WO2018070424A1 - 樹脂組成物および成形体 - Google Patents
樹脂組成物および成形体 Download PDFInfo
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- WO2018070424A1 WO2018070424A1 PCT/JP2017/036814 JP2017036814W WO2018070424A1 WO 2018070424 A1 WO2018070424 A1 WO 2018070424A1 JP 2017036814 W JP2017036814 W JP 2017036814W WO 2018070424 A1 WO2018070424 A1 WO 2018070424A1
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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
- C08L67/00—Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
- C08L67/02—Polyesters derived from dicarboxylic acids and dihydroxy compounds
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K7/00—Use of ingredients characterised by shape
- C08K7/02—Fibres or whiskers
- C08K7/04—Fibres or whiskers inorganic
- C08K7/14—Glass
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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
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
- C08L23/04—Homopolymers or copolymers of ethene
- C08L23/08—Copolymers of ethene
- C08L23/0807—Copolymers of ethene with unsaturated hydrocarbons only containing more than three carbon atoms
- C08L23/0838—Copolymers of ethene with aromatic monomers
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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
- C08L25/00—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 aromatic carbocyclic ring; Compositions of derivatives of such polymers
- C08L25/02—Homopolymers or copolymers of hydrocarbons
- C08L25/04—Homopolymers or copolymers of styrene
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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
- C08L25/00—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 aromatic carbocyclic ring; Compositions of derivatives of such polymers
- C08L25/02—Homopolymers or copolymers of hydrocarbons
- C08L25/04—Homopolymers or copolymers of styrene
- C08L25/08—Copolymers of styrene
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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
- C08L31/06—Homopolymers or copolymers of esters of polycarboxylic acids
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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
- C08L51/06—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 homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond
Definitions
- the present invention relates to a resin composition having a specific composition and a molded body obtained from the resin composition.
- Polyester resins such as polybutylene terephthalate are widely used for injection molding. Moreover, it is known that mechanical strength and heat resistance will improve by containing inorganic fillers, such as glass fiber.
- the stress-concentrated portion tends to brittlely break depending on the shape of the molded product and particularly when the blending amount of the filler is relatively high.
- An ethylene / glycidyl methacrylate copolymer or the like may be blended with a polyester resin to have an impact resistance improving effect, but the impact resistance improving effect may not be sufficient.
- the blending amount must be increased in order to enhance the reforming effect, and in that case, the tensile strength, elastic modulus, and moldability may be sacrificed.
- An object of the present invention is to provide a polyester resin composition excellent in impact resistance and excellent in tensile strength, elastic modulus and moldability, and a molded product obtained therefrom.
- the present inventors have intensively studied to solve the above problems. As a result, it has been found that the above problem can be solved by using a resin composition having a specific composition, and the present invention has been completed.
- this invention relates to the following resin compositions and the molded object obtained from this.
- a polyester resin (A), a polymer (B), and an inorganic filler (C) are contained, and the total content of the (A), (B), and (C) is 100 parts by mass.
- (A) is 50 to 95 parts by mass
- (B) is 0.5 to 10 parts by mass
- (C) is 5 to 40 parts by mass.
- A-1) comprising a structural unit (a1) derived from an aromatic dicarboxylic acid and a structural unit (a2) derived from a diol having 2 to 10 carbon atoms (A-2) a differential scanning calorimeter (DSC) (B-1)
- the melt viscosity at 160 ° C. is 10 to 10,000 mP ⁇ s.
- B-2) 5 to 5 structural units derived from styrene compounds [2]
- the (B) is a styrenic compound modified product of at least one homopolymer or copolymer selected from ethylene and an ⁇ -olefin having 3 to 12 carbon atoms.
- (B-3) Containing 10 to 70% by mass of a structural unit derived from a styrenic compound.
- the (B) is at least one ⁇ selected from ethylene and an ⁇ -olefin having 3 to 12 carbon atoms.
- (B-3 ′) Containing 50 to 70% by mass of a structural unit derived from styrene
- the content of the copolymer (D) having a structural unit derived from an olefin, a structural unit derived from an ⁇ , ⁇ -unsaturated carboxylic acid ester, and a structural unit having a cyclic oxyhydrocarbon structure is The resin composition according to any one of [1] to [6], which is less than 3 parts by mass with respect to 100 parts by mass in total of the contents of (B) and (C).
- a molded article comprising the resin composition according to any one of [1] to [7].
- the present invention it is possible to provide a polyester resin composition which is excellent in impact resistance and further excellent in tensile strength, elastic modulus and moldability, and a molded body obtained therefrom.
- FIG. 1 is a graph plotting the relationship of the 23 ° C. Charpy impact strength to the flexural modulus of the resin compositions obtained in Examples and Comparative Examples.
- FIG. 2 is a graph plotting the relationship between the flexural modulus and the ⁇ 30 ° C. Charpy impact strength of the resin compositions obtained in Examples and Comparative Examples.
- the resin composition of the present invention contains a polyester resin (A), a polymer (B), and an inorganic filler (C).
- the amount of (A) is 50 to 95 parts by mass.
- the amount is preferably 50 to 94.5 parts by mass, and more preferably 55 to 80 parts by mass.
- the amount of (B) is 0.5 to 10 parts by mass, preferably 2 to 5 parts by mass.
- the amount of the inorganic filler (C) is 5 to 40 parts by mass, preferably 20 to 40 parts by mass.
- the amount of the polymer (B) is within the above range, the impact resistance of the resulting resin composition can be improved. Moreover, the moldability of the resin composition can also be improved.
- the polymer (B) increases the impact resistance of the resin composition as will be described later, but the effect of increasing the impact resistance can be obtained without increasing the amount in the composition. ), The loss of tensile strength and elastic modulus of the resin composition can be reduced.
- polyester resin (A) The resin composition of the present invention may contain only one type of polyester resin (A) or two or more types, but satisfies the following requirements (A-1) and (A-2).
- Requirement (A-1) includes a structural unit (a1) derived from an aromatic dicarboxylic acid and a structural unit (a2) derived from a diol having 2 to 10 carbon atoms.
- a polyester resin that satisfies the requirement (A-1) is preferable because it is excellent in mechanical properties, heat resistance, processability, and electrical properties.
- structural unit (a1) derived from the aromatic dicarboxylic acid is, in terms of form, two carboxyls contained in the aromatic dicarboxylic acid.
- the aromatic dicarboxylic acid one kind may be used alone, or two or more kinds may be used in combination. Specific examples include terephthalic acid, isophthalic acid, 2-methylterephthalic acid, and naphthalenedicarboxylic acid.
- terephthalic acid is preferable from the viewpoint of further improving mechanical properties and workability.
- the structural unit (a2) derived from a diol having 2 to 10 carbon atoms has a formality of 2 to 10 carbon atoms. Is a structural unit having a structure obtained by removing —H from two hydroxyl groups contained in the diol.
- the diol having 2 to 10 carbon atoms one kind may be used alone, or two or more kinds may be used in combination, and specific examples include the following compounds.
- Examples of the diol having 2 to 10 carbon atoms include aliphatic diols having 2 to 10 carbon atoms.
