WO2017203716A1 - 樹脂組成物及びその成形体 - Google Patents
樹脂組成物及びその成形体 Download PDFInfo
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- WO2017203716A1 WO2017203716A1 PCT/JP2016/065820 JP2016065820W WO2017203716A1 WO 2017203716 A1 WO2017203716 A1 WO 2017203716A1 JP 2016065820 W JP2016065820 W JP 2016065820W WO 2017203716 A1 WO2017203716 A1 WO 2017203716A1
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- C08F279/00—Macromolecular compounds obtained by polymerising monomers on to polymers of monomers having two or more carbon-to-carbon double bonds as defined in group C08F36/00
- C08F279/02—Macromolecular compounds obtained by polymerising monomers on to polymers of monomers having two or more carbon-to-carbon double bonds as defined in group C08F36/00 on to polymers of conjugated dienes
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- C08K5/36—Sulfur-, selenium-, or tellurium-containing compounds
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- 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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- C08L53/00—Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
- C08L53/02—Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers of vinyl-aromatic monomers and conjugated dienes
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- C08L83/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon only; Compositions of derivatives of such polymers
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- C08L13/00—Compositions of rubbers containing carboxyl groups
Definitions
- the present invention relates to a resin composition containing an engineering plastic, a glass filler and a rubber-containing graft polymer, and a molded article formed by molding this resin composition.
- a glass filler is mixed with an aromatic polycarbonate resin having low water absorption.
- the conventionally disclosed rubber-containing graft polymer is blended with the aromatic polycarbonate resin and the glass filler, the effect of improving the notch strength is particularly small, while the rigidity such as bending strength is lowered.
- the rubber-containing graft polymer is generally produced by emulsion polymerization and is obtained by recovery with a calcium, magnesium or aluminum salt or acid.
- the recovery of rubber-containing graft polymers for engineering plastics often uses calcium, magnesium or aluminum based salts.
- the adhesion between the glass filler and the resin is reduced when a salt of calcium and magnesium derived from the rubber-containing graft polymer and a strong acid and a salt of aluminum and a strong acid are present.
- Patent Document 1 discloses an example in which about 10 parts by mass of a rubber-containing graft polymer (containing more than 1000 ppm of calcium), which is thought to be salted out with a calcium-based salt, is blended with an engineering plastic and a glass filler. .
- the rubber-containing graft polymer can also be emulsion polymerized using a fatty acid alkali metal salt as an emulsifier. Therefore, the rubber-containing graft polymer can be recovered by acid coagulation instead of salting out.
- the fatty acid-based emulsifier is converted into a fatty acid by an acid and the hydrophilicity is lowered, so that the rubber-containing graft polymer in the latex is aggregated. It can be dehydrated, washed and dried and recovered as a rubber-containing graft polymer powder.
- Patent Document 2 discloses an example in which a rubber-containing graft polymer powder obtained by collecting a latex containing a rubber-containing graft polymer produced with a fatty acid emulsifier with an acid is blended with an aromatic polycarbonate resin and a glass filler. ing.
- fatty acids also work to reduce the adhesion between glass and resin.
- the rubber-containing graft weight does not contain a salt of calcium and magnesium and a strong acid, a salt of aluminum and a strong acid, or a fatty acid, which lowers the adhesion between the glass filler and the resin. It is possible to blend rubber into the resin without lowering the adhesion between the glass filler and the resin by producing a coalescence and blending it in the resin composition of engineering plastic and glass filler.
- mechanical strength such as Charpy impact strength can be expressed without lowering the rigidity of the molded body, particularly bending strength and elongation at break.
- a resin composition comprising an engineering plastic (A), a glass filler (B) and a rubber-containing graft polymer (C), wherein the proportion of the acrylonitrile-derived component in the chloroform-soluble component of the resin composition is Calcium in 100 parts by mass of the dry sample, which is 2.0% by mass or less, the fatty acid content in 100 parts by mass of the resin composition is 0.03 parts by mass or less, and is measured by the following measurement method X And the total content of magnesium is 0.0008 parts by mass or less, and the aluminum content is 0.0008 parts by mass or less.
- a resin composition comprising an engineering plastic (A), a glass filler (B) and a rubber-containing graft polymer (C), wherein the rubber-containing graft polymer (C) has an acetone insoluble content of 25% by mass or more.
- the content of the fatty acid contained in the rubber-containing graft polymer (C) is 1% by mass or less, and the engineering plastic (A), the glass filler (B), and the rubber-containing graft polymer (C)
- the total content of calcium and magnesium in terms of the total content of calcium or magnesium and strong acid salt in the resin composition with respect to 100 parts by mass in total is 0.0008 parts by mass or less, and the salt of aluminum and strong acid
- the resin composition whose content of aluminum conversion of content is 0.0008 mass part or less.
- a rubber-containing graft polymer latex obtained by emulsion polymerization of a vinyl monomer in the presence of a rubber latex containing a salt (D) of an alkali metal and a strong acid.
- a salt of calcium or magnesium derived from components other than the glass filler (B) and a weak acid, an engineering plastic (A) glass filler (B), and a rubber-containing graft weight is contained in an amount of 0.0010 to 0.0060 parts by mass in terms of calcium and magnesium with respect to 100 parts by mass of the combined (C).
- the content of the rubber-containing graft polymer (C) is 0.25 to 15 in a total of 100 mass% of the engineering plastic (A), the glass filler (B), and the rubber-containing graft polymer (C).
- the resin composition according to any one of [1] to [12], wherein the resin composition is in mass%.
- the content of the rubber-containing graft polymer (C) is 0.25 to 7 in a total of 100 mass% of the engineering plastic (A), the glass filler (B), and the rubber-containing graft polymer (C).
- the content of the glass filler (B) is 5 to 40% by mass in a total of 100% by mass of the engineering plastic (A), the glass filler (B) and the rubber-containing graft polymer (C).
- the resin composition according to any one of [1] to [14].
- the rubber-containing graft polymer (C) includes one or more rubbers selected from butadiene rubber, styrene / butadiene copolymer rubber, and silicone / acrylic composite rubber. Resin composition.
- a rubber-containing graft polymer (C) having an engineering plastic (A), a glass filler (B), and an acetone insoluble content of 25% by mass or more and a fatty acid content of 1% by mass or less is mixed.
- a salt of calcium or magnesium derived from rubber-containing graft polymer (C) and a strong acid The total content is 0.0008 parts by mass or less in terms of calcium and magnesium, and the content of the salt of the aluminum and strong acid derived from the rubber-containing graft polymer (C) is 0.000 in terms of aluminum.
- the method to manufacture the resin composition which is 0008 mass parts or less.
- the present invention it is possible to improve the mechanical properties of the molded body by dispersing rubber in the resin while improving the adhesion between the resin and the glass filler, which has been difficult in the past.
- FIG. 1 is a fracture surface of a molded product of Example 3 after a Charpy impact test.
- FIG. 2 is a fracture surface of the molded article of Comparative Example 4 after a Charpy impact test.
- FIG. 3 is a fracture surface of the molded product of Example 4 after a Charpy impact test.
- 4 is a fracture surface of the molded article of Comparative Example 1 after a Charpy impact test.
- FIG. 5 is a fracture surface of the molded article of Comparative Example 2 after a Charpy impact test.
- 6 is a fracture surface of the molded article of Comparative Example 3 after a Charpy impact test.
- FIG. 7 is a fracture surface of the molded article of Comparative Example 5 after the Charpy impact test.
- engineering plastic In the resin composition of the present invention, conventionally known various engineering plastics can be used as the engineering plastic (A).
- “engineering plastic” refers to a material having a deflection temperature under load (HDT) of 100 ° C. or higher measured by a method according to ISO-75 under a load of 0.45 MPa.
- polyester polymers such as polyphenylene ether, polycarbonate, polyethylene terephthalate, polybutylene terephthalate, nylon polymers such as syndiotactic polystyrene, 6-nylon, 6,6-nylon, polyarylate, polyphenylene sulfide, polyether ketone , Polyether ether ketone, polysulfone, polyether sulfone, polyamideimide, polyetherimide, and polyacetal.
- polyester polymers such as polyphenylene ether, polycarbonate, polyethylene terephthalate, polybutylene terephthalate, nylon polymers such as syndiotactic polystyrene, 6-nylon, 6,6-nylon, polyarylate, polyphenylene sulfide, polyether ketone , Polyether ether ketone, polysulfone, polyether sulfone, polyamideimide, polyetherimide, and polyacetal.
- a resin having excellent heat resistance and having a melt flowability such as a special styrene resin such as heat-resistant ABS or a heat-resistant acrylic resin, and exhibiting the load deflection temperature (HDT) is also used as the engineering plastic (A) of the present invention. It can be illustrated.
- a resin having excellent heat resistance and having a melt flowability such as a special styrene resin such as heat-resistant ABS or a heat-resistant acrylic resin, and exhibiting the load deflection temperature (HDT) is also used as the engineering plastic (A) of the present invention.
- HDT load deflection temperature
- polyphenylene ether resins, polycarbonate resins, and the like are preferable, and aromatic polycarbonate resins are more preferable.
- these can be used individually or in combination of 2 or more types.
- aromatic polycarbonate resin examples include 4,4′-dioxydiarylalkane-based polycarbonates such as 4,4′-dihydroxydiphenyl-2,2-propane (that is, bisphenol A) -based polycarbonate.
- the molecular weight of the engineering plastic (A) can be appropriately set as desired, and is not particularly limited. However, when the engineering plastic (A) is an aromatic polycarbonate resin, if the viscosity average molecular weight is 15000 to 30000, the molding processability of the resin composition is good, and the resulting molded article has good impact resistance. . If the viscosity average molecular weight is 15000 or more, it is preferable in that the molded product at the time of injection molding of the resin composition has few cracks at the time of mold release and the impact strength of the obtained molded product is good. A viscosity average molecular weight of 30000 or less is preferable because the resin composition has a melt viscosity that can be molded by ordinary extrusion molding or injection molding. The “viscosity average molecular weight” is calculated in terms of viscosity from the viscosity method or gel permeation chromatography (GPC) method.
- GPC gel permeation chromatography
- Engineering plastic (A) can be manufactured by a known method.
- 4,4′-dihydroxydiphenyl-2,2-propane-based polycarbonate 4,4′-dihydroxydiphenyl-2,2-propane is used as a raw material in the presence of an alkaline aqueous solution and a solvent.
- Examples thereof include a method in which phosgene is blown in and a method in which 4,4′-dihydroxydiphenyl-2,2-propane and a carbonic acid diester are transesterified in the presence of a catalyst.
- the glass filler (B) is a substance containing silicate as a main component, porous particles such as layered silicate, talc, mica and silica, glass (glass fiber, milled glass, glass flake, glass). Beads) and the like. In view of the bending characteristics of the molded body, glass fiber is particularly preferable.
- the rubber-containing graft polymer (C) constituting the resin composition of the present invention is obtained by graft polymerization of a “vinyl monomer” to a “rubber-like polymer”.
- the component derived from the graft polymerization constituting the rubber-containing graft polymer (C) is hereinafter referred to as “graft component”.
- the rubbery polymer those having a glass transition temperature of 0 ° C. or lower can be used.
- the glass transition temperature of the rubber-like polymer is 0 ° C. or less, the impact strength represented by the Charpy impact test value of the molded product obtained from the resin composition of the present invention is improved.
- Specific examples of the rubbery polymer include the following.
- butadiene rubber In cold regions, improvement in impact strength of molded products at lower temperatures (-20 ° C or lower) is required, so butadiene rubber, styrene / butadiene copolymer rubber, silicone / acrylic composite rubber having a glass transition temperature of -20 ° C or lower. Is preferred.
- the mass average particle diameter of the rubbery polymer is preferably 300 nm or less because the impact strength of the molded article is excellent.
- the mass average particle diameter of the rubber-like polymer is preferably 50 nm or more, more preferably in the range of 70 to 300 nm, and still more preferably in the range of 100 to 300 nm.
- the mass average particle diameter of the rubber-like polymer is measured by a capillary particle size distribution meter.
- As a method of setting the mass average particle diameter to 300 nm or less production of a rubber-like polymer by emulsion polymerization is preferable, and a rubber-like polymer having a mass average particle diameter of 50 to 300 nm can be obtained by adjusting the amount of the emulsifier.
- vinyl monomers that are graft-polymerized to rubbery polymers include aromatic vinyl compounds such as styrene and ⁇ -methylstyrene; acrylic acid esters such as methyl acrylate and butyl acrylate; methyl methacrylate And methacrylates such as ethyl methacrylate. These monomers may be used alone or in combination of two or more.
- the vinyl monomer is selected so that the glass transition temperature of the polymer or copolymer obtained by polymerization (homopolymerization or copolymerization of two or more types) of the vinyl monomer is 70 ° C or higher. It is preferable from the viewpoint of the powder characteristics (powder fluidity and particle diameter) obtained from the subsequent coagulation step.
