation in order to impart a certain polarity to the shell polymer from the viewpoint of compatibility of the shell polymer with the vinyl ester resin because of the primary dispersibility according to the present invention. It is a monomer used as a part of the body (B), and is preferably contained in an amount of 5 to 95% by weight, more preferably 10 to 50% by weight in 100% by weight of the shell-forming monomer.
- 2-methoxyethyl (meth) acrylate, 2-ethoxyethyl (meth) acrylate, 2- (2-ethoxyethoxy) Examples include ethyl (meth) acrylate, phenoxyethyl (meth) acrylate, etc., preferably 2-methoxyethyl acrylate DOO, 2-ethoxyethyl acrylate, 2- (2-ethoxyethoxy) ethyl acrylate.
- the glycidyl (meth) acrylate is considered to be a monomer used as a part of the shell-forming monomer in order to introduce an epoxy group into the shell polymer, and undergoes the addition reaction of the (meth) acryloyloxy group described above. And used to generate (meth) acrylate groups grafted to the polymer fine particles according to the present invention, and is contained in 0 to 40% by weight in 100% by weight of the shell-forming monomer (B). More preferred is 1 to 40% by weight, still more preferred is 1 to 25% by weight.
- the polyfunctional vinyl monomer is considered to be a monomer that prevents swelling of polymer fine particles and is used as a part of the monomer for shell formation.
- the other vinyl monomer is a vinyl monomer other than the alkoxyalkyl (meth) acrylate, the glycidyl (meth) acrylate, and the polyfunctional vinyl monomer, and has an alkyl group having 1 to 8 carbon atoms ( And (meth) acrylate having a functional group other than an epoxy group, such as (meth) acrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl methacrylate, 4-hydroxybutyl methacrylate, and the like.
- Vinyl monomer (Vinyl monomer) The vinyl monomer which concerns on this invention is added to the said polymer fine particle containing epoxy (meth) acrylate, and the component which has the function to set to a required characteristic and performance in the hardened
- vinyl monomer examples include aromatic vinyl monomers, (meth) acrylate monomers, allyl monomers, and the like.
- aromatic vinyl monomer examples include styrene, ⁇ -methylstyrene, vinyl toluene, and divinyl benzene.
- Examples of the (meth) acrylate monomer include alkyl (meth) acrylate having 1 to 10 carbon atoms and hydroxyethyl (meth) acrylate, butanediol di (meth) acrylate, and 1,6-hexanediol.
- bifunctional (meth) acrylates such as di (meth) acrylate and di (meth) acrylate having a glycol structure
- polyfunctional (meth) acrylates such as trimethylolpropane tri (meth) acrylate can be exemplified.
- allyl esters examples include diallyl (iso) phthalate and triallyl isocyanurate.
- volume average particle diameter of polymer fine particles The volume average particle diameter of the polymer fine particles was measured as follows using a particle diameter measuring apparatus (Microtrac UPA manufactured by Nikkiso Co., Ltd.). Polymer fine particles (CS-1 to CS-7) in an aqueous latex state were measured by diluting them with water. Other polymer fine particle-containing polyepoxide compositions (ECS-1 to ECS-7) and polymer fine particle-containing vinyl ester resin compositions (VEM-1 to VEM-7) were measured in a state dissolved in methyl ethyl ketone.
- Viscosity of compositions in Examples The viscosity was measured in a cone / plate configuration using a 40 mm diameter cone on a Malvern Bohlin CVOR rheometer.
- Tg glass transition temperature of polymer of monomer for shell formation
- the following values were used as the glass transition temperature of the homopolymer used for the calculation in this example.
- the polymer of the monomer for shell formation that is, the Tg of the shell polymer is 96 ° C. (calculated value).
- This aqueous latex polymer fine particle was diluted with water, and the volume average particle size of the polymer fine particle was measured with a particle size measuring device (Microtrac UPA manufactured by Nikkiso Co., Ltd.). The particle size distribution was 0.2 ⁇ m. Was sharp monodisperse.
- Polymerization was initiated by adding 0.015 part of paramentane hydroperoxide, followed by 0.04 part of sodium formaldehyde sulfoxylate. Four hours after the start of polymerization, 0.01 part of paramentane hydroperoxide, 0.0015 part of ethylenediaminetetraacetic acid and 0.001 part of ferrous sulfate were added. At 10 hours after polymerization, the residual monomer was removed by devolatilization under reduced pressure, the polymerization was terminated, and an aqueous latex of core polymer particles made of a styrene / butadiene copolymer was obtained. The polymerization conversion rate was 98%.
- the core polymer particles were charged with 1155 g (including 375 g of styrene / butadiene rubber particles) in a 3 L glass container in an aqueous latex state, and 440 g of pure water was added. While stirring at 60 ° C. in a nitrogen atmosphere, 0.8 g of sodium formaldehyde sulfoxylate was added thereto, and then as a shell forming monomer (A), from 65 g of styrene, 30 g of acrylonitrile, and 30 g of glycidyl methacrylate. A mixture consisting of the monomer mixture and 0.13 g of t-butyl hydroperoxide was added over 150 minutes for graft polymerization.
- aqueous latex of a core polymer mainly composed of butyl acrylate described in the production method of CS-1 is prepared, and 200 g of water is subsequently added thereto, and stirring is continued in a nitrogen atmosphere.
- a monomer (A) a monomer mixture consisting of 55 g of styrene, 20 g of acrylonitrile, 15 g of glycidyl methacrylate, and 2.3 g of allyl methacrylate and 0.09 g of butyl hydroperoxide was added over 120 minutes. Graft polymerization was performed.
- polymer fine particles (CS-3) were obtained in the form of an aqueous latex.
- the polymerization conversion rate was 99%.
- a part of this aqueous latex is coagulated with a 3% magnesium sulfate solution, washed with water and dried to obtain a polymer solid, then hot pressed at 180 ° C. and processed into a sheet, and core-shell type polymer fine particles CS-
- the polymer of the shell-forming monomer that is, the Tg of the shell polymer was 93 ° C. (DMA measurement).
- the volume average particle size of the polymer fine particles in the aqueous latex state was 0.2 ⁇ m and was sharp monodisperse.
- TAIC triallyl isocyanurate
- the polymerization conversion rate was 99%.
- the volume average particle size of the polymer fine particles in the aqueous latex state was 0.2 ⁇ m and was sharp monodisperse.
- the polymerization conversion rate was 99%.
- This aqueous latex polymer fine particle was diluted with water, and the volume average particle size of the polymer fine particle was measured with a particle size measuring device (Microtrac UPA manufactured by Nikkiso Co., Ltd.).
- the particle size distribution was 0.2 ⁇ m. Was sharp monodisperse.
- the polymerization conversion rate was 99%.
- This aqueous latex polymer fine particle was diluted with water, and the volume average particle size of the polymer fine particle was measured with a particle size measuring device (Microtrac UPA manufactured by Nikkiso Co., Ltd.).
- the particle size distribution was 0.2 ⁇ m. Was sharp monodisperse.
- the polymerization conversion rate was 99%.
- This aqueous latex polymer fine particle was diluted with water, and the volume average particle size of the polymer fine particle was measured with a particle size measuring device (Microtrac UPA manufactured by Nikkiso Co., Ltd.).
- the particle size distribution was 0.2 ⁇ m. Was sharp monodisperse.
- the average particle size was as follows. The distribution was a sharp monodispersion similar to that of polymer fine particles in an aqueous latex state, and no aggregates were observed.
- ECS-1 0.2 ⁇ m
- ECS-2 0.1 ⁇ m
- ECS-3 0.2 ⁇ m
- ECS-4 0.1 ⁇ m
- ECS-5 0.2 ⁇ m
- ECS-6 0.2 ⁇ m
- ECS-7 0.2 ⁇ m
- VAM-1 polymer fine particle-containing vinyl ester resin composition
- the obtained cured product was observed with a TEM (transmission electron microscope) to confirm the dispersion state of the polymer fine particles.
- the primary particles were uniformly dispersed without agglomeration, and the dispersed particle size was 0.2 ⁇ m.
- the fracture toughness value (K1c) of this cured product was 1.2 MPa * m 0.5 .