- Examples of such aliphatic diols include 1,2-ethanediol (ethylene glycol: 2 carbon atoms), 1,3-propanediol (trimethylene glycol: 3 carbon atoms), 1,2-propanediol ( Propylene glycol: 3 carbon atoms, 1,4-butanediol (tetramethylene glycol: 4 carbon atoms), 2,2-dimethylpropane-1,3-diol (neopentyl glycol: 5 carbon atoms), 1 , 6-hexanediol (hexamethylene glycol: 6 carbon atoms), 1,8-octanediol (octamethylene glycol: 8 carbon atoms), 1,9-nonanediol (nonamethylene glycol: 9 carbon atoms), etc. Is mentioned.
- the diol having 2 to 10 carbon atoms may be a diol having an alkyl group in the side chain (hereinafter also referred to as “side-chain alkyl group-containing glycol”).
- side chain alkyl group-containing glycol examples include 2-methyl-1,3-propanediol, 2-ethyl-1,3-propanediol, 2-hexyl-1,3-propanediol, and 2-hexyl-1,6- Propanediol, neopentyl glycol, 2-ethyl-2-methyl-1,3-propanediol, 2,2-diethyl-1,3-propanediol, 2-methyl-2-n-butyl-1,3-propane Diol, 1,3-nonanediol, 2-methyl-1,8-octanediol, and the like.
- 1,4-butanediol is preferable from the viewpoint of increasing the crystallization rate.
- the molar ratio ((a1) / (a2)) of the structural unit (a1) to the structural unit (a2) is 0.9 to It is preferable to be in the range of 1.1.
- the polyester resin (A) is preferably composed of only the structural units (a1) and (a2), but is derived from other polyvalent carboxylic acids and polyhydric alcohols unless the effects of the present invention are significantly impaired.
- a structural unit may be included.
- the other polyvalent carboxylic acids include aliphatic dicarboxylic acids such as malonic acid, oxalic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, and undecadicarboxylic acid, Various dicarboxylic acids such as furandicarboxylic acid such as 5-furandicarboxylic acid, alicyclic dicarboxylic acid such as 1,4-cyclohexanedicarboxylic acid and 1,3-cyclohexanedicarboxylic acid, and carboxylic acid esters thereof.
- polyhydric alcohols examples include trihydric or higher polyhydric alcohols such as aromatic diol, trimethylolethane and glycerin, trihydric or higher polyvalent carboxylic acids such as butanetricarboxylic acid and trimellitic acid, 4-hydroxy Examples thereof include oxydicarboxylic acids such as phthalic acid.
- the content of other structural units is preferably 20 mol% or less, more preferably 10 mol% or less, particularly preferably, with the total of the structural units (a1) and (a2) and other structural units being 100 mol%. 5 mol% or less.
- Requirement (A-2) Melting point (Tm) by differential scanning calorimeter (DSC) is in the range of 200-245 ° C.
- the melting point (Tm) of the polyester resin (A) is preferably in the range of 210 to 240 ° C., more preferably 215 to 235 ° C.
- the melting point (Tm) is 245 ° C. or lower, the processing temperature does not become high, and the molecular weight reduction due to heat during kneading and / or molding of the resin composition can be suppressed.
- the melting point (Tm) is 200 ° C. or higher, the heat distortion temperature of the polyester resin is high and the heat resistance is improved.
- the polyester resin (A) may be modified with a small amount of a trivalent or higher polyhydroxy compound such as triol or tricarboxylic acid, polycarboxylic acid, or the like in order to bring the melting point (Tm) to the above temperature range.
- a trivalent or higher polyhydroxy compound such as triol or tricarboxylic acid, polycarboxylic acid, or the like
- polyester resin (A) that satisfies the requirements (A-1) and (A-2) include polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), polybutylene naphthalate (PBN), polyethylene isophthalate, A terephthalate copolymer etc. are mentioned.
- PBT polybutylene terephthalate
- PBT polytrimethylene terephthalate
- PBN polybutylene naphthalate
- polyethylene isophthalate A terephthalate copolymer etc.
- the polyester resin (A) preferably satisfies the following requirement (A-3).
- Requirement (A-3) The number average molecular weight (Mn) in terms of polystyrene measured by gel permeation chromatography (GPC) is in the range of 10,000 to 50,000, and the weight average molecular weight (Mw) is in the range of 60000 to 300,000.
- a polyester resin satisfying the requirement (A-3) is preferable because it is excellent in mechanical properties, heat resistance and processability.
- the resin composition of the present invention may contain only one type of polymer (B) or two or more types, but satisfies the following requirements (B-1) and (B-2).
- melt viscosity at 160 ° C. is 10 to 10,000 mP ⁇ s.
- the melt viscosity at 160 ° C. of the polymer (B) is preferably 20 to 5,000 mP ⁇ s, more preferably 30 to 2,500 mPa ⁇ s, still more preferably 50 to 1,000 mP ⁇ s, and particularly preferably. Is in the range of 100 to 800 mP ⁇ s.
- the melt viscosity at 160 ° C. of the polymer (B) is within the above range, the polymer (B) is easily compatible with the polyester resin (A). Therefore, since the polymer (B) is more easily dispersed more uniformly in the resin composition, a resin composition having more sufficient impact resistance can be obtained, and the molding processability of the resin composition, specifically, The kneadability and molding processability during injection molding are also improved.
- Requirement (B-2) Containing 5 to 100% by mass of a structural unit derived from a styrene compound.
- the content is preferably 10 to 100% by mass. More preferably, the content is 30 to 90% by mass, and further preferably 40 to 80% by mass.
- the polyester resin (A) and the polymer (B) are easily compatible, and the polymer (B) is the polyester resin (A). It becomes easy to finely disperse inside. Moreover, since the polymer (B) has an aromatic ring, the volume shrinkage of the resin composition when the resin composition is injection-molded is lower. Therefore, it is presumed that the impact resistance of the resin composition is increased also by maintaining the interface strength between the polyester resin (A) and the inorganic filler (C) in the molded body.
- the polymer (B) having a relatively low viscosity with respect to the polyester resin (A) is compatible, thereby improving the fluidity of the resin composition and further improving the molding processability.
- the resin composition is injection-molded or the like, the fluidity of the resin composition is increased, so that the moldability is improved, and at the same time, the inorganic filler (C) in the shearing force in the mold. Can be suppressed. That is, when the inorganic filler (C) is a fiber, it is presumed that the tensile strength and the elastic modulus are improved by maintaining the fiber length.
- Styrene compounds include styrene, ⁇ -methylstyrene, o-methylstyrene, p-methylstyrene, m-methylstyrene, p-chlorostyrene, m-chlorostyrene and p-chloromethylstyrene, 4-vinylpyridine, -Vinylpyridine, 5-ethyl-2-vinylpyridine, 2-methyl-5-vinylpyridine, 2-isopropenylpyridine, 2-vinylquinoline, 3-vinylisoquinoline, N-vinylcarbazole, N-vinylpyrrolidone and isopropenyl And toluene.
- the polymer (B) preferably satisfies the following physical properties.
- the softening point of the polymer (B) measured according to JIS K2207 is preferably 70 to 150 ° C, more preferably 80 to 140 ° C, still more preferably 90 ° C to 130 ° C, and particularly preferably 95 ° C to 115 ° C. It is.
- the softening point of the polymer (B) is in the above range, the polymer (B) is easily compatible with the polyester resin (A) and more easily dispersed, so that it has more sufficient impact resistance. , Which is preferable in that a resin composition having excellent processability can be obtained.