- the mass average particle diameter of the rubber-containing graft polymer (C) thus produced is preferably 300 to 500 ⁇ m.
- the particle diameter of the powder is 300 ⁇ m or more, scattering can be suppressed at the time of blending or charging into the mixing apparatus when preparing the resin composition, and there is no possibility of causing problems such as dust explosion.
- the particle diameter of the powder is 500 ⁇ m or less, the flow characteristics of the powder are good, and there is no possibility of causing inconvenience such as clogging of piping in the manufacturing process.
- the glass transition temperature of a polymer composed of a vinyl monomer that is graft-polymerized with respect to a rubber-like polymer is more preferably 80 ° C. or higher, and further preferably in the range of 80 ° C. to 90 ° C.
- a copolymer of methyl methacrylate and butyl acrylate and a copolymer of styrene and acrylonitrile are easily used because the glass transition temperature is easily set in the range of 80 ° C. to 90 ° C.
- the ratio of acrylonitrile with respect to 100% by mass of the monomer mixture is 35% by mass or less.
- This ratio is more preferably in the range of 15 to 30% by mass, further preferably in the range of 18 to 27% by mass, and particularly preferably in the range of 20 to 26% by mass.
- the vinyl monomer to be used for the graft polymerization is actually polymerized without being chemically bonded to the rubber-like polymer “vinyl monomer m gp ” that is chemically bonded to the rubber-like polymer, There are “vinyl monomer m fp ” that produces “free polymer P fr ” and “vinyl monomer m fm ” that does not undergo a polymerization reaction. Among these, it is preferable that the amount of vinyl monomer mgp chemically bonded to the rubbery polymer is large.
- the rubber-containing graft polymer (C) is easily dispersed in the engineering plastic (A), and the engineering plastic (A) and the rubber-containing polymer are contained. Interfacial strength with the graft polymer (C) is improved. The better the dispersibility of the rubber-containing graft polymer (C) and the higher the interfacial strength, the better the impact strength of the molded product.
- the vinyl monomer m fm which does not undergo the polymerization reaction is almost completely removed in the subsequent recovery process (coagulation or spray recovery process and drying process of the obtained powder).
- the vinyl monomer m gp forms a “graft component” of the rubber-containing graft polymer (C), and the vinyl monomer m fp forms a “free polymer P fr ” (hereinafter “non-graft component”).
- the “free polymer P fr ” is mixed in the rubber-containing graft polymer (C) recovered as a powder aggregate.
- the rubber-containing graft polymer (C) is a component composed of three components represented by the following formula.
- WC W rp + W gc + P fr (1)
- WC Mass of rubber-containing graft polymer (C)
- W rp Mass of rubber-like polymer
- W gc Mass of graft component
- P fr Free polymer.
- the proportion of the structural unit derived from the vinyl monomer chemically bonded to the rubber-like polymer is determined from the acetone-insoluble content of the rubber-containing graft polymer (C). It can be quantified as the mass reduced. From such a viewpoint, the acetone insoluble content is preferably 25% by mass or more, more preferably 50% by mass or more, further preferably 83% by mass or more, and 95% by mass or more. Particularly preferred.
- the acetone insoluble matter is measured by preparing a solution comprising 1% by mass of a rubber-containing graft polymer and 99% by mass of acetone and performing the following operations (1) to (4).
- (1) The solution is subjected to a centrifuge and centrifuged at 20000 rpm for 30 minutes.
- (3) The flask is set in a constant temperature bath at a temperature of 56 ° C., and volatile components are distilled off from the liquid by an evaporator.
- the residue in the flask is dried at a temperature of 120 ° C. for 3 hours to obtain a “dried sample”.
- acetone insoluble component (mass%) is calculated by the following formula.
- w ais (w c1 -w as ) / w c1 ⁇ 100 ⁇ (2)
- w c1 mass of rubber-containing graft polymer used for measurement w as : mass% of acetone-soluble matter w ais : mass% of acetone insoluble matter.
- “free polymer P fr ” is extracted as an acetone-soluble component.
- the content (100 W rp / W C ) of the rubber-like polymer in the rubber-containing graft polymer (C) is preferably in the range of 50 to 95% by mass, and 70 to 94% by mass from the viewpoint of the impact strength of the molded product. Is more preferably in the range of 75 to 93% by mass, particularly preferably in the range of 80 to 92% by mass, and most preferably in the range of 85 to 91% by mass. .
- the rubber-containing graft polymer (C) can be usually obtained by making a rubber-like polymer in a latex state in the presence of an emulsifier and water, and adding a vinyl monomer thereto and graft polymerization.
- polymerization initiator used in the graft polymerization examples include peroxides and azo initiators.
- the emulsifier used in the graft polymerization examples include alkali metal salts of acids such as fatty acid, sulfonic acid, sulfuric acid and phosphoric acid.
- the emulsifier is preferably an alkali metal salt of a strong acid such as sulfonic acid, sulfuric acid or phosphoric acid.
- an organic acid alkali containing sulfonic acid, sulfuric acid, or phosphoric acid is used as an emulsifier because it has excellent latex stability and is difficult to cause thermal deterioration of the engineering plastic even if it remains in the rubber-containing graft polymer.
- Metal salts are more preferred.
- the salt (D) of an alkali metal and a strong acid contained in the resin composition of the present invention is a rubber-containing graft polymer (C) as an emulsifier used in the polymerization of the rubber-containing graft polymer (C).
- the resin composition containing the engineering plastic (A), the glass filler (B), and the rubber-containing graft polymer (C) may be added later.
- strong acid refers to a pKa ( ⁇ log Ka) of 2 or less.
- Ka is an acid dissociation constant.
- the strong acid include hydrogen chloride, sulfuric acid, phosphoric acid, nitric acid, sulfonic acid and the like.
- the “alkali metal” is an element other than hydrogen among elements corresponding to Group 1 in the periodic table, and corresponds to sodium, potassium, and the like.
- alkali metal salts of sulfonic acid, sulfuric acid, and phosphoric acid are preferable, and examples thereof include the following. Potassium persulfate, sodium persulfate; alkali metal salt of perfluoroalkanesulfonic acid, preferably sodium salt or potassium such as sulfonic acid having a perfluoroalkane group having 1 to 19 carbon atoms, more preferably 4 to 8 carbon atoms Salts (eg, sodium or potassium salts such as perfluorobutanesulfonic acid, perfluoromethylbutanesulfonic acid, perfluorooctanesulfonic acid); sodium salts or potassium salts of primary phosphoric acid, sodium salts of secondary phosphoric acid or Potassium salt, sodium salt or potassium salt of tertiary phosphoric acid; alkali metal salt of organic acid containing sulfonic acid, sulfuric acid, phosphoric acid, more preferably sodium
- the latex As a salt (D) of an alkali metal and a strong acid, the latex is excellent in stability and has little adverse effect on the thermal deterioration of the engineering plastic (A) even if it remains in the rubber-containing graft polymer (C).
- Alkali metal salts of organic acids containing sulfonic acid, sulfuric acid and phosphoric acid are preferred.
- Alkylsulfonic acid or alkylarylsulfonic acid sodium salt or potassium salt, alkylsulfuric acid or alkylarylsulfuric acid sodium salt or potassium salt, alkylphosphoric acid or alkylarylphosphoric acid sodium salt or potassium salt, and mixtures thereof are more preferred.
- salt (D) of alkali metal and strong acid include the following. Potassium perfluorobutanesulfonate, potassium diphenylsulfonesulfonate, potassium paratoluenesulfonate, sodium paratoluenesulfonate, sodium dodecylbenzenesulfonate, potassium octylbenzenesulfonate, sodium lauryl sulfate, sodium alkylnaphthylsulfonate, alkyldiphenyl ether disulfonate Sodium, C8-C16 alkylated sodium diphenyl ether disulfonate, potassium hexyl phosphate, sodium dodecyl phosphate, sodium polyoxyethylene alkyl (12-15) ether phosphate, and mixtures thereof.
- Sodium or potassium salt with sulfonic acid is preferable because it does not promote hydrolysis such as carbonate bond or ester bond.
- Sodium alkyl sulfonate such as sodium dodecylbenzene sulfonate or sodium alkyldiphenyl ether disulfonate and perfluorobutane sulfonic acid. More preferred are potassium sulfonates such as potassium and potassium diphenylsulfone sulfonate.
- potassium alkyl diphenyl ether disulfonate and potassium diphenyl sulfone sulfonate are particularly preferable because they have good compatibility with the aromatic polycarbonate resin and do not cause thermal degradation of the resin.
- fatty acid refers to a hydrocarbon compound containing a carboxylic acid.
- an alkali metal salt of a fatty acid is used as an emulsifier during the graft polymerization, it is an emulsifier when sulfuric acid, phosphoric acid or the like is added as a strong acid coagulant to the latex of the obtained rubber-containing graft polymer (C).
- the alkali metal salt of the fatty acid is changed to a fatty acid with low water solubility.
- the rubber-containing graft polymer (C) and water are separated, the rubber-containing graft polymer (C) can be recovered.
- fatty acid is contained in the produced rubber-containing graft polymer (C). Since the fatty acid affects the adhesion between the glass filler (B) and the engineering plastic (A), the amount of the fatty acid contained in the rubber-containing graft polymer (C) is preferably small.
- the fatty acid content in 100 parts by mass of the resin composition of the present invention is preferably 0.03 parts by mass or less, more preferably 0.02 parts by mass or less, and 0.01 parts by mass or less. More preferably. Further, this content is 0.01 parts by mass or less, and it is most preferable that palmitic acid, stearic acid, oleic acid, alkenyl succinic acid and rosin acid are not detected in the measurement of fatty acid.
- the content of the fatty acid contained in the rubber-containing graft polymer (C) is preferably 1% by mass or less, more preferably 0.5% by mass or less, and 0.25% by mass or less. More preferably, it is particularly preferably 0.1% by mass or less.
- Examples of the fatty acid detection method include a method of esterifying carboxylic acid, extracting the obtained carboxylic acid ester with an optimum solvent, and detecting and quantifying it by gas chromatography.
- the amount of fatty acid can be quantified by limiting to palmitic acid, stearic acid, oleic acid, alkenyl succinic acid, and rosin acid.
- the amount of palmitic acid, stearic acid, oleic acid, alkenyl succinic acid, and rosin acid contained in the rubber-containing graft polymer (C) is preferably as described above (1% by mass or less).
- the rubber-containing graft weight is charged at the stage of preparation.
- the “emulsifier containing fatty acid” in the total of 100% by mass of the union (C) and “emulsifier containing fatty acid” (alkali metal salt of fatty acid) is, for example, 0.03% by mass or less.
- the rubber-like polymer listed above is polymerized in the presence of a polymerization emulsifier which is a salt (D) of an alkali metal and a strong acid and deionized water, and then a vinyl monomer is graft polymerized. Is preferable in terms of reducing the amount of fatty acid in the rubber-containing graft polymer (C).
- a polymerization emulsifier which is a salt (D) of an alkali metal and a strong acid and deionized water
- the latex-containing rubber-containing graft polymer (C) obtained by the graft polymerization can be obtained as a powder by coagulation, washing and drying, or by spray recovery.
- a rubber-containing graft polymer (C) is obtained by converting a rubber-containing graft polymer latex obtained by emulsion polymerization of a vinyl monomer in the presence of a rubber latex containing a salt (D) of an alkali metal and a strong acid into a coagulant. It is preferable that the product is obtained by coagulation and recovery using the above, or that obtained by spray recovery, and more preferably that obtained by spray recovery.
- the emulsifier contains a rubber in the state of a salt (D) of an alkali metal and a strong acid. Since it remains in the graft polymer (C), it is preferable.
- an alkali metal and strong acid salt (D) as an emulsifier and the rubber-containing graft polymer (C) is recovered by a coagulation method
- an alkaline earth metal (Group 2) or aluminum is used as a coagulant.
- a salt containing calcium metal (group 13) calcium chloride, calcium acetate, aluminum sulfate, etc.
- using a large amount of water at the time of washing, and using a centrifuge, etc. to ensure sufficient water in the slurry It is preferable to remove it.
- the reason for using the coagulant is that, in order to use an acid as the coagulant, it is necessary to use an acid having a lower pKa than the “strong acid” of the “salt of alkali metal and strong acid (D)”. When such a strong acid remains in the rubber-containing graft polymer (C), the engineering plastic (A) is deteriorated. In the coagulation process using the coagulant, the “salt of alkali metal and strong acid (D)” used as the emulsifier is replaced by “salt of alkaline earth metal and strong acid” or “earth metal (13 Group) and a strong acid salt.
- alkaline earth metal and strong acid salts and earth metal (Group 13) and strong acid salts have low water solubility, polymer particles in the latex can be aggregated. As a result, since the rubber-containing graft polymer (C) and water are separated, the rubber-containing graft polymer (C) can be recovered. If the agglomerate is washed and dried, a powder of the rubber-containing graft polymer (C) can be obtained. However, compared to alkali metal and strong acid salts (D), alkaline earth metal and strong acid salts, or earth metal such as aluminum (Group 13) and strong acid salts are filled with engineering plastic (A) and glass. Adhesiveness with an agent (B) is reduced.