- Example 2 Production of polymer fine particle-containing vinyl ester resin composition
- ECS-2 polymer fine particle-containing polyepoxide
- Epicoat 828EL bisphenol A type epoxy resin
- 187 g / eq manufactured by Japan Epoxy Resin
- Example 1 50 g of the vinyl ester resin thus obtained was mixed with 50 g of a commercially available vinyl ester resin (Neopol 8250L, manufactured by Nippon Iupika), and further N, N-dimethylaniline 0. 095 g and 1.9 g of benzoyl peroxide paste (Luperox ACT50, manufactured by Arkema, purity 50 wt%) were added and cured in the same procedure as in Example 1.
- the dispersion state of the polymer fine particles in the cured product was observed in the same manner as in Example 1, the primary particles were uniformly dispersed without agglomeration, and the dispersed particle size was 0.11 ⁇ m.
- the fracture toughness value (K1c) of this cured product was 1.2 MPa * m 0.5 .
- Example 3 Production of polymer fine particle-containing vinyl ester resin composition
- ECS-3 acid value of the obtained polymer fine particle-containing epoxy methacrylate
- Example 3 50 g of the polymer fine particle-containing vinyl ester resin obtained in Example 3 is mixed with Neopol 8250L and styrene monomer in the same manner as in Example 1, and cured using N, N-dimethylaniline and benzoyl peroxide paste. It was.
- the obtained cured product was observed with a TEM (transmission electron microscope) to confirm the dispersion state of the polymer fine particles. As a result, the primary particles were uniformly dispersed without agglomeration, and the dispersed particle size was 0.2 ⁇ m. .
- the fracture toughness value (K1c) of this cured product was 1.2 MPa * m 0.5 .
- Example 3 47 g of the polymer fine particle-containing vinyl ester resin obtained in Example 3 was mixed with 50 g of a commercially available vinyl ester resin (Neopol 8450, novolac-type vinyl ester resin, manufactured by Nippon Iupika) and 3 g of styrene monomer.
- a commercially available vinyl ester resin Naopol 8450, novolac-type vinyl ester resin, manufactured by Nippon Iupika
- 3 styrene monomer 3 g
- curing was performed using N, N-dimethylaniline and benzoyl peroxide paste (Luperox ACT50). An exotherm was observed after approximately 30 minutes.
- the dispersion state of the polymer fine particles was confirmed, it was uniformly dispersed with primary particles without agglomeration, and the dispersed particle size was 0.2 ⁇ m.
- the fracture toughness value (K1c) of this cured product was 1.2 MPa * m 0.5 .
- Example 4 Production of polymer fine particle-containing vinyl ester resin composition
- the reaction was performed in the same procedure for 3.3 hours except that the polymer fine particle-containing polyepoxide was different from Example 2 and ECS-4 was used.
- the acid value of the obtained polymer fine particle-containing epoxy methacrylate was 15 mgKOH / g.
- Example 2 50 g of polymer fine particle-containing vinyl ester resin obtained in Example 4 was mixed with Neopol 8250L and cured using N, N-dimethylaniline and benzoyl peroxide paste. The obtained cured product was observed with a TEM (transmission electron microscope) to confirm the dispersion state of the polymer fine particles. As a result, the primary particles were uniformly dispersed without agglomeration, and the dispersed particle size was 0.1 ⁇ m. . The fracture toughness value (K1c) of this cured product was 1.2 MPa * m 0.5 .
- Example 5 Production of polymer fine particle-containing vinyl ester resin composition
- ECS-5 polymer fine particle-containing polyepoxide
- 20.4 g of bis A type epoxy resin epoxy equivalent (EEW) of the polymer fine particle-containing polyepoxide (ECS-5) was 248 g / eq as a result of measurement by the above-described method, so that the polymer fine particle-containing polyepoxide (ECS-5) 82.
- VAM-5 polymer fine particle-containing vinyl ester resin composition
- This vinyl ester resin (VEM-5) was diluted with methyl ethyl ketone, and the volume average particle size of the polymer fine particles was measured with a particle size measuring device (Microtrac UPA). As a result, the particle size distribution was 0.2 ⁇ m. Monodispersed.
- the polymer fine particle-containing vinyl ester resin 50 g obtained in this way was mixed with 50 g of a commercially available vinyl ester resin (Neopol 8250L, made by Nippon Iupika), and N, N-dimethylaniline was prepared in the same manner as in Example 2. And cured with benzoyl peroxide paste. The obtained cured product was observed with a TEM (transmission electron microscope) to confirm the dispersion state of the polymer fine particles. As a result, the primary particles were uniformly dispersed without agglomeration, and the dispersed particle size was 0.2 ⁇ m. .
- Example 6 Production of polymer fine particle-containing vinyl ester resin composition
- Polymer fine particle-containing polyepoxide (ECS-6) 93.6 g, bis-A type epoxy resin (Epicoat 828EL, 187 g / eq) 0.8 g, phenol novolac type epoxy resin (EPALLOY 8250, manufactured by CVC Specialty Chemicals, 174 g / eq) 17 .8 g was charged into a 500 mL separable flask and heated to 120 ° C.
- VAM-6 polymer fine particle-containing vinyl ester resin composition
- the vinyl ester resin (VEM-6) was diluted with methyl ethyl ketone, and the volume average particle size of the polymer fine particles was measured with a particle size measuring device (Microtrac UPA). As a result, the particle size distribution was 0.2 ⁇ m. Monodispersed.
- Example 7 Production of polymer fine particle-containing vinyl ester (epoxy acrylate) resin composition
- Polymer fine particle-containing polyepoxide (ECS-7) 76.8 g and bis A type epoxy resin (Epicoat 828EL, 187 g / eq) 44 g were charged into a 500 mL separable flask and heated to 120 ° C. with stirring.
- SR-454 ethoxylated (3 mol) trimethylolpropane triacrylate, manufactured by Sartomer
- SR-454 ethoxylated (3 mol) trimethylolpropane triacrylate, manufactured by Sartomer
- isobornyl acrylate 4.8 g were added to 9.1 g of this polymer fine particle-containing vinyl ester resin composition (VEM-7).
- VAM-7 vinyl ester resin composition
- 0.8 g of benzoin isopropyl ether as a photoinitiator and 0.32 g of N-methyldiethanolamine as a photosensitizer were added and diluted with 2.4 g of methyl ethyl ketone to obtain a photocurable composition.
- aqueous latex 1155 g (including 375 g of styrene / butadiene rubber particles) of a core polymer mainly composed of styrene / butadiene rubber obtained by the procedure described in Example 2 was charged into a 3 L glass container, and 440 g of pure water was added. While stirring at 60 ° C. in a nitrogen atmosphere, as a monomer mixture that is not a shell-forming monomer (A), from 62 g of methyl methacrylate, 38 g of styrene, and 0.1 g of t-butyl hydroperoxide The resulting monomer mixture was added over 120 minutes to allow graft polymerization.
- A shell-forming monomer
- the volume-average particle size of the aqueous latex polymer fine particles (CS-1C) was 0.1 ⁇ m, and the particle size distribution was sharply monodispersed, similar to CS-2 in Example 2.
- Comparative Example 2 1300 g of an aqueous latex of a core polymer mainly composed of styrene / butadiene rubber obtained by the procedure described in Example 2 (including 420 g of styrene / butadiene rubber particles) was charged into a 3 L glass container, and 440 g of pure water was added to add nitrogen. It stirred at 70 degreeC, performing substitution. A monomer mixture consisting of 60 g of methyl methacrylate, 10 g of butyl acrylate, 35 g of styrene, and 0.4 g of t-butyl hydroperoxide was added to the monomer mixture which is not the shell-forming monomer (A) over 120 minutes.
- aqueous latex polymer particles (CS-2C) were obtained.
- the polymerization conversion rate was 99%.
- the aqueous latex polymer fine particles were diluted with water and the particle size was measured in the same manner as in Example 2. As a result, the particle size was 0.1 ⁇ m, and the particle size distribution was sharply monodispersed. It was almost the same.