- the density measured by the density gradient tube method of the polymer (B) is preferably in the range of 900 to 1200 kg / m 3 , more preferably 910 to 1180 kg / m 3 , still more preferably 920 to 1160 kg / m 3 , It is particularly preferably 930 to 1120 kg / m 3 , particularly preferably 935 to 1100 kg / m 3 .
- the polymer (B) is easily compatible with the polyester resin (A), more easily disperses more uniformly, has a sufficient impact resistance, and has excellent workability. Is preferable in that it is obtained.
- the polymer (B) is preferably at least one homopolymer or copolymer selected from ethylene and an ⁇ -olefin having 3 to 12 carbon atoms (hereinafter simply referred to as olefin wax). Or an unmodified olefin wax).
- the toughness of the resin composition is increased and the impact resistance and tensile strength are further increased by aggregation of the olefin component of the finely dispersed polymer (B).
- the polymer (B) satisfies the following (B-3).
- Requirement (B-3) Containing 10 to 70% by mass of a structural unit derived from a styrene compound. Preferably, the content is 15 to 65% by mass.
- the content of the structural unit derived from the styrene compound can be calculated as a ratio of the styrene compound to the total amount of the olefin wax and the styrene compound.
- the styrenic compound may be one kind or plural kinds. Further, it can be calculated from the quantitative ratio of the peak derived from ethylene and the peak derived from the styrene compound by analysis of 13 C-NMR spectrum.
- the polymer (B) is a styrene-modified copolymer of ethylene and at least one ⁇ -olefin selected from ⁇ -olefins having 3 to 12 carbon atoms. And satisfies the following (B-3 ′).
- Requirement (B-3 ′) Containing 50 to 70% by mass of a structural unit derived from styrene.
- the content of the structural unit derived from styrene is within the range of (B-3) or (B-3 ′)
- the polymer (B) is more easily dispersed uniformly in the polyester resin (A).
- a resin composition having sufficient impact resistance is obtained, and the processability and kneadability of the resin composition are also improved.
- the polymer (B) preferably satisfies the following requirement (B-4).
- Requirement (B-4) Crystallinity is in the range of 70% or less and 10% or more. The degree of crystallinity is preferably 65% or less and 15% or more, more preferably 60% or less and 20% or more, and particularly preferably 55% or less and 25% or more.
- the polymer (B) satisfying the requirement (B-4) has good dispersibility with respect to the polyester resin (A) when crystallized, and it is considered that the impact resistance of the resin composition can be easily improved.
- the unmodified olefin wax is at least one homopolymer or copolymer selected from ethylene and an ⁇ -olefin having 3 to 12 carbon atoms.
- ⁇ -olefin having 3 to 12 carbon atoms Are propylene having 3 carbon atoms, 1-butene having 4 carbon atoms, 1-pentene having 5 carbon atoms, 1-hexene having 6 carbon atoms, 4-methyl-1-pentene, 1 having 8 carbon atoms. -Octene and so on.
- the unmodified olefin wax is preferably at least one homopolymer or copolymer selected from ethylene, propylene, 1-butene, 1-hexene and 4-methyl-1-pentene.
- the content ratio of the structural unit can be determined by analysis of 13 C-NMR spectrum.
- polyethylene wax When the unmodified olefin wax is a polyethylene wax, for example, a polyethylene wax described in JP 2009-144146 A is preferable. A particularly preferred polyethylene wax is briefly described below.
- the polyethylene wax is preferably an ethylene homopolymer or a copolymer composed mainly of ethylene of ethylene and an ⁇ -olefin having 3 to 12 carbon atoms.
- Examples of the ethylene homopolymer include high density polyethylene wax, medium density polyethylene wax, low density polyethylene wax, and linear low density polyethylene wax.
- the structural unit amount derived from ethylene is preferably 91.0 to 99.9 mol%. More preferably, it is 93.0-99.9 mol%, still more preferably 95.0-99.9 mol%, particularly preferably 95.0-99.0 mol%, having 3 or more carbon atoms.
- the amount of the structural unit derived from ⁇ -olefin is preferably from 0.1 to 9.0 mol%, preferably from 0.1 to 7.0 mol%, more preferably from 0.1 to 5.0 mol%.
- the mol% is particularly preferably 1.0 to 5.0 mol%.
- the total of the structural units derived from ethylene and the structural units derived from ⁇ -olefin having 3 to 12 carbon atoms is preferably 100 mol%. Although it does not deny the inclusion of structural units other than ethylene or ⁇ -olefins having 3 to 12 carbon atoms, the amount of structural units other than these is preferably 5 mol% or less.
- the content ratio of the structural unit can be determined by analysis of 13 C-NMR spectrum.
- examples of the ⁇ -olefin having 3 to 12 carbon atoms include those described above.
- copolymers of propylene, 1-butene and ethylene tend to have good surface properties of molded products because the modified olefin wax tends to be hard and less sticky.
- a copolymer of propylene, 1-butene and ethylene is preferable from the viewpoint of high mechanical strength and heat resistance of the resin composition.
- the reason why the modified olefin wax is hard and solid is not clear, but propylene and 1-butene efficiently lower the melting point with a small amount of copolymerization compared to other ⁇ -olefins.
- the degree of crystallinity tends to be high.
- ⁇ -olefins may be used alone or in combination of two or more.
- the unmodified olefin wax is obtained by thermally decomposing 4-methyl-1-pentene / ⁇ -olefin copolymer disclosed in International Publication No. 2011/055803 or disclosed in JP-A-2015-028187. Such a 4-methyl-1-pentene polymer may be used.
- the modified styrenic compound may be, for example, a styrene-modified polyolefin wax obtained by graft-modifying an unmodified polyolefin wax with styrene.
- a styrene-modified polyolefin wax obtained by graft-modifying an unmodified polyolefin wax with styrene.
- These can be prepared by a conventionally known method. For example, (1) an unmodified polyolefin wax as a raw material and (2) a styrene compound or a sulfonate salt of a styrene compound are melt-kneaded in the presence of a polymerization initiator such as (3) an organic peroxide. Can be obtained.
- melt-kneading for example, an autoclave, a Henschel mixer, a V-type blender, a tumbler blender, a ribbon blender, a single screw extruder, a multi-screw extruder, a kneader, a Banbury mixer, etc. are used.
- an apparatus excellent in batch type melt kneading performance such as an autoclave is used, a polyolefin wax in which each component is more uniformly dispersed and reacted can be obtained.
- the batch method is easy to adjust the residence time, and since the residence time can be made longer, it is relatively easy to increase the modification rate and modification efficiency, and is preferable in the present invention.
- styrene compound examples include styrene, ⁇ -methylstyrene, o-methylstyrene, p-methylstyrene, m-methylstyrene, p-chlorostyrene, m-chlorostyrene and p-chloromethylstyrene, 4-vinylpyridine, 2-vinylpyridine, 5-ethyl-2-vinylpyridine, 2-methyl-5-vinylpyridine, 2-isopropenylpyridine, 2-vinylquinoline, 3-vinylisoquinoline, N-vinylcarbazole, N-vinylpyrrolidone, iso And propenyltoluene.
- the above-described polymer (B) may be a commercially available product.
- the polymer (B) may be a solid such as a powder, a tablet, or a block, and may be dispersed in a solvent or dissolved.