- alkali metal and strong acid salts (D) alkaline earth metal and strong acid salts, or earth metal such as aluminum (Group 13) and strong acid salts are filled with engineering plastic (A) and glass. Adhesiveness with an agent (B) is reduced.
- the salt of calcium and strong acid derived from the rubber-containing graft polymer (C), the salt of magnesium and strong acid, and the salt of aluminum and strong acid significantly reduce the adhesion. Therefore, it is preferable to wash the aggregated polymer particles (slurry) with water or the like.
- the resin composition of the present invention is a composition comprising an engineering plastic (A), a glass filler (B), and a rubber-containing graft polymer (C).
- the engineering plastic (A) and the rubber-containing graft polymer (C) may be referred to as “resin two components” of the resin composition.
- the engineering plastic (A), the glass filler (B), and the rubber-containing graft polymer (C) may be referred to as “main three components” of the resin composition.
- the ratio of the acrylonitrile-derived component in the chloroform-soluble component of the resin composition of the present invention is preferably 2.0% by mass or less.
- the “acrylonitrile-derived component” refers to an acrylonitrile constituent component contained in the “free polymer P fr ”.
- the rubber-containing graft polymer (C) recovered as a powder aggregate contains “free polymer P fr ” which is a “non-graft component”.
- the chloroform-soluble component of the resin composition includes engineering plastic (A) and “free polymer P fr ” which is a “non-grafted component”.
- the acrylonitrile-derived component in the chloroform-soluble component of the resin composition is obtained by preparing a solution comprising 1% by mass of the resin composition and 99% by mass of chloroform and performing the following operations (1) to (4). It can be quantified by calculating the amount of acrylonitrile in the “dry sample”.
- the solution is subjected to a centrifuge and centrifuged at 20000 rpm for 30 minutes.
- the flask is set in a constant temperature bath at a temperature of 68 ° C., and volatile components are distilled off from the liquid by an evaporator.
- the residue in the flask is dried at a temperature of 120 ° C. for 3 hours to obtain a “dried sample”.
- a method of calculating the amount of acrylonitrile in the “dry sample” a method of detection and quantification by gas chromatography is preferable.
- elemental analysis can be performed and the nitrogen content can be calculated.
- chloroform is selected instead of acetone as the solvent is that chloroform has higher solubility in engineering plastic (A) than acetone.
- engineering plastic (A) is an aromatic polycarbonate resin
- chloroform is optimal.
- the acrylonitrile-derived component in the chloroform-soluble component of the resin composition is more preferably 1.5% by mass or less, further preferably 0.8% by mass or less, from the viewpoint of improving the impact strength of the molded article. It is particularly preferably 5% by mass or less.
- the vinyl monomer to be graft-polymerized to the rubber-like polymer is a copolymer of methyl methacrylate and butyl acrylate, a copolymer of styrene and acrylonitrile (the ratio of acrylonitrile units is 35% by mass or less) ) Is preferred.
- the content of the rubber-like polymer in the rubber-containing graft polymer (C) is preferably in the range of 50% by mass to 95% by mass, and the amount of the graft component chemically bonded to the rubber-like polymer is large. Therefore, it is more preferable that the acetone insoluble content is 83% by mass or more.
- the content of the glass filler (B) is 5% with respect to 100% by mass of the “main three components”.
- the acrylonitrile-derived component of the chloroform-soluble component is 2.0% by mass or less. can do.
- the content of the engineering plastic (A) is preferably 95 to 60% by mass in a total of 100% by mass of “main 3 components”.
- the content is more preferably 80 to 60% by mass, and further preferably 80 to 70% by mass. If the content is 60% by mass or more, the moldability of the resin composition is easy, and if it is 95% by mass or less, the molded body of the resin composition has sufficient bending characteristics (strength, elastic modulus). Have.
- the content of the glass filler (B) is preferably 5 to 40% by mass in a total of 100% by mass of the “main 3 components”.
- the content is more preferably 10 to 40% by mass, and further preferably 20 to 30% by mass. If the content is 5% by mass or more, the molded body of the resin composition can have sufficient bending characteristics (strength, elastic modulus), and if it is 40% by mass or less, the molded body of the resin composition is The balance between Charpy impact strength and bending properties will be sufficient.
- the content of the rubber-containing graft polymer (C) is preferably 0.25 to 15% by mass in 100% by mass of the “main three components”.
- the content is more preferably 0.25 to 7.5% by mass, and further preferably 1 to 3% by mass. If the content is 0.25% by mass or more, the molded body of the resin composition has an effect of improving impact strength. If the content is 15% by mass or less, the molded body can be improved in impact strength without a significant decrease in bending properties (strength, elastic modulus).
- the engineering plastic (A) and the glass filler (B) have a fatty acid content of 0.03 parts by mass or less in 100 parts by mass of the resin composition. It is preferable at the point that adhesiveness with is favorable. Further, it is more preferable that palmitic acid, stearic acid, oleic acid, alkenyl succinic acid and rosin acid are not detected (0.01 parts by mass or less).
- the resin composition of the present invention further contains a salt (D) of an alkali metal and a strong acid because of excellent adhesion between the engineering plastic (A) and the glass filler (B).
- the content of the salt (D) of alkali metal and strong acid in 100 parts by mass of the resin composition of the present invention is preferably 0.01 to 0.5 parts by mass.
- the content is more preferably 0.2 parts by mass or less, and further preferably 0.02 to 0.15 parts by mass.
- This content is preferably 0.01 parts by mass or more because the adhesion between the engineering plastic (A) and the glass filler (B) is excellent. If this content is 0.5 part by mass or less, thermal degradation during molding of the resin composition and hydrolyzability of the molded product are not a problem, which is preferable.
- the salt (D) of an alkali metal and a strong acid may be previously contained in the rubber-containing graft polymer (C) as an emulsifier used in the graft polymerization of the rubber-containing graft polymer (C). You may post-add with respect to the resin composition containing a plastic (A), a glass filler (B), and a rubber containing graft polymer (C).
- the salt of calcium or magnesium and a strong acid in the resin composition reduces adhesion between the engineering plastic (A) and the glass filler (B), promotes thermal deterioration during molding of the resin composition, and a molded body.
- the properties such as hydrolysis resistance under high temperature and high humidity are markedly deteriorated.
- the salt of calcium or magnesium derived from the rubber-containing graft polymer (C) and a strong acid significantly deteriorates the adhesion between the engineering plastic (A) and the glass filler (B).
- the total content of calcium and magnesium in 100 parts by mass of the dry sample measured by the following measurement method X is 0.0008 parts by mass or less (8 ppm or less). . If the value of the total content in terms of calcium and magnesium is within this range, the adhesion between the above-mentioned engineering plastic (A) and the glass filler (B), thermal deterioration during molding of the resin composition and the molded body Since hydrolyzability is not a problem, the impact strength and bending properties (elastic modulus and strength) of the molded article are excellent.
- the total content in terms of calcium and magnesium is more preferably 0.0006 parts by mass or less (6 ppm or less), and further preferably 0.0002 parts by mass or less (2 ppm or less).
- the above-mentioned resin composition soluble in chloroform is the same as the “dry sample” obtained in (4) of measurement method X.
- the amount of calcium and magnesium in the “dry sample” approximately the total content “W cas + mgs ” of calcium or magnesium and a strong acid salt in the resin composition of the present invention is converted into calcium and magnesium.
- the total content of “W ca + mg ” can be obtained.
- the reason is that a salt of calcium or magnesium and a weak acid, particularly a salt of calcium or magnesium and a fatty acid is difficult to dissolve in chloroform, and the glass filler (B) is difficult to dissolve in chloroform.
- the glass filler (B) may contain calcium and magnesium (calcium or a salt of magnesium and silicic acid), but the glass filler (B) is difficult to dissolve in chloroform, so chloroform in the resin composition.
- the soluble component is substantially free of calcium and magnesium derived from the glass filler (B).
- the engineering plastic (A) and glass filler (B) basically do not contain a salt of calcium or magnesium and a strong acid.
- the glass filler (B) may contain calcium and magnesium, and silicon dioxide having an amorphous structure contains magnesium and calcium as ions in the skeleton. Since silicic acid is not a strong acid, the glass filler (B) basically does not contain a salt of calcium or magnesium and a strong acid.
- W cas + mgs W ca + W mg (3)
- W cas + mgs W cas + W mgs (4)
- W cas content of salt of calcium and strong acid
- W mgs content of salt of magnesium and strong acid
- W ca content of calcium
- W mg content of magnesium
- the measurement method X is carried out using a resin composition consisting of only two components of an engineering plastic (A) not containing calcium, magnesium and aluminum and a glass filler (B) containing calcium, magnesium and aluminum, and the glass filler.
- A engineering plastic
- B glass filler
- the calcium and magnesium derived from (B) is extracted in the chloroform-soluble matter in the resin composition and the “supernatant extraction” in (2) is performed so that it is not detected. preferable.
- the total content of calcium and magnesium is 0.0006 parts by mass or more (6 ppm or more) and / or the aluminum content is 0.0006 parts by mass or more (6 ppm or more) in 100 parts by mass of the “dry sample”.
- a filter having a hole smaller than the diameter of the glass filler (B) and larger than the primary particle diameter of the polymer particles of the rubber-containing graft polymer (C) (1 ⁇ m to 5 ⁇ m hole) It is preferable to filter the supernatant using a chloroform-resistant filter having a diameter.
- the total content of calcium and magnesium in 100 parts by mass of “dry sample” is 0.0008 parts by mass or less (8 ppm or less), the impact strength and bending characteristics (elastic modulus and strength) of the molded article are excellent.
- the total content of calcium and magnesium is more preferably 0.0006 parts by mass or less (6 ppm or less), and further preferably 0.0002 parts by mass or less (2 ppm or less). If the total content of calcium and magnesium in 100 parts by mass of the “dry sample” is 0.0008 parts by mass or less (8 ppm or less), the calcium or magnesium and strong acid in 100 parts by mass of the resin composition of the present invention
- the total salt content is less than 0.0008 parts by mass (less than 8 ppm) in terms of total calcium and magnesium equivalents.
- the salt of calcium or magnesium and “strong acid” in the resin composition with respect to a total of 100 parts by mass of the “main three components” of the resin composition of the present invention.
- the total content “T ca + mg ” in terms of calcium and magnesium in the total content is 0.0008 parts by mass or less.
- the value of T ca + mg is the total content “C ca + mg ” of the total content of calcium or magnesium and strong acid salt derived from the rubber-containing graft polymer (C), and the rubber-containing graft polymer.
- C ca + mg is calculated by the following formula.
- C ca + mg Mc ⁇ ( cq cas ⁇ r ca + cq mgs ⁇ r mg) ⁇ (6)
- Mc part by mass of rubber-containing graft polymer (C) in 100 parts by mass of “main three components” of the resin composition
- cq cas concentration of salt of calcium and strong acid in rubber-containing graft polymer
- cq mgs Concentration of salt of magnesium and strong acid in rubber-containing graft polymer
- r ca Concentration of calcium in salt of calcium and strong acid r mg : Concentration of magnesium in salt of magnesium and strong acid.
- T ca + mg is 0.0008 parts by mass or less (8 ppm or less)
- the thermal deterioration during molding of the resin composition and the molded product Since hydrolyzability does not become a problem, the impact strength and bending characteristics (elastic modulus and strength) of the molded product are excellent.
- the value of T ca + mg is more preferably 0.0006 parts by mass or less, and further preferably 0.0002 parts by mass or less.
- weak acid refers to a pKa ( ⁇ log Ka) of 3 or more.
- a fatty acid is mentioned.
- Preferred examples include calcium stearate and magnesium stearate.
- silicon dioxide having an amorphous structure in the glass filler (B) may contain calcium, magnesium, and / or aluminum as ions in the skeleton, but silicic acid has a pKa of 3 or more. It corresponds to.
- the value of the total content NB ′ ca + mg is the total content C ′ ca + mg in terms of calcium and magnesium in terms of the total content of calcium or magnesium and weak acid salt in the rubber-containing graft polymer (C), and glass filling.
- NB'ca + mg C'ca + mg + NBC'ca + mg (8)
- C ′ ca + mg is calculated by the following formula.
- C ′ ca + mg Mc ⁇ (cq ′ cas ⁇ r ′ ca + cq ′ mgs ⁇ r ′ mg ) ... (9) Mc: part by mass of the rubber-containing graft polymer (C) in 100 parts by mass of the “main three components” of the resin composition
- cq ′ cas the concentration cq of the salt of calcium and weak acid in the rubber-containing graft polymer (C) 'mgs: rubber-containing graft polymer concentration r of the salts of magnesium and the weak acid in (C)' ca: calcium concentration r 'mg of Shiochu of calcium and weak: magnesium concentration Shiochu of magnesium and a weak acid.