- Calcium chloride is added to the aqueous latex (CS-2C) to coagulate and dehydrate the graft rubber particles (CS-2C), and then dried at 50 ° C. for 1 day to obtain powdered (CS-2C). It was.
- Polymer fine particle-containing polyepoxide (ECS-2C) 101.8 g was charged into a 500 mL separable flask and heated to 120 ° C. with stirring.
- Methacrylic acid (39.4 g) in which 0.107 g of MEHQ (hydroquinone monomethyl ether) and 0.006 g of OH-TEMPO (4-hydroxy-2,2,6,6-tetramethylpiperidine-1-oxyl) were dissolved was added.
- 0.39 g of N, N-dimethylbenzylamine was added and reacted at 110 to 115 ° C. for 3 hours in an air atmosphere.
- the resulting polymer fine particle-containing epoxy methacrylate had an oxidation of 17.
- Example 2 In the same manner as in Example 1, 0.095 g of N, N-dimethylaniline and 1.9 g of benzoyl peroxide paste (Luperox ACT50, manufactured by Arkema, purity 50 wt%) were added to 50 g of the vinyl ester resin thus obtained. In addition, it was cured in the same procedure as in Example 1. When the dispersion state of the polymer fine particles in the cured product was observed in the same manner as in Example 1, (CS-2C) was aggregated and dispersed, and most of the particles were dispersed at 1 to 2 ⁇ m. The fracture toughness value (K1c) of this cured product was 0.7 MPa * m 0.5 .
- K1c fracture toughness value
- Table 1 summarizes the materials used in Examples 1 to 7 and Comparative Examples 1 and 2 and some of the measurement results.
- this aqueous latex is coagulated with a 3% magnesium sulfate solution, washed with water and dried to obtain a polymer solid, then hot pressed at 160 ° C. to be processed into a sheet, and core-shell polymer fine particles CS-
- the polymer of the monomer for shell formation that is, the Tg of the shell polymer was ⁇ 33 ° C. (DMA measurement).
- Table 2 summarizes the results.
- This aqueous latex polymer fine particle was diluted with water, and the volume average particle size of the polymer fine particle was measured with a particle size measuring device (Microtrac UPA manufactured by Nikkiso Co., Ltd.). The particle size distribution was 0.2 ⁇ m. Was sharp monodisperse.
- polymer fine particles (CS-102) were obtained in the form of an aqueous latex.
- the polymerization conversion rate was 99%.
- the polymer of the shell-forming monomer that is, the Tg of the shell polymer was ⁇ 22 ° C. (DMA measurement).
- the volume average particle size of the polymer fine particles in the aqueous latex state was 0.2 ⁇ m and was sharp monodisperse.
- the average particle size was as follows. The distribution was a sharp monodispersion similar to that of polymer fine particles in an aqueous latex state, and no aggregates were observed.
- ECS-101 0.2 ⁇ m
- ECS-102 0.2 ⁇ m
- ECS-101 polymer fine particle-containing polyepoxide
- Epicoat 828EL 187 g / eq, manufactured by Japan Epoxy Resin
- VAM-101 polymer fine particle content 10 wt%, vinyl ester resin 90 wt%, epoxy methacrylate
- Styrene monomer ratio 65/35 (charged weight ratio), viscosity 1.2 Pa ⁇ s (25 ° C.)).
- Example 12 91.7 g of polymer epoxide containing polymer fine particles (ECS-102) and 25.2 g of bis A type epoxy resin (Epicoat 828EL, 187 g / eq, manufactured by Japan Epoxy Resin) were charged into a 500 mL separable flask and stirred at 120 ° C. The temperature rose. To this was added 43.7 g of methacrylic acid in which 0.064 g of MEHQ (hydroquinone monomethyl ether) and 0.006 g of monotertiary butylhydroquinone were added and mixed uniformly, and then 0.42 g of N, N-dimethylbenzylamine was added.
- MEHQ hydroquinone monomethyl ether
- the reaction was performed at 120 to 125 ° C. for 2.3 hours in a nitrogen / oxygen mixed gas atmosphere containing 6 vol% oxygen.
- the acid value of the resulting polymer fine particle-containing epoxy methacrylate was 12 mgKOH / g.
- VAM-102 polymer fine particle-containing vinyl ester resin composition
- Styrene monomer ratio 70/30 (charged weight ratio), viscosity 1.2 Pa ⁇ s (25 ° C.)
- Example 13 88 g of polymer fine particle-containing polyepoxide (ECS-1) and 22.1 g of bis-A type epoxy resin (Epicoat 828EL, 187 g / eq, manufactured by Japan Epoxy Resin) were charged into a 500 mL separable flask and heated to 120 ° C. with stirring. did. To this, 0.46 g of methacrylic acid in which 0.061 g of MEHQ (hydroquinone monomethyl ether) and 0.006 g of monotertiary butylhydroquinone were dissolved was added and mixed uniformly, and then 0.39 g of N, N-dimethylbenzylamine was added.
- MEHQ hydroquinone monomethyl ether
- the reaction was performed at 115 to 120 ° C. for 2.7 hours in a nitrogen / oxygen mixed gas atmosphere containing 6 vol% oxygen.
- the acid value of the obtained polymer fine particle-containing epoxy methacrylate was 13 mgKOH / g.
- VAM-1 polymer fine particle content 10 wt%, vinyl ester resin 90 wt%, epoxy methacrylate
- Styrene monomer ratio 65/35 (charged weight ratio), viscosity 1.2 Pa ⁇ s (25 ° C.)).
- Example 14 As Example 14, a polymer fine particle-containing epoxy methacrylate having an acid value of 11 mgKOH / g was obtained in the same manner as in Example 13, except that ECS-3 was used instead of the polymer fine particle-containing polyepoxide in ECS-1. It was.
- Example 14 50 g of the polymer fine particle-containing vinyl ester resin (VEM-3) obtained in Example 14 was mixed with Neopol 8250L and styrene monomer in the same procedure as in Example 13, and N, N-dimethylaniline, A defoamer (BYK-A555) was added and mixed uniformly. It was then cured using a benzoyl peroxide paste. The obtained cured product was observed with a TEM (transmission electron microscope) to confirm the dispersion state of the polymer fine particles. As a result, the primary particles were uniformly dispersed without agglomeration, and the dispersed particle size was 0.2 ⁇ m. . The fracture toughness value (K1c) of this cured product was 1.2 MPa * m 0.5 .
- Example 15 88 g of polymer fine particle-containing polyepoxide (ECS-101), 21 g of bis A type epoxy resin (Epicoat 828EL, 187 g / eq, manufactured by Japan Epoxy Resin), and bis A type epoxy resin (Epicoat 1001, 470 g / eq, manufactured by Japan Epoxy Resin) 9.7 g was charged into a 500 mL separable flask and heated to 120 ° C. with stirring.
- Example 12 and Comparative Example 11 are compared, unlike the prior art, Tg is not lowered, that is, rigidity is not substantially lowered, and toughness is greatly improved. I understand.