- inorganic filler (C) As the inorganic filler (C), known inorganic fillers can be used without any particular limitation. For example, talc, mica, calcium carbonate, hydrotalcite, wollastonite, zonotlite, barium sulfate, sulfuric acid Calcium, calcium silicate, clay, glass fiber, glass beads, glass flake, carbon fiber, carbon black, graphite, gypsum, magnesium carbonate, magnesium oxide, titanium oxide, potassium titanate and other titanates, iron oxide, alumina, and more Includes metal powders such as zinc, copper, iron, aluminum, magnesium, silicon, titanium, and metal fibers.
- metal powders such as zinc, copper, iron, aluminum, magnesium, silicon, titanium, and metal fibers.
- pumice powder pumice balun, aluminum hydroxide, magnesium hydroxide, basic magnesium carbonate, dolomite, calcium titanate, calcium sulfite, asbestos, montmorillonite, bentonite, molybdenum sulfide and the like can be mentioned. These may be used alone or in combination. Of these, talc, mica, calcium carbonate, glass fiber and the like are preferable, and glass fiber is particularly preferable.
- the inorganic filler (C) may have any shape such as a granular shape, a plate shape, a rod shape, a fiber shape, and a whisker shape.
- the inorganic filler (C) may be a commercially available filler for polymer.
- it may be commercially available in any form such as powder form, roving form, chopped strand form, compressed soul form, pellet (granulated) form, granule form and the like.
- the inorganic filler (C) is talc, it is preferably processed into a powder form, a compressed soul form, or a granular form.
- the resin composition of the present invention may contain only one kind of inorganic filler (C), or may contain two or more kinds.
- the average particle size of the inorganic filler (C) when it is granular is preferably 1 to 15 ⁇ m, more preferably 3 to 14 ⁇ m.
- the average particle diameter is a value measured by a laser diffraction method.
- the inorganic filler (C) is manufactured by various known manufacturing methods.
- talc is manufactured by pulverizing the raw stone with an impact pulverizer or micron mill type pulverizer, or further pulverizing with a jet mill or the like and then adjusting the classification with a cyclone or micron separator. be able to.
- the inorganic filler (C) may be untreated, or may be at least partially surface-treated.
- the surface treatment agent include an organic titanate coupling agent, an organic silane coupling agent, a modified polyolefin grafted with an unsaturated carboxylic acid or an anhydride thereof, a fatty acid, a fatty acid metal salt, a fatty acid ester, and the like.
- these surface treating agents may be used individually by 1 type, and may be used in combination of 2 or more type.
- Copolymer (D) The copolymer (D), which is preferably contained in the resin composition of the present invention, is preferably little or not contained.
- the copolymer (D) is a copolymer having a structural unit derived from an olefin, a structural unit derived from an ⁇ , ⁇ -unsaturated carboxylic acid ester, and a structural unit having a cyclic oxyhydrocarbon structure.
- the copolymer (D) can generally be used as an impact modifier.
- the content of the copolymer (D) is usually less than 3 parts by weight, preferably less than 2 parts by weight, more preferably with respect to 100 parts by weight in total of the contents of (A), (B) and (C).
- the amount is less than 1.3 parts by mass, more preferably less than 1 part by mass, further preferably less than 0.5 parts by mass, and particularly preferably less than 0.2 parts by mass.
- the content of the copolymer (D) is in the above range because the elastic modulus or tensile strength of the resin composition is increased.
- Examples of the olefin having a structural unit derived from the olefin constituting the copolymer (D) include ethylene, propylene, 1-butene, 1-hexene, 1-octene, 1-decene and the like, and ethylene is generally used.
- Examples of ⁇ , ⁇ -unsaturated carboxylic acid esters derived from ⁇ , ⁇ -unsaturated carboxylic acid esters include acrylic acid esters such as methyl acrylate, ethyl acrylate, butyl acrylate, methyl methacrylate, Examples include methacrylic acid esters such as ethyl methacrylate, and methyl acrylate is common.
- Examples of the structural unit having a cyclic oxyhydrocarbon structure include structural units derived from ⁇ , ⁇ -unsaturated carboxylic acid glycidyl ester.
- Examples of the ⁇ , ⁇ -unsaturated carboxylic acid glycidyl ester include acrylic acid glycidyl ester and methacrylic acid glycidyl ester, and methacrylic acid glycidyl ester is common.
- Examples of the copolymer (D) include an ethylene / methyl acrylate (methyl acrylate) / glycidyl methacrylate copolymer as represented by the following structural formula.
- the copolymer (D) represented by the above formula usually contains ethylene units at a ratio of 30 to 99% by mass with respect to the total amount (100% by mass) of ethylene units, methyl acrylate units and glycidyl methacrylate units.
- the copolymer (D) represented by the above formula is usually in a proportion of 0 to 60% by mass of methyl acrylate units with respect to the total amount (100% by mass) of ethylene units, methyl acrylate units and glycidyl methacrylate units. Including.
- the copolymer (D) represented by the above formula usually contains glycidyl methacrylate units in a proportion of 1 to 30% by mass with respect to the total amount (100% by mass) of ethylene units, methyl acrylate units and glycidyl methacrylate units. .
- the copolymer (D) may contain other copolymer components in addition to the above-described copolymer components.
- specific examples of other copolymer components include ⁇ , ⁇ -unsaturated glycidyl ethers such as allyl glycidyl ether and 2-methylallyl glycidyl ether, styrene, ⁇ -methyl styrene, 4-methyl styrene, 4-methoxy styrene, Aromatic vinyl compounds such as chlorostyrene and 2,4-dimethylstyrene, and unsaturated vinyl esters such as vinyl acetate and vinyl propionate can be included.
- the resin composition of the present invention may further contain a resin other than the polyester resin (A), the polymer (B), and the polymer (D) as long as the effects of the present invention are not significantly impaired.
- the content of the other resin is not particularly limited, but is preferably about 0.1 to 30 parts by mass with respect to 100 parts by mass of the polyester resin (A).
- the resin composition of the present invention may contain fillers other than inorganic fillers, that is, fillers made of organic substances (hereinafter also referred to as “organic fillers”).
- organic fillers include lignin, starch, wood flour, wood fibers, bamboo, cotton, cellulose, natural fibers such as nanocellulosic fibers, and products containing them.
- the resin composition may contain only one kind of these organic fillers, or may contain two or more kinds.
- the content of these organic fillers is not particularly limited, but is preferably 70% by mass or less, more preferably 30% by mass with respect to 100% by mass of the total mass of the polyester resin (A) and the polymer (B). It is at most 20% by mass, more preferably at most 20% by mass.
- the resin composition of the present invention may contain additives other than fillers.
- additives include those known in the polyolefin field. Examples of additives include nucleating agents, anti-blocking agents, pigments, dyes, lubricants, foaming agents, plasticizers, mold release agents, antioxidants, flame retardants, UV absorbers, antibacterial agents, surfactants, antistatic agents Agent, weather stabilizer, heat stabilizer, anti-slip agent, foaming agent, crystallization aid, anti-fogging agent, anti-aging agent, hydrochloric acid absorbent, impact modifier, crosslinking agent, co-crosslinking agent, crosslinking aid, adhesive Agents, softeners, processing aids and the like.
- the resin composition may contain only one kind of additive, or may contain two or more kinds.
- the content of these additives is not particularly limited as long as it does not impair the object of the present invention, but 0.05% with respect to 100% by mass of the total mass of the polyester resin (A) and the polymer (B). It is preferably about 70% by mass. The upper limit is more preferably 30% by mass.