- the NBC ′ ca + mg is calculated by the following formula.
- NBC 'ca + mg (mnbc ' cas ⁇ r 'ca) + (mnbc' mgs ⁇ r 'mg) ⁇ (Ten) mnbc ' cas : parts by mass of a salt of calcium and a weak acid other than the glass filler (B) and the rubber-containing graft polymer (C) in the resin composition with respect to 100 parts by mass of the “main three components” of the resin composition
- mnbc ′ mgs parts by mass of a salt of magnesium and a weak acid other than the glass filler (B) and the rubber-containing graft polymer (C) in the resin composition with respect to 100 parts by mass in total of the “main three components” of the resin composition r ′ ca : calcium concentration in a salt of calcium and weak acid r ′ mg : magnesium concentration in a salt of magnesium and weak acid
- the salt of calcium and magnesium and a weak acid in the rubber-containing graft polymer uses a salt of a fatty acid and an alkali metal as an emulsifier when producing the rubber-containing graft polymer, and an alkaline earth metal (Group 2) It is obtained by using a salt containing calcium (calcium chloride, calcium acetate, magnesium sulfate, magnesium chloride, etc.).
- an alkaline earth metal Group 2
- the “salt of alkali metal and weak acid” used as an emulsifier is “alkaline earth metal and It turns into a "weak acid salt”.
- alkaline earth metal and weak acid salts have low water solubility, polymer particles in the latex can be aggregated. As a result, since the rubber-containing graft polymer (C) and water are separated, the rubber-containing graft polymer (C) can be recovered. If the agglomerate is washed and dried, a powder of the rubber-containing graft polymer (C) can be obtained. Content of the salt of calcium and magnesium, and a weak acid can be adjusted with the compounding quantity of a fatty acid type emulsifier, the amount of washing water, etc.
- the content of calcium and magnesium and a weak acid salt other than those derived from the glass filler (B) or rubber-containing graft polymer (C) is the same as that of the above calcium or magnesium and weak acid salt during molding of the resin composition. It can also be adjusted by blending.
- the salt of aluminum and strong acid in the resin composition reduces the adhesion between the engineering plastic (A) and the glass filler (B) and promotes thermal deterioration during molding of the resin composition. Deteriorates the hydrolysis resistance under high temperature and high humidity.
- the salt of aluminum and strong acid derived from the rubber-containing graft polymer (C) significantly reduces the adhesion between the engineering plastic (A) and the glass filler (B).
- the engineering plastic (A) and the glass filler (B) basically contain no salt of aluminum and strong acid.
- the glass filler (B) may contain aluminum, and silicon dioxide having an amorphous structure contains aluminum as ions in its skeleton. Therefore, the glass filler (B) basically does not contain a salt of aluminum and a strong acid.
- the aluminum content in 100 parts by mass of the dry sample measured by the measurement method X is 0.0008 parts by mass or less.
- this content is 0.0008 parts by mass (8 ppm) or less, the adhesiveness between the above-mentioned engineering plastic (A) and the glass filler (B) decreases, thermal deterioration or molding during molding of the resin composition. Since the hydrolyzability of the body is not a problem, the impact strength and bending properties (elastic modulus and strength) of the molded body are excellent.
- the aluminum content is preferably 0.0006 parts by mass or less (6 ppm or less), and more preferably 0.0002 parts by mass or less (2 ppm or less). If the value of this content is 0.0006 parts by mass or less, the adhesion between the engineering plastic (A) and the glass filler (B) is further improved.
- the content of aluminum in 100 parts by mass of the “dry sample” obtained by the measuring method X is 0.0008 parts by mass or less (8 ppm or less)
- the aluminum and the strong acid in 100 parts by mass of the resin composition of the present invention The salt is lower than 0.0008 parts by mass (less than 8 ppm) in terms of aluminum.
- a rubber-containing graft polymer is used. (C) is preferably recovered by spraying.
- a salt calcium chloride, calcium acetate, alkaline earth metal (Group 2) or earth metal (Group 13) such as aluminum as a coagulant is used. It is preferable to use magnesium sulfate, magnesium chloride, aluminum sulfate, etc.), use a large amount of water at the time of washing, and sufficiently remove the water in the slurry using a centrifuge or the like.
- the total amount of aluminum and strong acid salt in the resin composition relative to 100 parts by mass of the “main three components” of the resin composition is converted into aluminum.
- content "T al” is less 0.0008 parts by weight.
- the Cal is calculated by the following equation.
- C al Mc ⁇ cq al ⁇ r al ⁇ (12)
- Mc part by mass of rubber-containing graft polymer (C) in 100 parts by mass of “main three components” of the resin composition
- cq als concentration r al of salt of aluminum and strong acid in rubber-containing graft polymer (C) : Aluminum concentration in the salt of aluminum and strong acid.
- NC al mnc als ⁇ r al ⁇ (13)
- mnc als Mass part of salt of aluminum and strong acid derived from components other than rubber-containing graft polymer (C) with respect to 100 parts by mass of “main 3 components” of resin composition
- r al Salt of aluminum and strong acid Aluminum concentration inside.
- the aluminum equivalent content T al is more preferably 0.0006 parts by mass or less (6 ppm or less), and further preferably 0.0002 parts by mass or less (2 ppm or less).
- the resin composition of the present invention includes various known additives such as a stabilizer, a flame retardant, a flame retardant aid, a hydrolysis inhibitor, a charge, and the like within a range that does not impair the object of the present invention.
- a stabilizer such as a stabilizer, a flame retardant, a flame retardant aid, a hydrolysis inhibitor, a charge, and the like within a range that does not impair the object of the present invention.
- An inhibitor, a foaming agent, a dye, a pigment and the like can be contained.
- the blending method of each material when preparing the resin composition of the present invention includes a known blending method, and is not particularly limited. Examples thereof include a method of mixing and kneading with a tumbler, V-type blender, super mixer, nauter mixer, Banbury mixer, kneading roll, extruder and the like. Moreover, for example, a solution blending method in which an engineering plastic (A) such as methylene chloride and a rubber-containing graft polymer (C) are mixed and dissolved in a common good solvent may be used.
- A engineering plastic
- C rubber-containing graft polymer
- the resin composition of the present invention can be molded into a desired shape by a known molding method.
- the resin composition can be molded directly or directly by a melt extruder and then molded by an extrusion molding method, an injection molding method, a compression molding method, or the like.
- the molded body is not particularly limited, and includes various members (TV frames, personal computer casings, vehicle interior members (instrument panels, etc.), vehicle exterior members (fenders, pillars, etc.), etc.) in the automotive field and the household electrical appliance field. It is done.
- Production Examples 1 to 12 are production examples of a rubber-like polymer and a rubber-containing graft polymer (C). “Part” means “part by mass”, and “%” means “% by mass”.
- DBSNa sodium dodecylbenzenesulfonate
- siloxane latex was put into a separable flask equipped with a condenser, a thermometer and a stirrer, and 0.5 part of dodecylbenzenesulfonic acid was added as a catalyst to obtain a siloxane latex composition. Subsequently, the obtained siloxane latex composition was maintained at 80 ° C. for 8 hours to polymerize the organosiloxane. After the polymerization, the latex containing the polymerization product was cooled and neutralized to pH 7.0 using a 5% aqueous sodium hydroxide solution to obtain a POSi (S-1) latex. The solid content of the POSi (S-1) latex was 35.5%, and the mass average particle size of the polymer was 220 nm.
- the mixed solution of “Component 3” shown in Table 1 was forcibly emulsified and dropped into the separable flask over 150 minutes. Thereafter, the mixture was held for 60 minutes, the mixture of “component 4” shown in Table 1 was added, and the mixture of “component 5” shown in Table 1 was dropped into the separable flask over 60 minutes, and held for 90 minutes. .
- a latex of a silicone polymer-containing vinyl polymer was obtained.
- the obtained latex was sprayed at an inlet temperature of 140 ° C. and an outlet temperature of 65 ° C. of the heating gas for drying using an atomizer spray dryer (trade name: L-8 type spray dryer, manufactured by Okawahara Chemical Co., Ltd.). By drying, a powder of rubber-containing graft polymer (Csa-1) was obtained.
- aqueous solution containing “Component 1” shown in Table 2 was set to a temperature of 30 ° C., and the latex obtained in Production Example 2 was put into the aqueous solution, and the liquid temperature was raised to 80 ° C. for salting out.
- the agglomerated polymer was recovered, immersed in 1500 parts of deionized water and dehydrated twice, and dried at a temperature of 80 ° C. overnight to obtain a rubber-containing graft polymer (Csa-2) powder.
- aqueous solution containing “Component 4” shown in Table 3 was set at a temperature of 30 ° C., the latex was put into the aqueous solution, the liquid temperature was raised to 80 ° C., and salting out was performed. The agglomerated polymer was collected and dried overnight at a temperature of 80 ° C. to obtain a powder of a rubber-containing graft polymer (Csa-3).
- Component 1 shown in Table 10 was blended to prepare an aqueous solution having a temperature of 35 ° C.
- the latex was put into this aqueous solution, and the temperature of the solution was raised to 75 ° C. for acid coagulation. Thereafter, a 10% aqueous sodium hydroxide solution was added, and the pH in the slurry was set to 3.
- the slurry was cooled, the agglomerates were collected, immersed in 1500 parts of deionized water and dehydrated twice, and dried at a temperature of 80 ° C. overnight. In this way, a powder of rubber-containing graft polymer (Cba-6) was obtained.
- test solution 0.25 g of a sample was weighed in a decomposition container, 8 ml of nitric acid was added to the container, and the sample was decomposed (wet decomposition) using a microwave. After cooling the sample solution, 2 ml of hydrofluoric acid was placed in the vessel, treated again with microwaves, made up to 50 ml with distilled water, and used as a test solution.
- sample solution In a container, 0.2 g of a sample and 10 ml of 0.1% trifluoroacetic acid (toluene solution) were placed and stirred at a temperature of 80 ° C. for 60 minutes to dissolve the sample. Next, 1 g of boron trifluoride methanol was added into this container, and methyl esterification treatment was performed at a temperature of 80 ° C. for 30 minutes. Distilled water (10 ml) and hexane (10 ml) were added to the container to separate into two layers, and the hexane layer was used as a sample solution.
- trifluoroacetic acid toluene solution
- Wacr (mass%) Wn (mass%) ⁇ 53.06 ⁇ 14.00 ⁇ (14) Molecular weight of acrylonitrile: 53.06 Molecular weight of nitrogen: 14.00.
- Examples 1 to 5 and Comparative Examples 1 to 5 1. Production of Resin Composition Rubber-containing graft copolymer (Csa-1) obtained in Production Example 2, glass fiber-containing aromatic polycarbonate ("Iupilon GS2030M9001" (trade name), manufactured by Mitsubishi Engineering Plastics Co., Ltd., nominal The composition shown in Table 14 includes 30% by mass of glass fiber, Mv of aromatic polycarbonate resin: 20000), and aromatic polycarbonate (trade name “Iupilon S3000”, manufactured by Mitsubishi Engineering Plastics Co., Ltd., Mv: 20000). Blended and mixed to obtain a mixture.
- Si-1 Resin Composition Rubber-containing graft copolymer obtained in Production Example 2
- glass fiber-containing aromatic polycarbonate (“Iupilon GS2030M9001” (trade name), manufactured by Mitsubishi Engineering Plastics Co., Ltd., nominal
- the composition shown in Table 14 includes 30% by mass of glass fiber, Mv of aromatic polycarbonate resin: 20000), and aromatic polycarbonate (trade name “Iupilon S
- This mixture was supplied to a devolatilizing twin screw extruder (Ikegai Iron Works Co., Ltd., PCM-30) heated to a barrel temperature of 310 ° C., kneaded, and 27% by mass of glass fiber was blended. Composition pellets were made.
- Examples 2 to 5 and Comparative Examples 1 to 5 were the same as described above except that the type and / or amount of the rubber-containing graft copolymer and the amount of other raw materials were changed to the conditions shown in Table 14.
- a pellet of each resin composition was prepared.
- As a salt (D) of an alkali metal and a strong acid in Comparative Example 3, sodium dodecylbenzenesulfonate (DBSNa) was blended in the resin composition.
- DBSNa sodium dodecylbenzenesulfonate
- perfluorocarbon was added in the resin composition.
- Potassium butanesulfonate (F-114) was added.
- the measured value (Mdet mole) of the fatty acid is the total value of the number of moles Ma of the fatty acid present in the resin composition and the number of moles Ms of the fatty acid salt, and is represented by the following formula.
- Mdet Ma + Ms (15) Therefore, when 8 ppm or more of calcium ion, magnesium ion or aluminum ion metal ion is detected in the rubber-containing graft polymer by the method of “Measurement 1”, and when fatty acid is detected by the method of “Measurement 2” Assuming that all of these metal ions are derived from the fatty acid salt, the number of moles Ma of the fatty acid is calculated by the following formula.