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Abstract
Description
前記ポリマー微粒子の1次粒子径が0.05~1μmであり、かつ、
前記ポリマー微粒子が、前記ポリマー微粒子含有ビニルエステル系樹脂組成物中で、1次粒子の状態で分散していることを特徴とする、ポリマー微粒子含有ビニルエステル系樹脂組成物に関する。
前記ポリマー微粒子含有ポリエポキシドを得る工程、
該ポリマー微粒子含有ポリエポキシドにエチレン性不飽和二重結合含有モノカルボン酸を反応させてポリマー微粒子含有ビニルエステル樹脂を得る工程、及び
該ビニルエステル樹脂に前記ビニルモノマーを添加する工程、を含むことを特徴とする、ポリマー微粒子含有ビニルエステル系樹脂組成物の製造方法に関する。
本発明のポリマー微粒子含有ビニルエステル系樹脂組成物は、ビニルエステル樹脂100重量部、ポリマー微粒子1~100重量部、及びビニルモノマー0~100重量部を含み、前記ポリマー微粒子の1次粒子径が0.05~1μmであり、かつ、前記ポリマー微粒子が、前記ポリマー微粒子含有ビニルエステル系樹脂組成物中で、1次粒子の状態で分散していることを特徴とする、ポリマー微粒子含有ビニルエステル系樹脂組成物なので、その硬化物は機械物性に優れる。
本発明における、ポリマー微粒子含有ビニルエステル系樹脂組成物やポリエポキシド(以下、連続層とも呼ぶ。)の中で、ポリマー微粒子が1次粒子の状態で分散している(以下、一次分散とも呼ぶ。)とは、本発明に係る1次粒子径が0.05~1μmのポリマー微粒子同士が実質的に独立して(接触なく)分散していることで、その分散状態は、例えば、前記ポリマー微粒子含有ポリエポキシドの一部をメチルエチルケトンのような溶剤に溶解し、これをレーザー光散乱による粒子径測定装置等により、その粒子径を測定することにより確認できる。
本発明のポリマー微粒子含有ビニルエステル系樹脂組成物は、後述するポリマー微粒子含有ポリエポキシドを得る工程により得た、1次粒子径が0.05~1μmであるポリマー微粒子が1次粒子の状態で分散しているポリマー微粒子含有ポリエポキシドに、エチレン性不飽和二重結合含有モノカルボン酸を反応させる工程で得られる。
前記(メタ)アクリロイルオキシ基の付加反応に供する前記ポリマー微粒子含有ポリエポキシド中のポリエポキシドのエポキシ基量と、前記エチレン性不飽和二重結合含有モノカルボン酸中のカルボン酸基の量は、モル比で、そのカルボン酸基の量が、ポリエポキシドのみに含まれるエポキシ基とカルボン酸基が等量である付近を中心として、上限を小過剰量、即ち、ポリエポキシドとポリマー微粒子の両方のエポキシ基の合計量が1モル等量に対して、カルボン酸基1.1モル等量とすると、ポリマー微粒子に(メタ)アクリロイルオキシ基を十分に付与させることができるので好ましく、下限をポリエポキシドに含まれるエポキシ基1モル等量に対して、カルボン酸基0.5モル等量となる量とすることが好ましい。
本発明に係るポリマー微粒子含有ポリエポキシドは、ポリエポキシド中に、ポリマー微粒子が1次粒子の状態で分散している組成物である。
本発明の組成物は、ハンドレイアップ法、スプレーアップ法、プルトルージョン法、フィラメントワインディング法、マッチドダイ法、プリプレグ法、遠心成形法、レジントランスファーモールディング(RTM)法、バキュームバッグ成型法、コールドプレス法等の公知の成型方法で成形可能であり、ガラス繊維や炭素繊維との複合材料、BMC(バルクモールディングコンパウンド)やSMC(シートモールディングコンパウンド)の原材料、ゲルコート、ライニング材、塗料、接着剤、ペースト、パテなどの他、エポキシアクリレートが一般的に使用されている紫外線や電子線によって硬化する接着剤、塗料、インク等の用途に好ましく用いられる。
本発明に係るビニルエステル樹脂は、一般に、ポリエポキシド(例:エポキシ樹脂)とエチレン性不飽和二重結合含有モノカルボン酸(例:(メタ)アクリル酸)とを反応させて得られる反応生成樹脂であり、主鎖に前記ポリエポキシドと同じ骨格を有し、分子内の不飽和二重結合により、硬化性を有する。
本発明に係るポリエポキシドは、エポキシ基を分子内に有するエポキシ化合物であり、前記一次分散性を確保する観点から、好ましい数平均分子量は50以上、4,000以下であり、より好ましい数平均分子量は100以上、2,500以下である。従来技術では靭性改良が困難であった、数平均分子量1,000以下のポリエポキシドを用いたビニルエステル樹脂において、本発明の効果は特に有効であり、特に好ましい。
本発明におけるエチレン性不飽和二重結合含有モノカルボン酸としては、(メタ)アクリル酸、クロトン酸、桂皮酸、ソルビン酸、HE(M)Aマレート((メタ)アクリル酸ヒドロキシエチルとマレイン酸無水物の反応生成物)、マレイン酸やイタコン酸のハーフエステル等が挙げられるが、反応性、コストの観点から、好ましくは、(メタ)アクリル酸である。
本発明に係るポリマー微粒子は、その体積平均1次粒子径が、0.05~1μmであることを要し、好ましい粘度と高度に安定なビニルエステル樹脂を得る観点から、好ましくは0.1~0.8μmであり、好ましくは、その内側に存在するコアポリマー層、及びその最も外側に存在するシェルポリマー層の少なくとも2層を含むコアシェル型構造のポリマー微粒子であって、かつ、そのコアポリマー層が、ガラス転移温度が0℃未満の弾性体からなる。より好ましくは、本発明に係るポリマー微粒子は、このような弾性体からなる弾性コア層の存在下に、グラフト共重合可能なモノマー成分をグラフト重合してシェルポリマー層を形成したポリマー微粒子であり、この場合、その内部に存在する弾性コア層と、その表面にグラフト重合してこの弾性コア層の周囲、又は一部を覆っている、少なくとも1つのシェルポリマー層を有する構造となる。
ポリマー微粒子の内部に存在するコアポリマー層(多層構造であってよい)を構成するポリマーは、そのガラス転移温度(Tg)が、好ましくは0℃未満、より好ましくは-20℃以下、さらに好ましくは-45℃以下である弾性を有するゴム、即ち、ゴムコアであることが好ましい。このようなコアポリマー層は、通常球形の形状を有するが、この場合のポリマー微粒子中のコア部分の体積平均粒子径は、ポリマー微粒子の体積平均粒子径が0.05~1μmの範囲となる限りにおいて、好ましくは0.05~1μmであり、より好ましくは0.05~0.6μmである。コアポリマー層の粒子径は、例えば、本発明の組成物を含む硬化物を作成した後、透過型電子顕微鏡(TEM)を使って観察すれば、容易に確認できる。
このようなゴムコアは、上記単量体を重合してなるポリマー成分に架橋構造が導入されていることが好ましい。架橋構造の導入方法としては、特に限定されるものではなく、一般的に用いられる手法を採用することができる。例えば、上記モノマーを重合してなるポリマー成分に架橋構造を導入する方法としては、ゴムコア形成用単量体成分に後述する多官能性単量体等の架橋性単量体を添加し、次いで重合する方法等が挙げられる。具体的には、前記ゴムコアは、ゲル含量が60質量%以上であることが好ましく、80質量%以上であることがより好ましく、90質量%以上であることがさらに好ましく、95質量%以上であることが特に好ましい。なお、本明細書でいうゲル含量とは、凝固、乾燥により得られたクラム約1.2gをトルエン100gに浸漬し、23℃で24時間静置した後に不溶分と可溶分を分別したときの、不溶分と可溶分の合計量に対する不溶分の比率を意味する。