- the resin composition of the present invention can be produced by dry blending or melt blending using any of various methods.
- a polyester resin (A), a polymer (B), an inorganic filler (C), and other optional components can be used simultaneously or in any order in a tumbler, V-type blender, Nauta mixer. , A Banbury mixer, a kneading roll, a single-screw or twin-screw extruder, and the like.
- the polyester resin (A), the polymer (B), the inorganic filler (C) and other optional components are once dispersed or dissolved in an arbitrary solvent, natural drying, forced heating drying or the like is appropriately performed. You may blend by making it dry.
- melt blending it is preferable from the viewpoint of the appearance and impact resistance of a molded product from which a melt blend is obtained from a dry blend.
- the appearance and impact resistance of the resulting molded product tend to be increased.
- two or more kinds of compounds are used in combination as the polymer (B)
- a method of melt blending the above method, a method using a batch kettle, or the like is appropriately used.
- the flexural modulus of the resin composition of the present invention measured according to JIS K7171, is preferably 8000 MPa or more. More preferably, it is in the range of 8000 to 10,000 MPa.
- the Charpy impact strength measured in accordance with JIS K7111 of the resin composition of the present invention is preferably 13.0 kJ / m 2 or more at 23 ° C., more preferably 14.0 kJ / m 2 or more, Preferably it is 15.0 kJ / m 2 or more.
- the upper limit is usually 20.0 kJ / m 2 or less. Furthermore, it is preferably 11.0 kJ / m 2 or more at ⁇ 30 ° C., more preferably 12.0 kJ / m 2 or more, and further preferably 13.0 kJ / m 2 or more.
- the upper limit is usually 18.0 kJ / m 2 or less.
- the molded body of the present invention can be produced by molding the resin composition into a desired shape by a conventionally known method such as injection molding, coating, extrusion molding, compression molding or the like.
- the shape of the molded body is not particularly limited, and is, for example, a film shape, a plate shape, a prismatic shape, a cylindrical shape, or the like.
- the molded product of the present invention can be used for the same applications as conventionally known polyester resins. Specifically, it can be used for automobile parts, home appliance parts, and the like.
- Polyester resin (A) As the polyester resin (A), DURANEX 2002 manufactured by Wintech Polymer Co., Ltd., which is a polybutylene terephthalate resin, was used. As a result of measurement by the following method, this polyester resin (A) had a melting point (Tm) of 225 ° C., a number average molecular weight (Mn) of 28300, and a weight average molecular weight (Mw) of 83300.
- Tm melting point
- Mn number average molecular weight
- Mw weight average molecular weight
- ⁇ Melting point> It was measured by DSC-20 (manufactured by Seiko Denshi Kogyo Co., Ltd.) by differential scanning calorimetry (DSC). About 10 mg of the sample was sealed in an aluminum pan, heated from 0 ° C. to 280 ° C. at 10 ° C./min, and the endothermic peak of the obtained curve was determined as the melting point. Prior to this temperature rise measurement, the sample was once heated to about 280 ° C., held for 5 minutes, and then lowered to 0 ° C. at 10 ° C./min to unify the thermal history of the sample. When there were a plurality of endothermic peaks in the obtained curve, the peak temperature at which the endothermic amount at the endothermic peak was the largest was taken as the melting point (Tm).
- Polymer (B) As the polymer (B), B1 to B3 produced by the method described later were used. Further, in Comparative Examples, B′1 and B′2 produced by the method described later as a polymer not corresponding to the polymer (B), or an impact modifier (D), Arotema Rotada AX8900 (D1) As other impact modifiers, Tafmer MH5020 (D2) manufactured by Mitsui Chemicals, Inc. or EM505 (MBS) (D3) manufactured by LG Chem was used.
- compositions and physical properties were analyzed by the following methods.
- ⁇ Crystallinity> The measurement sample was hot-pressed at 180 ° C. for 5 minutes and then cold-pressed with water for cooling for 5 minutes to produce a 1 mm thick press sheet. With respect to the obtained press sheet, an X-ray profile was measured by a transmission method under the condition of 50 kV-300 mA using an X-ray diffraction apparatus (RINT 2500 manufactured by Rigaku) having a rotating sample stage. From the obtained X-ray profile, the crystal part and the amorphous part were separated, and the crystallinity was determined.
- C2 represents a structural unit derived from ethylene
- C3 represents a structural unit derived from propylene
- C3: 4 mol% represents that 4 mol% of a structural unit derived from propylene is included.
- Inorganic filler (C) Glass fiber (CSF3PE-941S manufactured by Nittobo Co., Ltd.) was used as the inorganic filler (C).
- Example 1 Comparative Examples 1 to 7
- Dry blending was carried out at the ratio shown in Table 2, and the hopper was charged.
- the screw rotation speed was 120 rpm
- the feed amount was 10 kg / h
- the outlet temperature was 260 ° C.
- water-cooled to form a strand The glass fiber used as the inorganic filler (C) was supplied from a side feeder. These melt-kneaded materials were cut to produce pellets.
- the obtained resin composition was evaluated according to the following criteria. The results are shown in Table 2.
- the obtained pellet-shaped resin composition was dried at 120 ° C. for 5 hours, and then used with an injection molding machine (PNX60, manufactured by Nissei Plastic Industry Co., Ltd.) with a cylinder temperature of 250 ° C., a screw rotation speed of 80 rpm, an injection pressure of 140 MPa, and gold. Injection was performed at a mold temperature of 90 ° C. to prepare a cup-shaped ( ⁇ 50 mm ⁇ h 50 mm ⁇ t 1.6 mm) test piece. The stress applied when the ejector was activated and the cup-shaped molded product was released from the mold was measured with a pressure sensor.
- PNX60 manufactured by Nissei Plastic Industry Co., Ltd.
- the mold releasability was evaluated according to the following criteria from the stress for releasing the mold.
- a The stress for releasing was less than 10 MPa
- B The stress for releasing was 10 MPa or more and less than 20 MPa
- C The stress for releasing was 20 MPa or more
- D The molded product was not released from the mold
- pellet-shaped resin composition was dried at 120 ° C. for 5 hours, and then an injection molding machine (Niigata NN100, manufactured by Niigata Machine Techno Co., Ltd.) was used.
- the cylinder temperature was 250 ° C.
- the screw rotation speed was 75 rpm
- the injection pressure was 140 MPa
- a test piece was produced by injection molding under the condition of a mold temperature of 75 ° C.
- test pieces were evaluated by Charpy impact test (23 ° C. and ⁇ 30 ° C.), tensile test (tensile strength, elongation), and bending test (bending strength, flexural modulus) as follows. The evaluation results are shown in Table 2.
- ⁇ Charpy impact test> According to JIS K7111, a Charpy impact test at 23 ° C. and ⁇ 30 ° C. was performed. The notch was machined, and the test piece was 10 mm (width) ⁇ 4 mm (thickness) ⁇ 80 mm (length).
- ⁇ Tensile test (tensile strength, elongation)> Based on JIS K-7162, tensile strength and tensile elongation were measured under conditions of a load range of 2 kN and a test speed of 50 mm / min.
- ⁇ Bending test (bending strength, flexural modulus)> Based on JIS K-7171, bending strength and bending elastic modulus were measured under the conditions of a load range of 200 N, a test speed of 2 mm / min, and a bending span of 64 mm.