- Ma Mdet ⁇ Ms (16) In the case of mol%, the following formula is established.
- Ma (mol%) Mdet (mol%) ⁇ Ms (mol%) (17).
- the following calculation examples 1 and 2 explain the method of calculating the amount of fatty acid (Ma mol) actually present from the measured value of fatty acid (Mdet mol).
- the allocation order of the metal ions involved in the formation of the salt with the fatty acid is Aluminum, magnesium and calcium.
- the order of high basicity is aluminum, magnesium, and calcium, and this is because fatty acids and salts are preferentially formed in the order of high basicity.
- fatty acid content The amount is less than 0.03% by mass, and calcium and magnesium detected in the polymer are salts with strong acids.
- the strong acid here is a sulfonic acid such as dodecylbenzenesulfonic acid or alkyldiphenyl ether disulfonic acid.
- the strong acid here is a sulfonic acid such as dodecylbenzenesulfonic acid.
- Table 14 shows the aluminum equivalent amount and the calcium and magnesium equivalent total amount of the salt of aluminum, calcium or magnesium and a strong acid with respect to a total of 100 parts by mass of the aromatic polycarbonate resin, glass filler and rubber-containing graft polymer. Described.
- FIGS. 1 to 7 summarize the fracture surfaces after the Charpy impact test of the compacts obtained in each Example and each Comparative Example.
- Comparative Example 1 is an aromatic polycarbonate resin composition containing 27% glass fiber (glass filler).
- Comparative Example 2 is an example in which the rubber-containing graft polymer (Csa-2) was blended while fixing the glass fiber content in the resin composition to 27%.
- Ca-2 the rubber-containing graft polymer
- main three components of the resin composition
- calcium or a salt of the rubber-containing graft polymer (C) or magnesium and a strong acid is calcium and 0.0185 part in terms of magnesium, exceeding 0.0008 part. Therefore, the adhesion between the glass fiber and the aromatic polycarbonate resin was lowered (FIG. 5). Since the adhesion decreased, the unnotched Charpy impact strength was not improved, but decreased. Furthermore, the bending property improvement effect by glass fiber blending was significantly reduced.
- Comparative Example 3 is an example in which a rubber-containing graft polymer (Cba-6) was blended.
- the rubber-containing graft polymer (Cba-6) contains 1.4% fatty acid. Therefore, the adhesion between the glass fiber and the aromatic polycarbonate resin was lowered (FIG. 6). Since the adhesion decreased, the Charpy impact strength was not improved, but decreased. Furthermore, the bending property improvement effect by glass fiber blending was significantly reduced.
- the total content of calcium and / or magnesium and strong acid salt derived from the rubber-containing graft polymer (C) is the total in terms of calcium and magnesium with respect to 100 parts of the “main three components” of the resin composition. The content is 0.0028 part, exceeding 0.0008 part. Therefore, the adhesion between the glass fiber and the aromatic polycarbonate resin was lowered (FIG. 2). Notch-free Charpy impact strength was not improved, and the effect of improving bending properties by blending glass fibers was significantly reduced.
- Comparative Example 5 is an example in which a rubber-containing graft polymer (Cba-7) was blended.
- 10% of the rubber-containing graft polymer (Cba-7) is blended in the resin composition, 100 parts of “main three components” of the resin composition and aluminum and strong acid derived from the rubber-containing graft polymer (C)
- the salt content is 0.0014 parts in terms of aluminum, exceeding 0.0008 parts. Therefore, the adhesion between the glass fiber and the aromatic polycarbonate resin was lowered (FIG. 7). Since the adhesion decreased, the Charpy impact strength was not improved, but decreased. Furthermore, the bending property improvement effect by glass fiber blending was significantly reduced.
- the rubber-containing graft polymer (C) used had an acetone insoluble content of 25% by mass or more, and the amount of fatty acid contained in the rubber-containing graft polymer (C) was 1% by mass or less.
- the total content of calcium or magnesium and strong acid salt derived from the rubber-containing graft polymer (C) is the total content in terms of calcium and magnesium.
- the content of the salt of aluminum and strong acid is 0.0008 parts or less in terms of aluminum. The impact strength of the molded body is improved both with and without the notch.
- the resin composition containing 10 parts by mass of the rubber-containing graft polymer (Example 3) had a lower bending strength than the resin composition containing no rubber-containing graft rubber polymer (Comparative Example 1).
- the bending strength of the molded product of the resin composition (Examples 1, 2, 4, 5) containing 2.5 to 5 parts by mass of the rubber-containing graft polymer is that the molded product of the resin composition not containing the rubber-containing graft polymer
- the impact strength of the molded body was improved with the same bending strength (Comparative Example 1) and with and without notches.
- Example 3 and Comparative Examples 2, 4, and 5 the constituent components of the rubber-containing graft polymer are almost the same and the blending amount of the rubber-containing graft polymer is the same, but derived from the rubber-containing graft polymer (C).
- the total content of calcium and magnesium in terms of calcium and magnesium and the content in terms of aluminum of the content of salt of aluminum and strong acid are different.
- the total content of calcium and magnesium equivalent salt of calcium and magnesium and strong acid derived from rubber-containing graft polymer (C) in the resin composition, or the aluminum equivalent of salt content of aluminum and strong acid The greater the content of, the lower the mechanical strength such as bending strength and Charpy impact strength.
- the resin composition containing the rubber-containing graft polymer of Example 3 contains the rubber-containing graft polymer of Comparative Example 2, 4 or 5.
- the adhesion between the glass fiber and the aromatic polycarbonate is excellent.
- the mixture was supplied to a devolatilizing twin-screw extruder (PCM-30, manufactured by Ikekai Tekko Co., Ltd.) heated to a barrel temperature of 280 ° C. and kneaded, and the resin composition of Example 6 was blended with 27% by mass of glass fiber. Article pellets were made.
- PCM-30 devolatilizing twin-screw extruder
- Examples 7 to 18 and Comparative Examples were the same as described above except that the type and / or amount used of the rubber-containing graft copolymer (C) and the amount of other raw materials were changed to the conditions shown in Table 15. 6-8 pellets of each resin composition were prepared. In Examples 8 and 11 and Comparative Example 7, potassium diphenylsulfone sulfonate (KSS) was blended in the resin composition, and in Example 10, potassium perfluorobutane sulfonate (F--) was added in the resin composition. 114).
- KSS potassium diphenylsulfone sulfonate
- F-- potassium perfluorobutane sulfonate
- Examples 12 to 14 calcium stearate or magnesium stearate was blended. The charge value was calculated, and the calcium and magnesium equivalent amounts of calcium, magnesium and a weak acid salt were calculated for 100 parts by mass of the “main 3 components” of the resin composition.
- Charpy impact test A Charpy impact test was conducted in the same manner as in Example 1 except that the cylinder temperature was changed to 280 ° C. The measurement results are shown in Table 15.
- Examples 6 to 14 and Comparative Examples 6 to 8 are evaluation results of resin compositions obtained at an extrusion and molding temperature of 280 ° C.
- Comparative Example 8 is an aromatic polycarbonate resin composition containing 27% by mass of glass fibers.
- the total content of calcium and magnesium and strong acid salts derived from the rubber-containing graft polymer (C) is 0.0008 mass relative to 100 mass parts of the “main 3 components” of the resin composition. The impact strength of the molded body is not sufficient, and particularly the bending strength is greatly reduced.
- the total content of calcium and magnesium and strong acid salts derived from the rubber-containing graft polymer (C) is calculated in terms of calcium and magnesium.
- the total content is 0.0008 parts by mass or less, and the molded article is excellent in impact strength.
- Examples 12 to 14 are obtained by blending the resin composition of Example 6 with a salt of calcium or magnesium and a weak acid during extrusion. Even if the total content of calcium or a salt of magnesium and an acid in 100 parts by mass of the “main 3 components” of the resin composition is 0.0008 parts by mass or more as the total content in terms of calcium and magnesium, the Examples 6 shows that the impact strength and / or bending characteristics of the molded body are improved. According to Examples 12 to 14, the total content of calcium or a salt of magnesium and a weak acid in 100 parts by mass of “main three components” of the resin composition is 0.0010 to 0.00 in terms of the total content in terms of calcium and magnesium. Within the range of 0060, it can be seen that the bending properties and notch-free Charpy impact strength of the molded product are particularly excellent.
- Example 6 Each resin composition of Example 6, Example 9, and Example 12 satisfies all the requirements of the resin composition of the first aspect of the present invention, and the molded body of the obtained resin composition has an impact strength. Are better.
- the total content of calcium or a salt of magnesium and a strong acid is approximately the total content in terms of calcium and magnesium, and aluminum It is possible to determine the content of the salt of bismuth and a strong acid as the content in terms of aluminum. This is because a salt of calcium or magnesium and a weak acid, particularly a salt of calcium or magnesium and a fatty acid is difficult to dissolve in chloroform.
- calcium stearate which is a salt of calcium and weak acid is contained in terms of calcium with respect to 100 parts by mass of the total of the aromatic polycarbonate resin and the rubber-containing graft polymer (resin two components).
- the amount of calcium is below the detection limit (2 ppm or less: 0.0002 mass relative to 100 parts by mass of the resin two components). Or less). This indicates that calcium stearate, which is a salt of calcium and weak acid, was removed by measurement method X.
- the resin composition obtained by the present invention has both improved adhesion of glass filler and improved rubber dispersibility in an aromatic polycarbonate matrix which has been difficult in the past, and the molded product has excellent impact characteristics and rigidity.
- the present invention can be applied to materials in various fields including automobile members and home appliance members that are required to be thin and have dimensional stability.