前記多官能性単量体としては、ブタジエンは含まれず、アリル(メタ)アクリレート、アリルアルキル(メタ)アクリレート等のアリルアルキル(メタ)アクリレート類;アリルオキシアルキル(メタ)アクリレート類;(ポリ)エチレングリコールジ(メタ)アクリレート、ブタンジオールジ(メタ)アクリレート、エチレングリコールジ(メタ)アクリレート、トリエチレングリコールジ(メタ)アクリレート、テトラエチレングリコールジ(メタ)アクリレート等の(メタ)アクリル基を2個以上有する多官能(メタ)アクリレート類;ジアリルフタレート、トリアリルシアヌレート、トリアリルイソシアヌレート、ジビニルベンゼン等が挙げられる。特に好ましくはアリルメタアクリレート、トリアリルイソシアヌレート、ブタンジオールジ(メタ)アクリレート、及びジビニルベンゼンである。
ポリマー微粒子の最も外側存在するシェルポリマー層は、シェル形成用単量体を重合したシェルポリマーからなる層であるが、本発明に係る、ポリマー微粒子とビニルエステル樹脂との相溶性を向上させ、本発明に係る硬化性組成物、又はその硬化物中においてポリマー微粒子が一次粒子の状態で分散することを可能にする役割を担う。
本発明のポリマー微粒子を一次粒子の状態で分散し、かつ、特に本発明の組成物の硬化物の靱性を改良する観点から好ましいシェル形成用単量体(B)は、アルコキシアルキル(メタ)アクリレートを含んでなる、ガラス転移温度(Tg)が20℃未満のシェルポリマーとすることである。アルコキシアルキル(メタ)アクリレートの含量が、5~95重量%(シェルポリマー100重量%に対して)であることが好ましく、より好ましくは30~50重量%とすることである。
本発明に係るビニルモノマーは、前記ポリマー微粒子含有エポキシ(メタ)アクリレートに添加され、本発明のポリマー微粒子含有ビニルエステル系樹脂組成物の硬化物に、必要な特性や性能に設定する機能を有する成分である。
ポリマー微粒子の体積平均粒子径は、粒子径測定装置(日機装(株)製Microtrac UPA)を用いて次のようにして測定した。水性ラテックス状態にあるポリマー微粒子(CS-1~CS-7)は、これを水で希釈して測定した。その他の、ポリマー微粒子含有ポリエポキシド組成物(ECS-1~ECS-7)、ポリマー微粒子含有ビニルエステル樹脂組成物(VEM-1~VEM-7)では、メチルエチルケトンに溶解した状態で測定した。
実施例5中に記載のEEWは、ISO-3001に従って測定した。
JIS K6901に従って測定した。即ち、精秤した試料をアセトン(試薬特級)25mLにホットプレート上で少し加熱しながら溶解した後、フェノールフタレイン指示薬を5滴加えて、攪拌しつつ0.1N水酸化カリウム(KOH)溶液で滴定し、20秒間以上桃色を保つ時点を終点とした。空試験も試料を含まない以外は同じ操作で実施した。試料の量は酸価に応じて0.7~3gで精秤した。
Malvern社製のBohlin CVOR型レオメーターにて、40mm径のコーンを用いて、コーン/プレート型の構成で粘度を測定した。
ASTM D5045に従って、W=12.5mm、B=4mmのSENB型試験片を作成して23℃、クロスヘッド速度1mm/min.にて測定した。本明細書に記載のK1c値の単位は、MPa*m0.5である。
動的粘弾性測定装置DVA-200(アイティ計測制御株式会社製)を用いて、周波数1Hz、4℃/分で昇温し、Tanδピークの温度をTg値とする定法に従い測定した。
シェルポリマーのガラス転移温度(Tg)は、ポリマーを構成する各モノマーのホモポリマーのガラス転移温度の文献値からFOX式:1/Tg=Σ(Wx/Tx)(式中、Tg:共重合体のガラス転移温度、Wx:モノマーxの重量分率、Tx:モノマーxのホモポリマーのガラス転移温度を表す。)を用いて算出した値である。例えば、a、b、cの3成分からなる場合には、1/Tg=Wa/Ta+Wb/Tb+Wc/Tcにより導き出される。本実施例において計算に用いる、ホモポリマーのガラス転移温度としては、下記の値を用いた。
ポリ(n-ブチルアクリレート): -54℃
ポリ(2-メトキシエチルアクリレート): -50℃
ポリ(グリシジルメタクリレート): 78℃
ポリスチレン: 100℃
ポリアクリロニトリル: 97℃
一方、上述の方法でガラス転移温度が計算できない場合には、分析的手法によってもシェルポリマーのガラス転移温度を決定することができる。即ち、(1)水性ラテックスの状態にあるコアシェル型ポリマー微粒子を、塩析もしくは噴霧乾燥などの方法で処理してポリマー分を固形物として得た後、これを加熱下、典型的には130~180℃、でプレス加工してシート状にしたサンプル用いる方法、或いは(2)コアシェル型ポリマー微粒子を含んでなるビニルエステル樹脂組成物の硬化物を用いる方法、を挙げることができ、これら何れかのサンプルを動的粘弾性測定装置(Dynamic Mechanical Analyzer:DMA測定)で分析することで観察されるTanδの値から、一般的に行われているように、ガラス転移温度を決定することも可能である。
3Lのガラス反応容器に、窒素雰囲気下で水800g、ドデシルベンゼンスルホン酸ナトリウム0.2g、リン酸三カリウム0.25g、硫酸鉄(II)六水和物5mg、EDTA(エチレンジアミン四酢酸)20mg、及びナトリウムホルムアルデヒドスルホキシレート0.8gを仕込んで40℃とした後、アクリル酸ブチル410g、メタクリル酸アリル12.3g、クメンハイドロパーオキサイド0.2gを混合したものを300分にわたって加え、その後120分時間攪拌を続けた。この間、ドデシルベンゼンスルホン酸ナトリウム(合計8g)を3度に分けて加えた。このようにしてアクリル酸ブチルを主成分とするコアポリマーの水性ラテックスを得た。
100L耐圧重合機中に、水200部、リン酸三カリウム0.03部、リン酸二水素カリウム0.25部、エチレンジアミン4酢酸0.002部、硫酸第一鉄0.001部およびドデシルベンゼンスルホン酸ナトリウム1.5部を投入し、十分に窒素置換及び減圧を行なって酸素を除いた後、40℃に昇温し、ブタジエン75部、及びスチレン25部を系中に投入した。パラメンタンハイドロパーオキサイド0.015部、続いてナトリウムホルムアルデヒドスルホキシレート0.04部を投入し重合を開始した。重合開始から4時間目に、パラメンタンハイドロパーオキサイド0.01部、エチレンジアミン4酢酸0.0015部および硫酸第一鉄0.001部を投入した。重合10時間目に減圧下残存モノマーを脱揮除去し、重合を終了して、スチレン・ブタジエン共重合体からなるコアポリマー粒子の水性ラテックスを得た。重合転化率は98%であった。
CS-1の製造方法に記載されている、アクリル酸ブチルを主成分とするコアポリマーの水性ラテックスを調製し、続けてこれに水200gを加え窒素雰囲気下で攪拌を続けながら、シェル形成用単量体(A)として、スチレン55g、アクリロニトリル20g、グリシジルメタクリレート15g、及びメタクリル酸アリル2.3gからなる単量体混合物と、ブチルハイドロパーオキサイド0.09gと、からなる混合物を120分にわたり加え、グラフト重合させた。モノマー混合物の添加終了後、更に2時間攪拌を続けて反応を完結させ、ポリマー微粒子(CS-3)を水性ラテックスの状態で得た。重合転化率は99%であった。この水性ラテックスの一部を3%硫酸マグネシウム溶液で凝固し、水洗、乾燥してポリマー固形分を得た後、180℃で熱プレス加工してシート状に加工して、コアシェル型ポリマー微粒子CS-3のDMA分析を行ったところ、このシェル形成用単量体の重合物、即ち、シェルポリマーのTgは93℃(DMA測定)であった。この水性ラテックス状態のポリマー微粒子の体積平均粒子径は0.2μmであり、シャープな単分散であった。