- Figures 1 (23 ° C Charpy impact strength) and 2 (-30 ° C Charpy impact strength) plot the Charpy impact strength against the flexural modulus of the resin compositions obtained in Examples and Comparative Examples.
- the resin composition containing the polyester resin (A), the polymer (B), and the inorganic filler (C) in a predetermined ratio has impact resistance and tensile strength. Both the elastic modulus was high. Further, the resin composition containing the polyester resin (A), the polymer (B) and the inorganic filler (C) in a predetermined ratio has a low torque, that is, excellent mechanical properties and molding processability.
- a resin composition that does not contain the polymer (B) and instead contains a polymer that does not correspond to the polymer (B) or an impact resistance modifier (D) has a sufficient impact resistance. Although it did not increase or the impact resistance increased, the tensile strength or elastic modulus decreased.
- the resin composition of the present invention can improve all of impact resistance, tensile strength, elastic modulus and moldability. Therefore, the resin composition of the present invention can be applied to various resin molded products.
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Abstract
Description
[1]ポリエステル樹脂(A)と、重合体(B)と、無機充填材(C)と、を含有し、前記(A)、(B)および(C)の含有量の合計を100質量部としたときに、(A)を50~95質量部、(B)を0.5~10質量部、(C)を5~40質量部含み、前記(A)が、下記(A-1)および(A-2)を満たし、前記(B)が、下記(B-1)および(B-2)を満たす、樹脂組成物。
(A-1)芳香族ジカルボン酸に由来する構成単位(a1)と、炭素原子数2~10のジオールに由来する構成単位(a2)とを含む
(A-2)示差走査熱量計(DSC)による融点(Tm)が200~245℃の範囲にある
(B-1)160℃における溶融粘度が10~10,000mP・sである
(B-2)スチレン系化合物に由来する構成単位を5~100質量%含む
[2]前記(B)が、エチレンおよび炭素原子数3~12のα-オレフィンから選ばれる少なくとも1種の単独重合体または共重合体のスチレン系化合物変性物であり、下記(B-3)を満たす、[1]に記載の樹脂組成物。
(B-3)スチレン系化合物に由来する構成単位を10~70質量%含む
[3]前記(B)が、エチレンと、炭素原子数3~12のα-オレフィンから選ばれる少なくとも1種のα-オレフィンと、の共重合体の、スチレン変性物であり、下記(B-3’)を満たす、[1]に記載の樹脂組成物。
(B-3’)スチレンに由来する構成単位を50~70質量%含む
[4]前記(C)として、ガラス繊維を含有する、[1]~[3]のいずれかに記載の樹脂組成物。
[5]前記(A)として、ポリブチレンテレフタレートを含有する、[1]~[4]のいずれかに記載の樹脂組成物。
[6]前記(A)、(B)および(C)の含有量の合計を100質量部としたときに、(A)を55~80質量部、(B)を2~5質量部、(C)を20~40質量部含む、[1]~[5]のいずれかに記載の樹脂組成物。
[7]オレフィン由来の構造単位、α,β-不飽和カルボン酸エステル由来の構造単位および環状オキシ炭化水素構造を有する構造単位とを有する共重合体(D)の含有量が、前記(A)、(B)および(C)の含有量の合計100質量部に対して3質量部未満である、[1]~[6]のいずれかに記載の樹脂組成物。
[8][1]~[7]のいずれか一項に記載の樹脂組成物を含む成形体。
本発明の樹脂組成物は、ポリエステル樹脂(A)と、重合体(B)と、無機充填材(C)とを含有する。
本発明の樹脂組成物は、ポリエステル樹脂(A)を1種のみ含んでいてもよく、2種以上を含んでいてもよいが、下記要件(A-1)および(A-2)を満たす。
本発明の樹脂組成物は、重合体(B)を1種のみ含んでいてもよく、2種以上を含んでいてもよいが、下記要件(B-1)および(B-2)を満たす。
重合体(B)は、好ましくは、エチレンおよび炭素原子数3~12のα-オレフィンから選ばれる少なくとも1種の単独重合体または共重合体(以下、単にオレフィンワックスまたは未変性オレフィンワックスともいう)の、スチレン変性物である。
スチレン由来の構成単位の含有率が上記(B-3)または(B-3’)の範囲内にあると、重合体(B)がポリエステル樹脂(A)により均一に分散しやすくなるため、より十分な耐衝撃性を有する樹脂組成物が得られ、また、樹脂組成物の加工性、混練性も良好になる。
上記未変性オレフィンワックスは、エチレンおよび炭素原子数3~12のα-オレフィンから選ばれる少なくとも1種の単独重合体もしくは共重合体であるが、ここで炭素原子数3~12のα-オレフィンとしては、炭素原子数3のプロピレン、炭素原子数4の1-ブテン、炭素原子数5の1-ペンテン、炭素原子数6の1-ヘキセン、4-メチル-1-ペンテン、炭素原子数8の1-オクテンなどが挙げられる。上記未変性オレフィンワックスは、好ましくはエチレン、プロピレン、1-ブテン、1-ヘキセン、4-メチル-1-ペンテンから選ばれる少なくとも1種の単独重合体もしくは共重合体である。上記構成単位の含有割合は、13C-NMRスペクトルの解析により求めることができる。
未変性オレフィンワックスがポリエチレンワックスである場合、例えば特開2009-144146号公報などに記載されているポリエチレンワックスが好ましい。特に好ましいポリエチレンワックスについて、以下簡単に記載する。
一方、未変性オレフィンワックスがエチレンと炭素原子数3~12のα-オレフィンとの共重合体である場合、エチレン由来の構成単位量が91.0~99.9モル%であることが好ましく、より好ましくは93.0~99.9モル%であり、更に好ましくは95.0~99.9モル%であり、特に好ましくは95.0~99.0モル%であり、炭素原子数3以上のα-オレフィン由来の構成単位の量は0.1~9.0モル%であることが好ましく、好ましくは0.1~7.0モル%であり、更に好ましくは0.1~5.0モル%であり、特に好ましくは1.0~5.0モル%である。また、エチレン由来の構成単位と炭素原子数3~12のα-オレフィン由来の構成単位の合計の合計は100モル%であることが好ましい。エチレンまたは炭素原子数3~12のα-オレフィン以外の構成単位を含むことを否定するものではないが、これら以外の構成単位の量は、5モル%以下であることが好ましい。上記構成単位の含有割合は、13C-NMRスペクトルの解析により求めることができる。