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Abstract
Description
〔1〕 エンジニアリングプラスチック(A)、ガラス充填剤(B)及びゴム含有グラフト重合体(C)を含む樹脂組成物であって、該樹脂組成物のクロロホルム可溶分中のアクリロニトリル由来成分の割合が2.0質量%以下であり、該樹脂組成物100質量部中における脂肪酸の含有量が0.03質量部以下であり、下記の測定方法Xにて測定される乾燥試料100質量部中のカルシウム及びマグネシウムの合計含有量が0.0008質量部以下であり、アルミニウムの含有量が0.0008質量部以下である樹脂組成物。
[測定方法X]:
[1]乾燥試料の調製
樹脂組成物5質量%及びクロロホルム95質量%からなる溶液を調製して、以下(1)~(4)の操作を行ない、「乾燥試料」を得る。
(1)前記溶液を遠心分離機に供して5000rpmで30分間、遠心分離する。
(2)上澄み液を抽出し、フラスコ内に入れる。
(3)該フラスコを温度68℃の恒温槽中にセットして、エバポレータで該液から揮発分を留去する。
(4)該フラスコ内の残存物を温度120℃で3時間乾燥して「乾燥試料」を得る。
[2]前記乾燥試料中のアルミニウム、マグネシウム及びカルシウムを定量する。
本発明の樹脂組成物において、エンジニアリングプラスチック(A)としては、従来知られている各種の熱可塑性エンジニアリングプラスチックを用いることができる。本発明において、「エンジニアリングプラスチック」とは、0.45MPaの荷重下でISO-75に準拠した方法で測定した荷重たわみ温度(HDT)が100℃以上のものをいう。例えば、ポリフェニレンエーテル、ポリカーボネート、ポリエチレンテレフタレート、ポリブチレンテレフタレート等のポリエステル系重合体、シンジオタクチックポリスチレン、6-ナイロン、6,6-ナイロン等のナイロン系重合体、ポリアリレート、ポリフェニレンスルフィド、ポリエーテルケトン、ポリエーテルエーテルケトン、ポリスルホン、ポリエーテルスルホン、ポリアミドイミド、ポリエーテルイミド、ポリアセタールを例示することができる。
本発明においてガラス充填剤(B)は、ケイ酸塩を主成分とする物質であり、層状珪酸塩、タルク、マイカ、シリカ等の多孔質粒子、ガラス(ガラス繊維、ミルドガラス、ガラスフレーク、ガラスビーズなど)等が挙げられる。成形体の曲げ特性の観点から、特にガラス繊維が好ましい。
本発明の樹脂組成物を構成するゴム含有グラフト重合体(C)は、「ゴム状重合体」に対して「ビニル系単量体」がグラフト重合されたものである。ゴム含有グラフト重合体(C)を構成するグラフト重合に由来する成分を、以下「グラフト成分」という。
WC=Wrp+Wgc+Pfr ・・・(1)
WC:ゴム含有グラフト重合体(C)の質量
Wrp:ゴム状重合体の質量
Wgc:グラフト成分の質量
Pfr:遊離重合体。
(1)前記溶液を遠心分離機に供して20000rpmで30分間、遠心分離する。
(2)上澄み液を抽出し、フラスコ内に入れる。
(3)該フラスコを温度56℃の恒温槽中にセットして、エバポレータによって該液から揮発分を留去する。
(4)該フラスコ内の残存物を温度120℃で3時間乾燥して「乾燥試料」を得る。
wais=(wc1-was)/wc1×100 ・・・(2)
wc1:測定に供したゴム含有グラフト重合体の質量
was:アセトン可溶分の質量%
wais:アセトン不溶分の質量%。
前記操作において、「遊離重合体Pfr」は、アセトン可溶分として抽出される。
本発明の樹脂組成物中に含有されるアルカリ金属と強酸との塩(D)は、ゴム含有グラフト重合体(C)の重合の際に使用される乳化剤等としてゴム含有グラフト重合体(C)にあらかじめ含まれていてもよく、エンジニアリングプラスチック(A)、ガラス充填剤(B)及びゴム含有グラフト重合体(C)を含む樹脂組成物に対して後添加してもよい。
本発明において「脂肪酸」とは、カルボン酸を含む炭化水素化合物をいう。グラフト重合の際に乳化剤として脂肪酸のアルカリ金属塩を用いた場合、得られたゴム含有グラフト重合体(C)のラテックス中に、強酸凝析剤として硫酸、リン酸などを加えると、乳化剤である脂肪酸のアルカリ金属塩が水溶性の低い脂肪酸へと変わる。その結果、ゴム含有グラフト重合体(C)と水が分離するので、ゴム含有グラフト重合体(C)を回収できる。よって、この場合は、製造したゴム含有グラフト重合体(C)中に脂肪酸が含まれている。脂肪酸はガラス充填剤(B)とエンジニアリングプラスチック(A)との密着性に影響を与えることから、ゴム含有グラフト重合体(C)中に含まれる脂肪酸の量は少ないことが好ましい。本発明の樹脂組成物100質量部中における脂肪酸の含有量は、0.03質量部以下であることが好ましく、0.02質量部以下であることがより好ましく、0.01質量部以下であることがさらに好ましい。また、この含有量は、0.01質量部以下であって、脂肪酸の測定の際に、パルミチン酸、ステアリン酸、オレイン酸、アルケニルコハク酸、ロジン酸が検出されないことが最も好ましい。
グラフト重合によって得られたラテックス状態のゴム含有グラフト重合体(C)は、凝析し洗浄した後に乾燥することにより、または、噴霧回収することにより、粉体として得ることができる。
本発明の樹脂組成物はエンジニアリングプラスチック(A)、ガラス充填剤(B)及びゴム含有グラフト重合体(C)を含む組成物である。以下の説明において、エンジニアリングプラスチック(A)及びゴム含有グラフト重合体(C)を、樹脂組成物の「樹脂2成分」という場合がある。また、エンジニアリングプラスチック(A)、ガラス充填剤(B)及びゴム含有グラフト重合体(C)を、樹脂組成物の「主要3成分」という場合がある。
本発明の樹脂組成物のクロロホルム可溶分中のアクリロニトリル由来成分の割合は2.0質量%以下であることが好ましい。「アクリロニトリル由来成分」とは、「遊離重合体Pfr」中に含まれるアクリロニトリル構成成分をいう。既に説明したが、粉体集合物として回収されたゴム含有グラフト重合体(C)中には、「非グラフト成分」である「遊離重合体Pfr」が混在している。従って、樹脂組成物のクロロホルム可溶分には、エンジニアリングプラスチック(A)と「非グラフト成分」である「遊離重合体Pfr」が含まれる。
(1)前記溶液を遠心分離機に供して20000rpmで30分間、遠心分離する。
(2)上澄み液を抽出し、フラスコ内に入れる。
(3)該フラスコを温度68℃の恒温槽中にセットして、エバポレータによって該液から揮発分を留去する。
(4)該フラスコ内の残存物を温度120℃で3時間乾燥し、「乾燥試料」を得る。
樹脂組成物中のカルシウム又はマグネシウムと強酸との塩は、エンジニアリングプラスチック(A)とガラス充填剤(B)との密着性を低減し、樹脂組成物の成形時の熱劣化を促進し、成形体の高温高湿下での耐加水分解性などの性質を顕著に悪化させる。特にゴム含有グラフト重合体(C)由来のカルシウム又はマグネシウムと強酸との塩は、エンジニアリングプラスチック(A)とガラス充填剤(B)との密着性を顕著に悪化させる。
樹脂組成物5質量%及びクロロホルム95質量%からなる溶液を調製して、以下(1)~(4)の操作を行ない、「乾燥試料」を得る。次いで、乾燥試料100質量部中のカルシウム、マグネシウム及びアルミニウムの質量を測定する。
(1)前記溶液を遠心分離機に供して5000rpmで30分間、遠心分離する。
(2)上澄み液を抽出し、フラスコ内に入れる。
(3)該フラスコを温度68℃の恒温槽中にセットして、エバポレータで該液から揮発分を留去する。
(4)該フラスコ内の残存物を温度120℃で3時間乾燥して「乾燥試料」を得る。
Wca+mg=Wca+Wmg ・・・・・(3)
Wcas+mgs=Wcas+Wmgs ・・・(4)
Wcas:カルシウムと強酸との塩の含有量
Wmgs:マグネシウムと強酸との塩の含有量
Wca:カルシウムの含有量
Wmg:マグネシウムの含有量。
また本発明の第二の態様の樹脂組成物において、本発明の樹脂組成物の「主要3成分」の合計100質量部に対する,該樹脂組成物中のカルシウム又はマグネシウムと「強酸」との塩の合計含有量の、カルシウム及びマグネシウム換算の合計含有量「Tca+mg」は、0.0008質量部以下である。このTca+mgの値は、ゴム含有グラフト重合体(C)由来のカルシウム又はマグネシウムと強酸との塩の合計含有量の、カルシウム及びマグネシウム換算の合計含有量「Cca+mg」と、ゴム含有グラフト重合体(C)以外の成分に由来するカルシウム及びマグネシウムと強酸との塩の合計含有量の、カルシウム及びマグネシウム換算の合計含有量「NCca+mg」とを、それぞれ算出することにより、次式にて算出される。
Tca+mg=Cca+mg+NCca+mg ・・・(5)
Cca+mg=Mc×(cqcas×rca + cqmgs×rmg) ・・・(6)
Mc:樹脂組成物の「主要3成分」100質量部中におけるゴム含有グラフト重合体(C)の質量部
cqcas:ゴム含有グラフト重合体(C)中のカルシウムと強酸との塩の濃度
cqmgs:ゴム含有グラフト重合体(C)中のマグネシウムと強酸との塩の濃度
rca:カルシウムと強酸との塩中のカルシウム濃度
rmg:マグネシウムと強酸との塩中のマグネシウム濃度。
NCca+mg=(mnccas×rca)+(mncmgs×rmg) ・・・(7)
mnccas:樹脂組成物の「主要3成分」の合計100質量部に対する樹脂組成物中のゴム含有グラフト重合体(C)以外の成分に由来するカルシウムと強酸との塩の質量部
mncmgs:樹脂組成物の「主要3成分」の合計100質量部に対する樹脂組成物中のゴム含有グラフト重合体(C)以外の成分に由来するマグネシウムと強酸との塩の質量部
rca:カルシウムと強酸との塩中のカルシウム濃度
rmg:マグネシウムと強酸との塩中のマグネシウム濃度。
本発明の第一の態様及び第二の態様の樹脂組成物において、更に、樹脂組成物の「主要3成分」の合計100質量部中におけるガラス充填剤(B)以外のカルシウム又はマグネシウムと「弱酸」との塩の合計含有量が、カルシウム及びマグネシウム換算の合計含有量「NB’ca+mg」で0.0010~0.0060質量部であることが好ましい。この含有量NB’ca+mgの値が0.0010~0.0060質量部であれば、成形体は衝撃強度や曲げ特性(弾性率・強度)に優れる。この含有量NB’ca+mgの値は0.0020~0.0030質量部がさらに好ましい。
NB’ca+mg=C’ca+mg+NBC’ca+mg ・・・(8)
C’ca+mg=Mc×(cq’cas×r’ca + cq’mgs×r’mg)
・・・(9)
Mc:樹脂組成物の「主要3成分」100質量部中におけるゴム含有グラフト重合体(C)の質量部
cq’cas:ゴム含有グラフト重合体(C)中のカルシウムと弱酸との塩の濃度
cq’mgs:ゴム含有グラフト重合体(C)中のマグネシウムと弱酸との塩の濃度
r’ca:カルシウムと弱酸との塩中のカルシウム濃度
r’mg:マグネシウムと弱酸との塩中のマグネシウム濃度。
NBC’ca+mg=(mnbc’cas×r’ca)+(mnbc’mgs×r’mg)
・・・(10)
mnbc’cas:樹脂組成物の「主要3成分」の合計100質量部に対する樹脂組成物中のガラス充填剤(B)及びゴム含有グラフト重合体(C)以外のカルシウムと弱酸との塩の質量部
mnbc’mgs:樹脂組成物の「主要3成分」の合計100質量部に対する樹脂組成物中のガラス充填剤(B)及びゴム含有グラフト重合体(C)以外のマグネシウムと弱酸との塩の質量部
r’ca:カルシウムと弱酸との塩中のカルシウム濃度
r’mg:マグネシウムと弱酸との塩中のマグネシウム濃度。
樹脂組成物中のアルミニウムと強酸との塩は、エンジニアリングプラスチック(A)とガラス充填剤(B)との密着性を低下させ、かつ樹脂組成物の成形時の熱劣化を促進し、また成形体の高温高湿下での耐加水分解性を悪化させる。特にゴム含有グラフト重合体(C)由来のアルミニウムと強酸との塩は、エンジニアリングプラスチック(A)とガラス充填剤(B)との密着性を顕著に低下させる。尚、エンジニアリングプラスチック(A)とガラス充填剤(B)中には基本的にアルミニウムと強酸との塩は含まれない。ガラス充填剤(B)にはアルミニウムを含むことがあり、アモルファス構造を有する二酸化ケイ素がその骨格中にアルミニウムをイオンとして含む。そのためガラス充填剤(B)には基本的にアルミニウムと強酸との塩は含まれない。
本発明の第一の態様の樹脂組成物において、前記測定方法Xにて測定される乾燥試料100質量部中のアルミニウム含有量は0.0008質量部以下である。この含有量が0.0008質量部(8ppm)以下の場合は、上述のエンジニアリングプラスチック(A)とガラス充填剤(B)との密着性の低下や、樹脂組成物の成形時の熱劣化や成形体の加水分解性は問題とならないため、成形体の衝撃強度や曲げ特性(弾性率、強度)が優れる。このアルミニウムの含有量は好ましくは0.0006質量部以下(6ppm以下)であり、0.0002質量部以下(2ppm以下)がさらに好ましい。この含有量の値が、0.0006質量部以下であれば、エンジニアリングプラスチック(A)とガラス充填剤(B)との密着性がさらに優れる。