CS-2の製造方法に記載されている、スチレン・ブタジエン共重合体からなるコアポリマー粒子の水性ラテックスをそのまま用いて、3Lガラス容器にこのコアポリマー粒子の水性ラテックス1155g(スチレン・ブタジエンゴム粒子375gを含む)を仕込み、純水440gを加えた。窒素雰囲気下にて60℃で攪拌しながら、ここにトリアリルイソシアヌレート(TAIC)10gを加えた後、クメンハイドロパーオキサイド0.02gとナトリウムホルムアルデヒドスルホキシレート0.8gを加え、1時間攪拌した。その後、シェル形成用単量体(A)として、スチレン65g、アクリロニトリル30g、及びグリシジルメタクリレート30gからなる単量体混合物と、t-ブチルハイドロパーオキサイド0.09gと、からなる混合物を120分にわたり加え、グラフト重合させた。モノマー混合物の添加終了後、更に2時間攪拌を続けて反応を完結させ、ポリマー微粒子を水性ラテックスの状態で得た。重合転化率は99%であった。この水性ラテックス状態のポリマー微粒子の体積平均粒子径は0.2μmであり、シャープな単分散であった。
3Lのガラス反応容器に、窒素雰囲気下で水800g、ドデシルベンゼンスルホン酸ナトリウム0.12g、リン酸三カリウム0.25g、硫酸鉄(II)六水和物5mg、EDTA(エチレンジアミン四酢酸)20mg、及びナトリウムホルムアルデヒドスルホキシレート0.8gを仕込んで40℃とした後、アクリル酸ブチル400g、メタクリル酸アリル12g、クメンハイドロパーオキサイド0.2gを混合したものを300分にわたって加え、その後120分時間攪拌を続けた。この間、ドデシルベンゼンスルホン酸ナトリウム(合計8g)を3度に分けて加えた。このようにしてアクリル酸ブチルを主成分とするコアポリマーの水性ラテックスを得た。
3Lのガラス反応容器に、窒素雰囲気下で水800g、ドデシルベンゼンスルホン酸ナトリウム0.12g、リン酸三カリウム0.25g、硫酸鉄(II)六水和物5mg、EDTA(エチレンジアミン四酢酸)20mg、及びナトリウムホルムアルデヒドスルホキシレート0.8gを仕込んで40℃とした後、アクリル酸ブチル375g、メタクリル酸アリル11.3g、クメンハイドロパーオキサイド0.2gを混合したものを270分にわたって加え、その後120分時間攪拌を続けた。この間、ドデシルベンゼンスルホン酸ナトリウム(合計8g)を3度に分けて加えた。このようにしてアクリル酸ブチルを主成分とするコアポリマーの水性ラテックスを得た。
3Lのガラス反応容器に、窒素雰囲気下で水800g、ドデシルベンゼンスルホン酸ナトリウム0.12g、リン酸三カリウム0.25g、硫酸鉄(II)六水和物5mg、EDTA(エチレンジアミン四酢酸)20mg、及びナトリウムホルムアルデヒドスルホキシレート0.8gを仕込んで40℃とした後、アクリル酸ブチル410g、メタクリル酸アリル14.4g、クメンハイドロパーオキサイド0.2gを混合したものを300分にわたって加え、その後120分時間攪拌を続けた。この間、ドデシルベンゼンスルホン酸ナトリウム(合計8g)を3度に分けて加えた。このようにしてアクリル酸ブチルを主成分とするコアポリマーの水性ラテックスを得た。
水性ラテックス状態であるポリマー微粒子CS-1~CS-7をそれぞれ、メチルエチルケトンを使用して、WO2005/28546に記載の方法に従って処理し、ビスフェノールA型エポキシ樹脂(エピコート828EL、EEW=187、ジャパンエポキシレジン製)へ混合して、ビスフェノールA型エポキシ樹脂中にポリマー微粒子を25wt%含む、ポリマー微粒子含有ポリエポキシド組成物(ECS-1~ECS-7)をそれぞれ得た。
ECS-1: 0.2μm
ECS-2: 0.1μm
ECS-3: 0.2μm
ECS-4: 0.1μm
ECS-5: 0.2μm
ECS-6: 0.2μm
ECS-7: 0.2μm
(実施例1: ポリマー微粒子含有ビニルエステル樹脂組成物の製造)
ポリマー微粒子含有ポリエポキシド(ECS-1)88gと、ビスA型エポキシ樹脂(エピコート828EL、187g/eq、ジャパンエポキシレジン製)22.1gを500mLのセパラブルフラスコへ仕込み、攪拌下で120℃に昇温した。ここにMEHQ(ヒドロキノンモノメチルエーテル)0.061gとモノターシャリーブチルヒドロキノン0.006gを溶解したメタクリル酸40.6gを加えて均一に混合した後、N,N-ジメチルベンジルアミン0.39gを加えて、6vol%酸素を含む窒素/酸素混合ガス雰囲気下、115~120℃にて2.7時間反応させた。得られたポリマー微粒子含有エポキシメタクリレートの酸価は13mgKOH/gであった。フラスコ内へ69.3gのスチレンモノマーを加え混合して、ポリマー微粒子含有ビニルエステル樹脂組成物(VEM-1)220g(ポリマー微粒子含量10wt%、ビニルエステル樹脂90wt%、エポキシメタクリレート/スチレンモノマー比=65/35(仕込み重量比)、粘度1.2Pa・s(25℃))を得た。
ポリマー微粒子含有ポリエポキシド(ECS-2)112.8gと、ビスフェノールA型エポキシ樹脂(エピコート828EL、187g/eq、ジャパンエポキシレジン製)0.4gを500mLのセパラブルフラスコへ仕込み、攪拌下で100℃に昇温した。ここにMEHQ(ヒドロキノンモノメチルエーテル)0.107gとOH-TEMPO(4-ヒドロキシ-2,2,6,6-テトラメチルピペリジン-1-オキシル)0.006gを溶解したメタクリル酸(39.1g)を加えて均一に混合した後、N,N-ジメチルベンジルアミン0.37gを加えて、空気雰囲気下、110~115℃で3.3時間反応させた。得られたポリマー微粒子含有エポキシメタクリレートの酸化は16であった。フラスコ内へ82.7gのスチレンモノマーを加え混合して、ポリマー微粒子含有ビニルエステル樹脂組成物(VEM-2)235g(ポリマー微粒子含量12wt%、ビニルエステル樹脂88wt%、エポキシメタクリレート/スチレンモノマー比=60/40(仕込み重量比)、粘度0.8Pa*s(25℃))を得た。このビニルエステル樹脂(VEM-2)中のポリマー微粒子の体積平均粒子径を、実施例1と同様に測定したところ、0.1μmであり、粒子径分布はシャープな単分散であった。
ポリマー微粒子含有ポリエポキシドが実施例1と異なりECS-3を用いる以外は、全て同様の手順で2.7時間反応させたところ、得られたポリマー微粒子含有エポキシメタクリレートの酸価は11mgKOH/gであった。実施例1と同様にスチレンモノマー(同量)を加え混合して、ポリマー微粒子含有ビニルエステル樹脂組成物(VEM-3)220g(ポリマー微粒子含量10wt%、ビニルエステル樹脂90wt%、エポキシメタクリレート/スチレンモノマー比=65/35(仕込み重量比)、粘度0.7Pa*s(25℃))を得た。
ポリマー微粒子含有ポリエポキシドが実施例2と異なりECS-4を用いる以外は、全て同様の手順で3.3時間反応させた。得られたポリマー微粒子含有エポキシメタクリレートの酸価は15mgKOH/gであった。実施例1と同様にスチレンモノマー(同量)を加え混合して、ポリマー微粒子含有ビニルエステル樹脂組成物(VEM-4)235g(ポリマー微粒子含量12wt%、ビニルエステル樹脂88wt%、エポキシメタクリレート/スチレンモノマー比=60/40(仕込み重量比)、粘度0.5Pa*s(25℃))を得た。