スチレン系化合物変性物は、例えば未変性ポリオレフィンワックスをスチレンでグラフト変性したスチレン変性ポリオレフィンワックスでありうる。これらは、従来公知の方法で調製することができる。例えば(1)原料となる未変性ポリオレフィンワックスと、(2)スチレン系化合物、またはスチレン系化合物のスルフォン酸塩とを、(3)有機過酸化物などの重合開始剤の存在下に溶融混練することにより得られる。
なお、上述の重合体(B)は市販品であってもよい。
無機充填材(C)としては、特に限定されることなく公知の無機充填材を用いることができるが、例えば、タルク、マイカ、炭酸カルシウム、ハイドロタルサイト、ワラストナイト、ゾノトライト、硫酸バリウム、硫酸カルシウム、珪酸カルシウム、クレー、ガラス繊維、ガラスビーズ、ガラスフレーク、炭素繊維、カーボンブラック、グラファイト、石膏、炭酸マグネシウム、酸化マグネシウム、酸化チタン、チタン酸カリウム等のチタン酸塩、酸化鉄、アルミナ、さらには亜鉛、銅、鉄、アルミニウム、マグネシウム、ケイ素、チタン等の金属粉末、および金属繊維等が挙げられる。さらに、軽石粉、軽石バルン、水酸化アルミニウム、水酸化マグネシウム、塩基性炭酸マグネシウム、ドロマイト、チタン酸カルシウム、亜硫酸カルシウム、アスベスト、モンモリロナイト、ベントナイト、硫化モリブデン等が挙げられる。これらは単独でまたは混合して用いることができる。中でもタルク、マイカ、炭酸カルシウム、ガラス繊維等が好ましく、特にガラス繊維が好ましい。
本発明の樹脂組成物において、含有量が少ない、あるいは含まれないことが好ましい、共重合体(D)について説明する。 共重合体(D)は、オレフィン由来の構造単位と、α,β-不飽和カルボン酸エステル由来の構造単位と、環状オキシ炭化水素構造を有する構造単位とを有する共重合体である。共重合体(D)は一般的に耐衝撃改質剤として用いられうるものである。
本発明の樹脂組成物は、ポリエステル樹脂(A)、重合体(B)、重合体(D)以外の樹脂を、本発明の効果を顕著に損ねない範囲でさらに含んでいても良い。上記他の樹脂の含有量には特に制限されないが、ポリエステル樹脂(A)100質量部に対して、0.1~30質量部程度であることが好ましい。
本発明の樹脂組成物は、無機充填材以外の充填材、すなわち有機物からなる充填材(以下、「有機充填材」とも称する)を含んでいてもよい。有機充填材の例には、リグニン、スターチ、木粉、木質繊維、竹、綿花、セルロース、ナノセルロース系繊維などの天然繊維、及びその含有製品等が含まれる。
本発明の樹脂組成物は、充填材以外の添加剤を含んでいてもよい。その他の添加剤としては、ポリオレフィンの分野において公知の添加剤が挙げられる。添加剤の例には、核剤、アンチブロッキング剤、顔料、染料、滑剤、発泡剤、可塑剤、離型剤、酸化防止剤、難燃剤、紫外線吸収剤、抗菌剤、界面活性剤、帯電防止剤、耐候安定剤、耐熱安定剤、スリップ防止剤、発泡剤、結晶化助剤、防曇剤、老化防止剤、塩酸吸収剤、衝撃改良剤、架橋剤、共架橋剤、架橋助剤、粘着剤、軟化剤、加工助剤等が含まれる。
本発明の樹脂組成物は、任意の種々の方法を利用して、ドライブレンド、または溶融ブレンドして製造することができる。具体的な方法としては、例えば、ポリエステル樹脂(A)、重合体(B)、無機充填材(C)および他の任意成分を、同時にまたは任意の順序で、タンブラー、V型ブレンダー、ナウターミキサー、バンバリーミキサー、混練ロール、単軸或いは二軸の押出機などでブレンドする方法とすることができる。あるいは、ポリエステル樹脂(A)、重合体(B)、無機充填材(C)および他の任意成分を、一度、任意の溶媒に分散、または溶解させた後に、自然乾燥や加熱強制乾燥等、適宜乾燥させることにより、ブレンドしてもよい。
本発明の樹脂組成物のJIS K7171に準拠して測定した曲げ弾性率は8000MPa以上であることが好ましい。より好ましくは8000~10000MPaの範囲にある。
本発明の成形体は、上記樹脂組成物を従来公知の方法、例えば射出成形、コーティング、押出成形、圧縮成形等により、所望の形状に成形することにより製造することができる。成形体の形状は、特に限定されず、例えばフィルム状、板状、角柱状、円柱状等である。本発明の成形体は、従来公知のポリエステル樹脂と同様の用途に用いることができる。具体的には、自動車部品や家電部品等に使用することができる。
ポリエステル樹脂(A)として、ポリブチレンテレフタラート樹脂である、ウィンテックポリマー社製ジュラネックス2002を用いた。下記方法で測定した結果、このポリエステル樹脂(A)の融点(Tm)は225℃、数平均分子量(Mn)は28300、重量平均分子量(Mw)は83300だった。
示差走査型熱量測定法(DSC)により、DSC-20(セイコー電子工業社製)を用いて測定した。試料約10mgをアルミパンに封じ、0℃から280℃まで10℃/分で昇温し、得られたカーブの吸熱ピークを融点として求めた。この昇温測定の前に、一旦、試料を280℃程度まで昇温し、5分間保持した後、10℃/分で0℃まで降温する操作を行い、試料の熱履歴を統一した。得られたカーブの吸熱ピークが複数存在する場合は、吸熱ピークにおける吸熱量が最も大きいピーク温度を融点(Tm)とした。
数平均分子量(Mn)、重量平均分子量(Mw)は、GPC測定から求めた。測定は以下の条件で行った。また、数平均分子量Mn、および重量平均分子量Mwは、市販の単分散標準ポリスチレンを用いて検量線を作成して求めた。
装置:515 ポンプ,717plus 自動注入装置(Waters社製)
溶剤:クロロホルム
カラム:PLgel 5μ MIXED‐D 7.5×300mm×2(ポリマーラボラトリーズ社製)
流速:1.0 ml/分
試料:1.2mg/mL クロロホルム
温度:40℃
重合体(B)として、後述する方法で製造したB1~B3を使用した。また、比較例において、重合体(B)に該当しない重合体として後述する方法で製造したB’1およびB’2、または耐衝撃改質剤(D)として、アルケマ社製ロタダーAX8900(D1)、その他の衝撃改質剤として三井化学社製タフマーMH5020(D2)またはLG Chem社製EM505(MBS)(D3)を用いた。
変性前の重合体について、エチレン由来の構成単位、及び炭素原子数3~4のα-オレフィン由来の構成単位の含有割合を、13C-NMRスペクトルの解析により求めた。なお、表1においてC2はエチレン、C3はプロピレンを意味する。
ブルックフィールド社製デジタル粘度計を使用し、サンプル量約8g、測定温度160℃で測定した。
JIS K2207に準拠し環球法により測定した。
JIS K7112に準拠し測定した。
測定サンプルをホットプレス180℃×5minの後、コールドプレス水冷×5minすることにより、1mm厚のプレスシートを作製した。得られたプレスシートについて、回転試料台を有するX線回折装置(リガク製RINT2500)を用い、50kV-300mAの条件で、透過法にてX線プロファイルを測定した。得られたX線プロファイルより、結晶部分と非結晶部分とを分離して、結晶化度を求めた。
JIS K5902に準拠し測定した。なお、酸価11mgKOH/gが、極性基の含有率1質量%に換算される。