また本発明の第二の態様の樹脂組成物において、樹脂組成物の「主要3成分」の合計100質量部に対する、該樹脂組成物中のアルミニウムと強酸との塩の合計含有量のアルミニウム換算の含有量「Tal」は、0.0008質量部以下である。ゴム含有グラフト重合体(C)中のアルミニウムと強酸との塩の含有量のアルミニウムの換算の含有量Calとゴム含有グラフト重合体(C)以外のアルミニウムと強酸との塩のアルミニウムの換算量NCalをそれぞれ算出することにより、次式にてTalが算出される。
Tal=Cal+NCal ・・・(11)
Cal=Mc×cqal×ral ・・・(12)
Mc:樹脂組成物の「主要3成分」100質量部中におけるゴム含有グラフト重合体(C)の質量部
cqals:ゴム含有グラフト重合体(C)中のアルミニウムと強酸との塩の濃度
ral:アルミニウムと強酸との塩中のアルミニウム濃度。
NCal=mncals×ral ・・・(13)
mncals:樹脂組成物の「主要3成分」の合計100質量部に対するゴム含有グラフト重合体(C)以外の成分に由来するアルミニウムと強酸との塩の質量部
ral:アルミニウムと強酸との塩中のアルミニウム濃度。
本発明の樹脂組成物は、上記の材料の他、本発明の目的を損なわない範囲で、周知の種々の添加剤、例えば、安定剤、難燃剤、難燃助剤、加水分解抑制剤、帯電防止剤、発泡剤、染料、顔料等を含有することができる。
本発明の樹脂組成物の調製する際の各材料の配合方法としては、公知のブレンド方法が挙げられ、特に限定されない。例えばタンブラー、V型ブレンダー、スーパーミキサー、ナウターミキサー、バンバリーミキサー、混練ロール、押出機等で混合、混練する方法が挙げられる。また、例えば塩化メチレン等のエンジニアリングプラスチック(A)とゴム含有グラフト重合体(C)の共通の良溶媒に溶解させた状態で混合する溶液ブレンド方法等が挙げられる。
本発明の樹脂組成物は、公知の成形方法によって、所望形状の成形体とすることができる。樹脂組成物は、直接に、或いは溶融押出機で一旦ペレットにしてから、押出成形法、射出成形法、圧縮成形法等によって成形することができる。成形体は、特に限定されず、自動車分野や家電分野等における各種部材(テレビフレーム、パソコンの筐体、車両用内装部材(インパネ等)、車両用外装部材(フェンダー、ピラー等)等)が挙げられる。
オクタメチルシクロテトラシロキサン97.5部、γ-メタクリロイルオキシプロピルジメトキシメチルシラン0.5部及びテトラエトキシシラン2.0部を混合してシロキサン混合物100部を得た。これに、脱イオン水180部にドデシルベンゼンスルホン酸ナトリウム(DBSNa)0.67部を溶解した溶液を添加し、ホモミキサーにて10,000rpmで5分間攪拌した。次いで、ホモジナイザーに20MPaの圧力で2回通過させて、シロキサンラテックスを得た。
製造例1で得られたPOSi(S-1)のラテックス28.5部(仕込みモノマー成分として10部)を、冷却管、温度計、窒素導入管及び攪拌装置を備えたセパラブルフラスコ内に投入し、更に表1に示す「成分1」を添加し、混合した。このセパラブルフラスコ内に窒素気流を通じることによりフラスコ内雰囲気の窒素置換を行ない、液温を70℃まで昇温した。液温が70℃となった時点で表1に示す「成分2」の混合液を添加し、重合を開始させた。その後、液温70℃を10分間保持した。
表2に示す「成分1」を配合した水溶液を温度30℃に設定し、その水溶液中に製造例2で得られたラテックスを投入し、液温を80℃に昇温し、塩析した。凝集ポリマーを回収し、脱イオン水1500部に浸し、脱水する工程を2度繰り返し、温度80℃で一晩乾燥して、ゴム含有グラフト重合体(Csa-2)の粉体を得た。
製造例1で得られたPOSi(S-1)のラテックス28.5部(仕込みモノマー成分として10部)を、冷却管、温度計、窒素導入管及び攪拌装置を備えたセパラブルフラスコ内に投入し、更に表3に示す「成分1」を添加し、混合した。このセパラブルフラスコ内に窒素気流を通じることによりフラスコ内雰囲気の窒素置換を行ない、液温を50℃まで昇温した。液温が50℃となった時点で表3に示す「成分2」の混合液を添加し、重合を開始させた。その後、液温65℃を30分間保持した。さらに表3に示す「成分3」の混合液を30分間かけてセパラブルフラスコ内に滴下し、60分間保持した。このようにしてラテックスを得た。
表4に示す「成分1」を攪拌機および還流冷却管を備えた反応容器内に仕込み、温度70℃で1.5時間加熱攪拌し、重合させた。引き続き、表4に示す「成分2」からなる混合物を1時間かけて反応容器内に滴下し、その後1時間加熱攪拌を続けて、酸基含有共重合体ラテックスを得た。
表5に示す「成分1」を温度80℃で溶解させた。次いで表5に示す「成分2」の水溶液を上記の溶液中に投入して強制乳化させ、安定剤のエマルションを調製した。
(1)ゴム状重合体のラテックス(R-1)の製造
第一単量体混合液として表6に示す「成分1」を容量70Lのオートクレーブ内に仕込み、昇温して、液温が43℃になった時点で、表6に示す「成分2」のレドックス系開始剤を添加して反応を開始し、その後さらに液温を65℃まで昇温した。重合開始から3時間後に表6に示す「成分3」の重合開始剤を添加し、その1時間後から「成分4」の第二単量体混合液、「成分5」の乳化剤水溶液、「成分6」の重合開始剤を8時間かけてオートクレーブ内に連続的に滴下した。重合開始から4時間反応させて、ゴム状重合体のラテックス(R-1)を得た。このラテックス中の重合体粒子の質量平均粒子径は170nmであり、dw/dn=1.2であった。
ラテックス(R-1)219部(仕込みモノマー成分として77.5部)を、攪拌機および還流冷却管を備えた反応容器内に仕込み、表7に示す「成分1」を添加した。次いで、反応容器内の液温を55℃に昇温し、表7に示す「成分2」からなる水溶液を加え、引き続き、表7に示す「成分3」の混合物を60分間かけて反応容器内に滴下し、さらに60分間加熱攪拌を続けた。引き続き表7に示す「成分4」の混合物を60分間かけて反応容器内に滴下し、さらに60分間加熱攪拌を続けた。このようにして、ゴム状重合体に対してビニル単量体をグラフト重合させて、ゴム含有グラフト重合体のラテックス(Rgr-1)を得た。
製造例7で得られたゴム含有グラフト重合体のラテックス(Rgr-1)243.9部に、製造例6の安定剤のエマルションを2.2部配合して、混合した。次いで、アトマイザー式噴霧乾燥機(大川原化工機(株)製、商品名;L-8型スプレードライヤー)を用いて、乾燥用加熱ガスの入口温度140℃及び出口温度65℃で噴霧乾燥して、ゴム含有グラフト重合体(Cba-4)の粉体を得た。
製造例7で得られたゴム含有グラフト重合体のラテックス(Rgr-1)243.9部に、製造例6の安定剤のエマルションを2.2部配合して、混合した。さらにアルキルジフェニルエーテルジスルホン酸ナトリウム(SS-L)を0.5部配合した。次いで、アトマイザー式噴霧乾燥機(大川原化工機(株)製、商品名;L-8型スプレードライヤー)を用いて、乾燥用加熱ガスの入口温度140℃及び出口温度65℃で噴霧乾燥して、ゴム含有グラフト重合体(Cba-5)の粉体を得た。
(1)ゴム状重合体のラテックス(R-2)の製造
攪拌機を備えたオートクレーブ内に、表8に示す「成分1」を加え、オートクレーブ内の雰囲気を窒素置換した。次いで、表8に示す「成分2」を加えて密封し、液温を50℃に昇温した。次いで表8に示す「成分3」を含む酸化還元触媒水溶液を加えた後、温度55℃で8時間重合させることによりゴム状重合体のラテックス(R-2)を得た。このラテックス中の重合体粒子の質量平均粒子径は100nmであり、固形分は32.1%であった。
ラテックス(R-2)242部を、攪拌機および還流冷却管を備えた反応容器内に仕込み、液温を40℃に昇温した。次いで表9に示す「成分1」を加え、30分間攪拌した。その後、表9に示す「成分2」の水溶液を配合した。得られたラテックス中の重合体粒子の質量平均粒子径は250nmであった。
表3に示す「成分4」の代わりに表11に示す「成分4’」を用いた以外は製造例4と同様にしてゴム含有グラフト重合体(Csa-7)の粉体を得た。
表3に示す「成分4」の代わりに表12に示す「成分4”」を用いた以外は製造例4と同様にしてゴム含有グラフト重合体(Csa-8)の粉体を得た。
〔測定1〕ゴム含有グラフト重合体中のナトリウム、カリウム、アルミニウム、マグネシウム、カルシウムイオン量の定量
試料として、各製造例で得られたゴム含有グラフト重合体を用いて、以下の方法で測定した。
試料0.25gを分解容器内に秤り取り、該容器内に硝酸8mlを添加してマイクロウエーブにて試料を分解(湿式分解)させた。試料液を、冷却後、該容器内にフッ化水素酸2mlを入れ、再度マイクロウエーブで処理し、蒸留水で50mlにメスアップし検液とした。
この検液をICP発光分析装置(IRIS Interpid II XSP:Thermo社製)を用いてナトリウム、カリウム、アルミニウム、マグネシウム、カルシウムのイオン量を定量(ppm単位)した。表13に結果をまとめた。
試料として、各製造例で得られたゴム含有グラフト重合体を用い、以下の方法で測定した。
容器内に、試料0.2g及び0.1%トリフロオロ酢酸(トルエン溶液)10mlを入れて、温度80℃で60分間撹拌して、試料を溶解した。次に、この容器内に、三フッ化ほう素メタノール1gを加え、温度80℃、30分間の条件でメチルエステル化処理を行った。この容器内に蒸留水10mlとヘキサン10mlを加えて二層分離させ、ヘキサン層を試料液とした。
試料液1μlをガスクロマトグラフ内に注入し、パルミチン酸、オレイン酸、ステアリン酸、アルケニルコハク酸ジカリウム、ロジン酸の量を測定した。測定値を試料質量当たりの濃度に換算した。表13に結果をまとめた。
[1]乾燥試料の調製
ゴム含有グラフト重合体1質量%、アセトン99質量%からなる溶液を調製して、以下(1)~(4)の操作を行ない、「乾燥試料」を得た。
(1)前記溶液を遠心分離機に供して20000rpmで30分間、遠心分離する。
(2)上澄みを抽出し、フラスコ内に入れる。
(3)フラスコを温度56℃の恒温槽中にセットして、エバポレータによって揮発分を留去する。
(4)フラスコ内の残存物を温度120℃で3時間乾燥して「乾燥試料」を得る。
上記「乾燥試料」がアセトン可溶分であるので「100-(アセトン可溶分)」によってアセトン不溶分を算出し、表13に結果をまとめた。
[1]乾燥試料の調製
試料として、実施例6、実施例9、実施例12及び比較例8において得られた樹脂組成物を用い、各樹脂組成物5質量%及びクロロホルム95質量%からなる溶液を調製して、以下(1)~(4)の操作を行ない、「乾燥試料」を得た。
(1)前記溶液を遠心分離機に供して5000rpmで30分間、遠心分離する。
(2)上澄み液を抽出し、フラスコ内に入れる。
(3)該フラスコを温度68℃の恒温槽中にセットして、エバポレータで該液から揮発分を留去する。
(4)該フラスコ内の残存物を温度120℃で3時間乾燥して「乾燥試料」を得る。
試料として、実施例6、実施例9、実施例12及び比較例8において得られた各樹脂組成物を用いて、「測定2」と同様の方法で脂肪酸の量を測定し、表16に結果をまとめた。
[1]乾燥試料の調製
実施例6、実施例9、実施例12及び比較例8においてで得られた樹脂組成物を用い、各樹脂組成物1質量%及びクロロホルム99質量%からなる溶液を調製して、以下(1)~(4)の操作を行ない、「乾燥試料」を得た。
(1)前記溶液を遠心分離機に供して20000rpmで30分間、遠心分離する。
(2)上澄み液を抽出し、フラスコ内に入れる。
(3)該フラスコを温度68℃の恒温槽中にセットして、エバポレータで該液から揮発分を留去する。
(4)該フラスコ内の残存物を温度120℃で3時間乾燥して「乾燥試料」を得る。
得られた「乾燥試料」(クロロホルム可溶分)の元素分析を行い、窒素含有量Wn(質量%)を測定した。
以下の算出式でアクリロニトリル由来成分の割合Wacr(質量%)を算出した。
Wacr(質量%)=Wn(質量%)×53.06÷14.00
・・・(14)
アクリロニトリルの分子量:53.06
窒素の分子量:14.00。
1.樹脂組成物の製造
製造例2で得られたゴム含有グラフト共重合体(Csa-1)、ガラス繊維配合芳香族ポリカーボネート(「ユーピロンGS2030M9001」(商品名)、三菱エンジニアリングプラスチックス(株)製、公称ガラス繊維30質量%配合、芳香族ポリカーボネート樹脂のMv:20000)、及び、芳香族ポリカーボネート(商品名「ユーピロンS3000」、三菱エンジニアリングプラスチックス(株)製、Mv:20000)を表14に示す組成で配合し、混合し、混合物を得た。この混合物を、バレル温度310℃に加熱した脱揮式二軸押出機(池貝鉄工社製、PCM-30)に供給して混練し、ガラス繊維が27質量%配合された、実施例1の樹脂組成物のペレットを作製した。
「測定4」の方法に従って、得られた各樹脂組成物100質量部中のアルミニウムと強酸との塩の含有量(アルミニウム換算量Wal)、カルシウム又はマグネシウムと強酸との塩の含有量(カルシウム換算量Wca及びマグネシウム換算量Wmg)を算出し、表14に記載した。
Mdet=Ma+Ms ・・・(15)
そのため「測定1」の方法でゴム含有グラフト重合体中にカルシウムイオン、マグネシウムイオン又はアルミニウムイオンの金属イオンが8ppm以上検出される場合であって、「測定2」の方法で脂肪酸が検出された場合は、これらの金属イオンが全て脂肪酸塩に由来すると見做して、次式によって、脂肪酸のモル数Maが算出される。
Ma=Mdet-Ms ・・・(16)
またモル%の場合、次式が成立する。