ポリマー微粒子含有ポリエポキシド(ECS-5)82.8gと、ビスA型エポキシ樹脂(エピコート828EL、187g/eq)20.4gを、500mLのセパラブルフラスコへ仕込んだ後に、ビスフェノールA4.1gを500mLのセパラブルフラスコへ仕込んで80℃に昇温した。ポリマー微粒子含有ポリエポキシド(ECS-5)のエポキシ等量(EEW)は前述の方法で測定の結果、248g/eqであったので、ビスフェノールA混合前の、ポリマー微粒子含有ポリエポキシド(ECS-5)82.8gと、ビスA型エポキシ樹脂(エピコート828EL、187g/eq)20.4gの混合物のEEWは、(82.8+20.4)/(82.8/248+20.4/187)=233g/eqである。続けてここへ攪拌下でN,N-ジメチルベンジルアミン0.12gを加えた。その後150℃へ昇温し1.5時間反応させて、EEW=266g/eqのポリマー微粒子含有ポリエポキシドを得た。その後120℃まで温度を下げてから、MEHQ(ヒドロキノンモノメチルエーテル)0.084gとモノターシャリーブチルヒドロキノン0.009gを溶解したメタクリル酸34.8gを加えて均一に混合した後、再度N,N-ジメチルベンジルアミン0.18gを加えて、6vol%酸素を含む窒素/酸素混合ガス雰囲気下、120~125℃にて3時間反応させた。得られたポリマー微粒子含有エポキシメタクリレートの酸価は15mgKOH/gであった。フラスコ内へ87.9gのスチレンモノマーを加え混合して、ポリマー微粒子含有ビニルエステル樹脂組成物(VEM-5)230g(ポリマー微粒子含量9wt%、ビニルエステル樹脂91wt%、エポキシメタクリレート/スチレンモノマー比=58/42(仕込み重量比))を得た。このビニルエステル樹脂(VEM-5)をメチルエチルケトンで希釈して、粒子径測定装置(Microtrac UPA)で、ポリマー微粒子の体積平均粒子径を測定したところ、0.2μmであり、粒子径分布はシャープな単分散であった。
ポリマー微粒子含有ポリエポキシド(ECS-6)93.6g、ビスA型エポキシ樹脂(エピコート828EL、187g/eq)0.8gと、フェノールノボラック型エポキシ樹脂(EPALLOY 8250、CVC Specialty Chemicals製、174g/eq)17.8gを、500mLのセパラブルフラスコへ仕込んで120℃に昇温した。ここにMEHQ(ヒドロキノンモノメチルエーテル)0.123gとOH-TEMPO(4-ヒドロキシ-2,2,6,6-テトラメチルピペリジン-1-オキシル)0.003gを溶解したメタクリル酸41.3gを加えて均一に混合した後、攪拌下でN,N-ジメチルベンジルアミン0.3gを加えて、8vol%酸素を含む窒素/酸素混合ガス雰囲気下、115~120℃にて3時間反応させた。得られたポリマー微粒子含有エポキシメタクリレートの酸価は18mgKOH/gであった。フラスコ内へ106.5gのスチレンモノマーを加え混合して、ポリマー微粒子含有ビニルエステル樹脂組成物(VEM-6)260g(ポリマー微粒子含量9wt%、ビニルエステル樹脂91wt%、エポキシメタクリレート/スチレンモノマー比=55/45(仕込み重量比))を得た。このビニルエステル樹脂(VEM-6)をメチルエチルケトンで希釈して、粒子径測定装置(Microtrac UPA)で、ポリマー微粒子の体積平均粒子径を測定したところ、0.2μmであり、粒子径分布はシャープな単分散であった。
ポリマー微粒子含有ポリエポキシド(ECS-7)76.8gと、ビスA型エポキシ樹脂(エピコート828EL、187g/eq)44gを500mLのセパラブルフラスコへ仕込み、攪拌下で120℃に昇温した。ここにMEHQ(ヒドロキノンモノメチルエーテル)0.072g、モノターシャリーブチルヒドロキノン0.005gと、OH-TEMPO(4-ヒドロキシ-2,2,6,6-テトラメチルピペリジン-1-オキシル)0.002gを溶解したアクリル酸39.2gを加えて均一に混合した後、N,N-ジメチルベンジルアミン0.42gを加えて、8vol%酸素を含む窒素/酸素混合ガス雰囲気下、115~120℃にて4時間反応させて、ポリマー微粒子含有ビニルエステル樹脂(エポキシアクリレート)樹脂組成物(VEM-7)160g(酸価=9mgKOH/g、ポリマー微粒子含量12wt%、ビニルエステル樹脂(エポキシアクリレート樹脂)88wt%、粘度6Pa*s(70℃))を得た。このビニルエステル樹脂(VEM-7)中のポリマー微粒子の体積平均粒子径を、実施例1と同様に測定したところ、0.2μmであり、粒子径分布はシャープな単分散であった。
実施例2に記載の手順で得たスチレン・ブタジエンゴムを主成分とするコアポリマーの水性ラテックス1155g(スチレン・ブタジエンゴム粒子375gを含む)を3Lガラス容器に仕込み、純水440gを加えた。窒素雰囲気下にて60℃で攪拌しながら、ここに、シェル形成用単量体(A)でない単量体混合物として、メタクリル酸メチル62g、スチレン38g、及びt-ブチルハイドロパーオキサイド0.1gからなるモノマー混合物を120分間に渡って加え、グラフト重合させた。モノマー混合物の添加終了後更に2時間攪拌を続けて反応を完結させた。重合転化率は99%であった。この水性ラテックス状態のポリマー微粒子(CS-1C)の体積平均粒径は0.1μmで、粒子径分布はシャープな単分散であり、実施例2のCS-2と同様であった。
実施例2に記載の手順で得たスチレン・ブタジエンゴムを主成分とするコアポリマーの水性ラテックス1300g(スチレン・ブタジエンゴム粒子420gを含む)を、3Lガラス容器に仕込み、純水440gを加えて窒素置換を行いながら70℃で攪拌した。これに、シェル形成用単量体(A)でない単量体混合物として、メタクリル酸メチル60g、アクリル酸ブチル10g、スチレン35g、及びt-ブチルハイドロパーオキサイド0.4gからなるモノマー混合物を120分間に渡って加え、グラフト重合させた。モノマー混合物の添加終了後更に2時間攪拌を続け、反応を完結させ、水性ラテックス状のポリマー微粒子(CS-2C)を得た。重合転化率は99%であった。この水性ラテックス状態のポリマー微粒子を水で希釈して、実施例2と同様に粒子径を測定したところ、粒子径は0.1μmで、粒子径分布はシャープな単分散であり、実施例2とほぼ同様であった。
3Lのガラス反応容器に水800g、ドデシルベンゼンスルホン酸ナトリウム0.2g、リン酸三カリウム0.25g、硫酸鉄(II)六水和物5mg、EDTA(エチレンジアミン四酢酸)20mg、及びナトリウムホルムアルデヒドスルホキシレート0.8gを仕込み、窒素雰囲気下で40℃とした後、アクリル酸ブチル415g、メタクリル酸アリル10.4g、クメンハイドロパーオキサイド0.2gを混合したものを300分にわたって加え、その後120分時間攪拌を続けた。この間、ドデシルベンゼンスルホン酸ナトリウム(合計8g)を3度に分けて加えた。このようにしてアクリル酸ブチルを主成分とするコアポリマーの水性ラテックスを得た。
3Lのガラス反応容器に水800g、ドデシルベンゼンスルホン酸ナトリウム0.2g、リン酸三カリウム0.25g、硫酸鉄(II)六水和物5mg、EDTA(エチレンジアミン四酢酸)20mg、及びナトリウムホルムアルデヒドスルホキシレート0.8gを仕込み、窒素雰囲気下で40℃とした後、アクリル酸ブチル415g、メタクリル酸アリル4.2g、クメンハイドロパーオキサイド0.2gを混合したものを300分にわたって加え、その後120分時間攪拌を続けた。この間、ドデシルベンゼンスルホン酸ナトリウム(合計8g)を3度に分けて加えた。このようにしてアクリル酸ブチルを主成分とするコアポリマーの水性ラテックスを得た。
水性ラテックス状態であるポリマー微粒子CS-101、及びCS-102をそれぞれ、メチルエチルケトンを使用して、WO2005/28546に記載の方法に従って処理し、ビスフェノールA型エポキシ樹脂(エピコート828EL、EEW=187、ジャパンエポキシレジン製)へ混合して、ビスフェノールA型エポキシ樹脂中にポリマー微粒子を25wt%含む、ポリマー微粒子含有ポリエポキシド組成物として、ECS-101、及びECS-102をそれぞれ得た。
ECS-101: 0.2μm
ECS-102: 0.2μm
(実施例11)
ポリマー微粒子含有ポリエポキシド(ECS-101)88gと、ビスA型エポキシ樹脂(エピコート828EL、187g/eq、ジャパンエポキシレジン製)22.1gを500mLのセパラブルフラスコへ仕込み、攪拌下で120℃に昇温した。ここにMEHQ(ヒドロキノンモノメチルエーテル)0.061gとモノターシャリーブチルヒドロキノン0.006gを溶解したメタクリル酸40.6gを加えて均一に混合した後、N,N-ジメチルベンジルアミン0.39gを加えて、6vol%酸素を含む窒素/酸素混合ガス雰囲気下、115~120℃にて2.7時間反応させた。得られたポリマー微粒子含有エポキシメタクリレートの酸価は13mgKOH/gであった。
ポリマー微粒子含有ポリエポキシド(ECS-102)91.7gと、ビスA型エポキシ樹脂(エピコート828EL、187g/eq、ジャパンエポキシレジン製)25.2gを500mLのセパラブルフラスコへ仕込み、攪拌下で120℃に昇温した。ここにMEHQ(ヒドロキノンモノメチルエーテル)0.064gとモノターシャリーブチルヒドロキノン0.006gを溶解したメタクリル酸43.7gを加えて均一に混合した後、N,N-ジメチルベンジルアミン0.42gを加えて、6vol%酸素を含む窒素/酸素混合ガス雰囲気下、120~125℃にて2.3時間反応させた。得られたポリマー微粒子含有エポキシメタクリレートの酸価は12mgKOH/gであった。
ポリマー微粒子含有ポリエポキシド(ECS-1)88gと、ビスA型エポキシ樹脂(エピコート828EL、187g/eq、ジャパンエポキシレジン製)22.1gを500mLのセパラブルフラスコへ仕込み、攪拌下で120℃に昇温した。ここにMEHQ(ヒドロキノンモノメチルエーテル)0.061gとモノターシャリーブチルヒドロキノン0.006gを溶解したメタクリル酸40.6gを加えて均一に混合した後、N,N-ジメチルベンジルアミン0.39gを加えて、6vol%酸素を含む窒素/酸素混合ガス雰囲気下、115~120℃にて2.7時間反応させた。得られたポリマー微粒子含有エポキシメタクリレートの酸価は13mgKOH/gであった。
実施例14として、実施例13においてポリマー微粒子含有ポリエポキシドをECS-1に代えて、ECS-3を用いたこと以外は、全て同様の手順で酸価が11mgKOH/gのポリマー微粒子含有エポキシメタクリレートを得た。
ポリマー微粒子含有ポリエポキシド(ECS-101)88gと、ビスA型エポキシ樹脂(エピコート828EL、187g/eq、ジャパンエポキシレジン製)21g、およびビスA型エポキシ樹脂(エピコート1001、470g/eq、ジャパンエポキシレジン製)9.7gを500mLのセパラブルフラスコへ仕込み、攪拌下で120℃に昇温した。ここにMEHQ(ヒドロキノンモノメチルエーテル)0.061gとモノターシャリーブチルヒドロキノン0.006gを溶解したメタクリル酸41.9gを加えて均一に混合した後、N,N-ジメチルベンジルアミン0.41gを加えて、6vol%酸素を含む窒素/酸素混合ガス雰囲気下、120~125℃にて3時間反応させた。得られたポリマー微粒子含有エポキシメタクリレートの酸価は14mgKOH/gであった。
市販のビスフェノールA型ビニルエステル樹脂(ネオポール8250L、ビスフェノールA型ビニルエステル樹脂、日本ユピカ製、エポキシメタクリレート/スチレンモノマー比=60/40)100gに、N,N-ジメチルアニリン0.1g、脱泡剤0.1g(BYK-A555、BYK-Chemie GmbH製)を加えて均一に混合した。最後に過酸化ベンゾイルペースト(Luperox ACT50、Arkema製、純度50wt%)1.9gを加えて室温で硬化させた。およそ30分後に発熱が認められ、混合物はゲル化した。室温にて1日間放置後、60℃にて4時間後硬化させた。この硬化物の破壊靭性値(K1c)は0.6MPa*m0.5であった。この硬化物のガラス転移温度(Tg)は95℃(DMA測定、実施例2と同じ測定条件で実施)であった。
ビスA型エポキシ樹脂(エピコート828EL、187g/eq、ジャパンエポキシレジン製)87g、およびビスA型エポキシ樹脂(エピコート1001、470g/eq、ジャパンエポキシレジン製)9.7gを500mLのセパラブルフラスコへ仕込み、攪拌下で120℃に昇温した。ここにMEHQ(ヒドロキノンモノメチルエーテル)0.061gとモノターシャリーブチルヒドロキノン0.006gを溶解したメタクリル酸41.9gを加えて均一に混合した後、N,N-ジメチルベンジルアミン0.41gを加えて、6vol%酸素を含む窒素/酸素混合ガス雰囲気下、120~125℃にて3時間反応させた。得られたポリマー微粒子含有エポキシメタクリレートの酸価は13mgKOH/gであった。
Claims (10)
- ビニルエステル樹脂100重量部、ポリマー微粒子1~100重量部、及びビニルモノマー0~100重量部を含むポリマー微粒子含有ビニルエステル系樹脂組成物であって、
該ポリマー微粒子の1次粒子径が0.05~1μmであり、かつ、
該ポリマー微粒子が、該ポリマー微粒子含有ビニルエステル系樹脂組成物中で、1次粒子の状態で分散していることを特徴とする、ポリマー微粒子含有ビニルエステル系樹脂組成物。 - 前記ビニルエステル樹脂が、ポリマー微粒子含有ポリエポキシドであって、ポリエポキシド100重量部、及び前記ポリマー微粒子1~100重量部を含んでなり、かつ、該ポリエポキシド中に前記ポリマー微粒子が一次粒子の状態で分散されてなるポリマー微粒子含有ポリエポキシドと、エチレン性不飽和二重結合含有モノカルボン酸と、の反応生成物である、請求項1に記載のポリマー微粒子含有ビニルエステル系樹脂組成物。
- 前記ポリマー微粒子に(メタ)アクリレート基がグラフト結合していることを特徴とする、請求項1、又は2に記載のポリマー微粒子含有ビニルエステル系樹脂組成物。
- 前記ポリマー微粒子含有ポリエポキシドであって、一次粒子の状態で分散している前記ポリマー微粒子の存在下、エポキシ等量が500g/eq未満から25g/eq以上大きくされてなるポリマー微粒子含有ポリエポキシドと、エチレン性不飽和二重結合含有モノカルボン酸と、の反応生成物である、請求項2、又は3のいずれかに記載のポリマー微粒子含有ビニルエステル系樹脂組成物。
- 前記ポリマー微粒子がコアシェル構造を有しており、かつ、そのシェルポリマーが、芳香族ビニルモノマー30~95重量%、ビニルシアンモノマー5~70重量%、エポキシ基含有(メタ)アクリレートモノマー0~55重量%、多官能性ビニルモノマー0~30重量%、及びその他のビニルモノマー0~50重量%からなるシェル形成用単量体(A)100重量%の共重合体であることを特徴とする、請求項1~4のいずれかに記載のポリマー微粒子含有ビニルエステル系樹脂組成物。
- 前記ポリマー微粒子がコアシェル型構造を有しており、かつ、そのシェルポリマーのガラス転移温度(Tg)が、20℃未満であることを特徴とする、請求項1~4のいずれかに記載のポリマー微粒子含有ビニルエステル系樹脂組成物。
- 前記シェルポリマーが、シェル形成用単量体(B)の共重合体であり、
該シェル形成用単量体100重量%が、アルコキシアルキル(メタ)アクリレート5~95重量%、グリシジル(メタ)アクリレート0~40重量%、官能性ビニルモノマーを0~20重量%、及びその他のビニルモノマー5~70重量%からなることを特徴とする、請求項6に記載のポリマー微粒子含有ビニルエステル系樹脂組成物。 - 請求項1~7のいずれかに記載のポリマー微粒子含有ビニルエステル系樹脂組成物を含んでなる硬化性組成物を、ラジカル重合して硬化させてなる硬化物であって、
前記ポリマー微粒子が1次粒子の状態で分散していることを特徴とする硬化物。 - 請求項1~7のいずれかに記載のポリマー微粒子含有ビニルエステル系樹脂組成物の製造方法であって、順に、
前記ポリマー微粒子含有ポリエポキシドを得る工程、
該ポリマー微粒子含有ポリエポキシドにエチレン性不飽和二重結合含有モノカルボン酸を反応させてポリマー微粒子含有ビニルエステル樹脂を得る工程、及び
該ビニルエステル樹脂に前記ビニルモノマーを添加する工程、を含むことを特徴とする、ポリマー微粒子含有ビニルエステル系樹脂組成物の製造方法。 - 請求項1からなる組成物が、T%(全光線透過率)で85%以上、Hzが20以下である、請求項1に記載の組成物。
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