Ma(モル%)=Mdet(モル%)-Ms(モル%) ・・・(17)。
ステアリン酸が1%検出された場合で、かつ、アルミニウムが100ppm(0.01%)、カルシウムが200ppm(0.02%)検出された場合は、各成分のモル%は以下の通りである。
ステアリン酸のモル%:1%÷245(ステアリン酸の分子量)=0.0040モル%
アルミニウムのモル%:[0.01%÷27(アルミニウムの分子量)]×3(価数)=0.0008モル%
カルシウムのモル%:[0.02%÷40(カルシウムの分子量)]×2(価数)=0.0010モル%。
従って、脂肪酸の量Ma(モル%)は、次式にて算出される。
Ma(モル%)=Mdet(モル%)-Ms(モル%)
=0040-0.0008-0.0010=0.0023
その脂肪酸の質量当たりの濃度は、次式にて算出される。
0.0023×245=0.54%。
ステアリン酸が0.5%検出された場合で、かつ、アルミニウムが100ppm(0.01%)、カルシウムが500ppm(0.05%)検出された場合は、各成分のモル%は、次式にて算出される。
ステアリン酸のモル%:0.5%÷245(ステアリン酸の分子量)=0.0020モル%
アルミニウムのモル%:[0.01%÷27(アルミニウムの分子量)]×3(価数)=0.0008モル%
カルシウムのモル%:[0.05%÷40(カルシウムの分子量)]×2(価数)=0.0025モル%
従って、脂肪酸の量Ma(モル%)は、次式にて算出され、ゼロ以下となる。
0.0020-0.0008-0.0025=-0.0013
この場合、アルミニウムはすべてステアリン酸との塩となり、カルシウムはその一部がステアリン酸との塩になる。残りのカルシウムは、他の酸との塩となり、そのカルシウム濃度は次式にて算出される。
0013÷2×40=0.026(26ppm)
ゴム含有グラフト重合体の製造時に強酸とアルカリ金属との塩を乳化剤等で配合している場合は、26ppmのカルシウムは強酸との塩由来と見なす。
前記10種類の各ペレットを、それぞれ別個に、住友射出成形機SE100DU(住友重機械工業(株)製)に供給し、シリンダー温度320℃、金型温度90℃にて、長さ80mm×幅10mm×厚さ4mmの成形体(試験片)を得た。シャルピー衝撃試験はISO-179-1に準拠し、ISO2818に準拠したTYPEAのノッチを刻んで測定した。測定結果を表14に示した。
前記10種類の各ペレットを、それぞれ別個に、住友射出成形機SE100DU(住友重機械工業(株)製)に供給し、シリンダー温度320℃、金型温度90℃にて、長さ80mm×幅10mm×厚さ4mmの成形体(試験片)を得た。ISO-178に準拠し、曲げ速度を2mm/minで測定した。測定結果を表14に示した。
シャルピー衝撃試験にて破断した試験片の破断面のSEM観察を実施し、芳香族ポリカーボネート樹脂とガラス繊維との密着性を評価した。図1~図7に各実施例、各比較例にて得られた成形体のシャルピー衝撃試験後の破断面をまとめた。
比較例1はガラス繊維(ガラス充填剤)27%の芳香族ポリカーボネート樹脂組成物である。比較例2は、樹脂組成物中のガラス繊維の含有量を27%に固定して、ゴム含有グラフト重合体(Csa-2)を配合した例である。芳香族ポリカーボネート樹脂及びゴム含有グラフト重合体の合計(樹脂組成物の「主要3成分」)100部に対して、ゴム含有グラフト重合体(C)由来のカルシウム又はマグネシウムと強酸との塩がカルシウム及びマグネシウム換算で0.0185部であり、0.0008部を超える。そのためガラス繊維と芳香族ポリカーボネート樹脂との密着性を低下させた(図5)。密着性が低下するので、ノッチ無しシャルピー衝撃強度は改善されず、逆に低下した。さらにガラス繊維配合による曲げ特性改善効果も著しく低減した。
1.樹脂組成物の製造
製造例2で得られたゴム含有グラフト共重合体(Csa-1)、ガラス繊維配合芳香族ポリカーボネート(「ユーピロンGS2030M9001」(商品名)、三菱エンジニアリングプラスチックス(株)製、公称ガラス繊維30質量%配合、芳香族ポリカーボネート樹脂のMv:20000)、及び、芳香族ポリカーボネート(商品名「ユーピロンS3000」、三菱エンジニアリングプラスチックス(株)製、Mv:20000)を表15に示す組成で配合し、混合した。この混合物をバレル温度280℃に加熱した脱揮式二軸押出機(池貝鉄工社製、PCM-30)に供給して混練し、ガラス繊維が27質量%配合された、実施例6の樹脂組成物のペレットを作製した。
「測定1」の方法及び「測定2」の方法で測定された金属量及び脂肪酸の結果から、各実施例及び各比較例の樹脂組成物の「主要3成分」100質量部に対する脂肪酸の量、芳香族ポリカーボネート樹脂、ガラス充填剤及びゴム含有グラフト重合体の合計100質量部に対しアルミニウム、カルシウム及びマグネシウムと強酸との塩のカルシウム及びマグネシウム換算量を算出し、表15に記載した。ゴム含有グラフト重合体(Csa-1)、(Csa-3)及び(Csa-8)中に脂肪酸やその塩は含まれないので、これらの重合体中に検出されたカルシウム及びマグネシウムは強酸との塩である。
シリンダー温度を280℃に変更した以外は実施例1と同様にシャルピー衝撃試験を行った。測定結果を表15に示した。
シリンダー温度を280℃に変更した以外は実施例1と同様に曲げ試験を行った。測定結果を表15に示した。
以上の評価結果を纏めると以下の通りである。
実施例6~14及び比較例6~8は、押出、成形温度を280℃として得られた樹脂組成物の評価結果である。比較例8はガラス繊維27質量%の芳香族ポリカーボネート樹脂組成物である。比較例6及び7は、樹脂組成物の「主要3成分」100質量部に対して、ゴム含有グラフト重合体(C)由来のカルシウム及びマグネシウムと強酸との塩の合計含有量が0.0008質量部を超え、成形体の衝撃強度は十分でなく、特に曲げ強度の低下が大きい。
実施例6、実施例9、実施例12及び比較例8の各樹脂組成物について、前記測定4、測定5及び測定6に従って、各成分の量を測定し、評価結果を表16にまとめた。
Claims (19)
- エンジニアリングプラスチック(A)、ガラス充填剤(B)及びゴム含有グラフト重合体(C)を含む樹脂組成物であって、
該樹脂組成物のクロロホルム可溶分中のアクリロニトリル由来成分の割合が2.0質量%以下であり、
該樹脂組成物100質量部中における脂肪酸の含有量が0.03質量部以下であり、
下記の測定方法Xにて測定される乾燥試料100質量部中のカルシウム及びマグネシウムの合計含有量が0.0008質量部以下であり、アルミニウムの含有量が0.0008質量部以下である樹脂組成物。
[測定方法X]
[1]乾燥試料の調製
樹脂組成物5質量%及びクロロホルム95質量%からなる溶液を調製して、以下(1)~(4)の操作を行ない、「乾燥試料」を得る。
(1)前記溶液を遠心分離機に供して5000rpmで30分間、遠心分離する。
(2)上澄み液を抽出し、フラスコ内に入れる。
(3)該フラスコを温度68℃の恒温槽中にセットして、エバポレータで該液から揮発分を留去する。
(4)該フラスコ内の残存物を温度120℃で3時間乾燥して「乾燥試料」を得る。
[2]前記乾燥試料中のアルミニウム、マグネシウム及びカルシウムを定量する。 - 前記カルシウム及びマグネシウムの合計含有量が0.0006質量部以下である請求項1に記載の樹脂組成物。
- エンジニアリングプラスチック(A)、ガラス充填剤(B)及びゴム含有グラフト重合体(C)を含む樹脂組成物であって、
ゴム含有グラフト重合体(C)のアセトン不溶分が25質量%以上であり、
ゴム含有グラフト重合体(C)中に含まれる脂肪酸の含有量が1質量%以下であり、
エンジニアリングプラスチック(A)、ガラス充填剤(B)、及びゴム含有グラフト重合体(C)の合計100質量部に対する、該樹脂組成物中のカルシウム又はマグネシウムと強酸との塩の合計含有量のカルシウム及びマグネシウム換算の合計含有量が0.0008質量部以下であり、アルミニウムと強酸との塩の含有量のアルミニウム換算の含有量が0.0008質量部以下である樹脂組成物。 - 前記カルシウム及びマグネシウム換算の合計含有量が、0.0006質量部以下である請求項3に記載の樹脂組成物。
- 更に、アルカリ金属と強酸との塩(D)を含有する請求項1~4のいずれか1項に記載の樹脂組成物。
- 前記樹脂組成物100質量部中における前記アルカリ金属と強酸との塩(D)の含有量が0.01~0.5質量部である請求項5に記載の樹脂組成物。
- 前記ゴム含有グラフト重合体(C)が、アルカリ金属と強酸との塩(D)を含むゴムラテックスの存在下でビニル単量体を乳化重合して得られるゴム含有グラフト重合体ラテックスを、凝析剤を用いて凝析回収して又は噴霧回収して得られたものである請求項1~4のいずれか1項に記載の樹脂組成物。
- 前記ゴム含有グラフト重合体(C)が、噴霧回収して得られたものである請求項1~4のいずれか1項に記載の樹脂組成物。
- 更に、前記樹脂組成物中に、ガラス充填剤(B)以外の成分に由来するカルシウム又はマグネシウムと弱酸との塩を、エンジニアリングプラスチック(A)ガラス充填剤(B)及びゴム含有グラフト重合体(C)の合計100質量部に対して、カルシウム及びマグネシウム換算の合計量で0.0010~0.0060質量部含有する請求項1~4のいずれか1項に記載の樹脂組成物。
- 前記ゴム含有グラフト重合体(C)中のゴム状重合体の質量平均粒子径が300nm以下である請求項1~4のいずれか1項に記載の樹脂組成物。
- 前記エンジニアリングプラスチック(A)が芳香族ポリカーボネート樹脂である請求項1~4のいずれか1項に記載の樹脂組成物。
- 前記アルカリ金属と強酸との塩(D)がナトリウムもしくはカリウムとスルホン酸との塩である請求項5に記載の樹脂組成物。
- 前記ゴム含有グラフト重合体(C)の含有量が、エンジニアリングプラスチック(A)、ガラス充填剤(B)及びゴム含有グラフト重合体(C)の合計100質量%中、0.25~15質量%である請求項1~4のいずれか1項に記載の樹脂組成物。
- 前記ゴム含有グラフト重合体(C)の含有量が、エンジニアリングプラスチック(A)、ガラス充填剤(B)及びゴム含有グラフト重合体(C)の合計100質量%中、0.25~7.5質量%である請求項1~4のいずれか1項に記載の樹脂組成物。
- 前記ガラス充填剤(B)の含有量が、エンジニアリングプラスチック(A)、ガラス充填剤(B)及びゴム含有グラフト重合体(C)の合計100質量%中、5~40質量%である請求項1~4のいずれか1項に記載の樹脂組成物。
- 前記ゴム含有グラフト重合体(C)が、ブタジエンゴム、スチレン・ブタジエン共重合ゴム及びシリコーン・アクリル複合ゴムから選ばれる一種以上のゴムを含む請求項1~4のいずれか1項に記載の樹脂組成物。
- 前記ガラス充填剤(B)がガラス繊維である請求項1~4のいずれか1項に記載の樹脂組成物。
- 請求項1~4のいずれか1項に記載の樹脂組成物を成形してなる成形体。
- エンジニアリングプラスチック(A)、ガラス充填剤(B)、及び、アセトン不溶分が25質量%以上であり脂肪酸の含有量が1質量%以下であるゴム含有グラフト重合体(C)を混合し、
エンジニアリングプラスチック(A)、ガラス充填剤(B)及びゴム含有グラフト重合体(C)の合計100質量部に対して、ゴム含有グラフト重合体(C)由来のカルシウム又はマグネシウムと強酸との塩の合計含有量がカルシウム及びマグネシウム換算の合計含有量で0.0008質量部以下であり、ゴム含有グラフト重合体(C)由来のアルミニウムと強酸との塩の含有量がアルミニウム換算の含有量で0.0008質量部以下である樹脂組成物を製造する方法。
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JP2014221850A (ja) * | 2013-05-13 | 2014-11-27 | 三菱エンジニアリングプラスチックス株式会社 | レーザーダイレクトストラクチャリング用樹脂組成物、樹脂成形品、およびメッキ層付樹脂成形品の製造方法 |
JP2015108119A (ja) * | 2013-10-07 | 2015-06-11 | 三菱エンジニアリングプラスチックス株式会社 | 樹脂組成物、樹脂成形品、および樹脂成形品の製造方法 |
JP2016102167A (ja) * | 2014-11-28 | 2016-06-02 | 三菱レイヨン株式会社 | 樹脂組成物及びその成形体 |
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KR20180126016A (ko) | 2018-11-26 |
JP6729377B2 (ja) | 2020-07-22 |
EP3467046A1 (en) | 2019-04-10 |
KR102167863B1 (ko) | 2020-10-21 |
US10982092B2 (en) | 2021-04-20 |
CN109071951B (zh) | 2022-02-18 |
JPWO2017203716A1 (ja) | 2019-03-28 |
US20190092941A1 (en) | 2019-03-28 |
CN109071951A (zh) | 2018-12-21 |
EP3467046A4 (en) | 2019-05-15 |
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