後述する、未変性オレフィンワックス(B’1)300gをガラス製反応器に仕込み、窒素雰囲気下160℃にて溶融した。次いで、スチレン450g及びジ-t-ブチルペルオキシド(以下DTBPOと略す)19gとを上記反応系(温度160℃)に6時間かけて連続供給した。その後、さらに1時間加熱反応させた後、溶融状態のまま10mmHg真空中で0.5時間脱気処理して揮発分を除去し、その後冷却し、B1を得た。表1に物性を示す。
後述する、未変性オレフィンワックス(B’1)600gをガラス製反応器に仕込み、窒素雰囲気下160℃にて溶融した。次いで、スチレン150g及びジ-t-ブチルペルオキシド(以下DTBPOと略す)6gとを上記反応系(温度160℃)に3時間かけて連続供給した。その後、さらに1時間加熱反応させた後、溶融状態のまま10mmHg真空中で0.5時間脱気処理して揮発分を除去し、その後冷却し、B2を得た。表1に物性を示す。
後述する、未変性オレフィンワックス(B’1)の製造条件であるプロピレンと水素の装入量を調整して得られた未変性オレフィンワックス630gをガラス製反応器に仕込み、窒素雰囲気下160℃にて溶融した。次いで、スチレン70g及びジ-t-ブチルペルオキシド(以下DTBPOと略す)3gとを上記反応系(温度160℃)に2時間かけて連続供給した。その後、さらに1時間加熱反応させた後、溶融状態のまま10mmHg真空中で0.5時間脱気処理して揮発分を除去し、その後冷却し、B3を得た。表1に物性を示す。
1.触媒の調製
内容積1.5リットルのガラス製オートクレーブにおいて、市販の無水塩化マグネシウム 25gをヘキサン500mlで懸濁させた。これを30℃に保ち撹拌しながらエタノール 92mlを1時間で滴下し、さらに1時間反応させた。反応終了後、ジエチルアルミニウムモノクロリド93mlを1時間で滴下し、さらに1時間反応させた。反応終了後、四塩化チタン90mlを滴下し、反応容器を80℃に昇温して1時間反応させた。反応終了後、固体部をデカンテーションにより遊離のチタンが検出されなくなるまでヘキサンで洗浄した。このものをヘキサン懸濁液としてチタン濃度を滴定により定量し、以下の実験に供した。
充分に窒素置換した内容積2リットルのステンレス製オートクレーブにヘキサン930mlおよびプロピレン70mlを装入し、水素を20.0kg/cm2(ゲージ圧)となるまで導入した。次いで、系内の温度を170℃に昇温した後、トリエチルアルミニウム0.1ミリモル、エチルアルミニウムセスキクロリド0.4ミリモル、上記得られた固体のヘキサン懸濁液を、チタン成分の量が原子換算で0.008ミリモルとなるようにエチレンで圧入することにより重合を開始した。
未変性オレフィンワックス(B’1)500gをガラス製反応器に仕込み、窒素雰囲気下160℃にて溶融した。次いで、無水マレイン酸30g及びジ-t-ブチルペルオキシド(以下DTBPOと略す)3gとを上記反応系(温度160℃)に5時間かけて連続供給した。その後、さらに1時間加熱反応させた後、溶融状態のまま10mmHg真空中で0.5時間脱気処理して揮発分を除去し、その後冷却し、B’2を得た。表1に物性を示す。
無機充填材(C)として、ガラス繊維(日東紡社製CSF3PE-941S)を使用した。
(樹脂組成物の作製)
表2に示す配合比で、ポリエステル樹脂(A)、および、重合体(B)、重合体(B)に該当しない重合体または耐衝撃改質剤(D)およびその他の衝撃改質剤を、表2に示す比率でドライブレンドし、ホッパーより投入した。パーカーコーポレーション社製同方向回転二軸押出機、HK25D(φ25mm、L/D=41)を用いて溶融混練した。スクリュー回転数120rpm、フィード量10kg/h、出口温度260℃とし、水冷しストランドとした。無機充填材(C)として用いたガラス繊維はサイドフィーダーより投入した。これらの溶融混練物をカッティングしてペレットを作製した。
[加工性の評価]
<トルク>
溶融混練開始10分後、運転状況が安定した際の二軸押出機の数値を読み取った。
得られたペレット状の樹脂組成物を、120℃、5時間乾燥後、射出成形機(EC60NII、東芝機械社製)を用いて、シリンダー温度260℃、スクリュー回転数150rpm、射出圧力100MPa、金型温度80℃の条件で射出し、厚み2mmの金型を使用して、樹脂の流動長を測定した。得られた流動長から、以下の基準でスパイラルフローを評価した。
A 流動長は31cm以上だった
B 流動長は30cm以上31cm未満だった
C 流動長は30cm未満だった
得られたペレット状の樹脂組成物を、120℃、5時間乾燥後、射出成形機(PNX60、日精樹脂工業社製)を用いて、シリンダー温度250℃、スクリュー回転数80rpm、射出圧力140MPa、金型温度90℃の条件で射出し、コップ型(φ50mm×h 50mm×t 1.6mm)の試験片を作製した。エジェクタが作動し、コップ型成形品を金型から離型させる際にかかる応力を圧力センサーにて測定した。上記離型させるための応力から、以下の基準で金型離型性を評価した。
A 離型させるための応力は10MPa未満だった
B 離型させるための応力は10MPa以上20MPa未満だった
C 離型させるための応力は20MPa以上だった
D 成形品は金型から離型しなかった
得られたペレット状の樹脂組成物を、120℃、5時間乾燥後、射出成形機(ニイガタNN100、ニイガタマシンテクノ社製)を用いて、シリンダー温度250℃、スクリュー回転数75rpm、射出圧力140MPa、金型温度75℃の条件で射出成形し、試験片を作製した。
得られた試験片について、以下のようにシャルピー衝撃試験(23℃及び-30℃)、引張試験(引張強度、伸び)、曲げ試験(曲げ強度、曲げ弾性率)の評価を行った。評価結果を表2に示す。
JIS K7111に従い、23℃及び-30℃におけるシャルピー衝撃試験を行った。ノッチは機械加工とし、試験片は、10mm(幅)×4mm(厚さ)×80mm(長さ)とした。
JIS K-7162に基づき、荷重レンジ2kN、試験速度50mm/minの条件で引張強度、引張伸び率を測定した。
JIS K-7171に基づき、荷重レンジ200N、試験速度2mm/min、曲げスパン64mmの条件で曲げ強度、曲げ弾性率を測定した。
Claims (8)
- ポリエステル樹脂(A)と、重合体(B)と、無機充填材(C)と、を含有し、
前記(A)、(B)および(C)の含有量の合計を100質量部としたときに、(A)を50~95質量部、(B)を0.5~10質量部、(C)を5~40質量部含み、
前記(A)が、下記(A-1)および(A-2)を満たし、
前記(B)が、下記(B-1)および(B-2)を満たす、
樹脂組成物。
(A-1)芳香族ジカルボン酸に由来する構成単位(a1)と、炭素原子数2~10のジオールに由来する構成単位(a2)とを含む
(A-2)示差走査熱量計(DSC)による融点(Tm)が200~245℃の範囲にある
(B-1)160℃における溶融粘度が10~10,000mP・sである
(B-2)スチレン系化合物に由来する構成単位を5~100質量%含む - 前記(B)が、エチレンおよび炭素原子数3~12のα-オレフィンから選ばれる少なくとも1種の単独重合体または共重合体のスチレン系化合物変性物であり、下記(B-3)を満たす、請求項1に記載の樹脂組成物。
(B-3)スチレン系化合物に由来する構成単位を10~70質量%含む - 前記(B)が、エチレンと、炭素原子数3~12のα-オレフィンから選ばれる少なくとも1種のα-オレフィンと、の共重合体の、スチレン変性物であり、下記(B-3’)を満たす、請求項1に記載の樹脂組成物。
(B-3’)スチレンに由来する構成単位を50~70質量%含む - 前記(C)として、ガラス繊維を含有する、請求項1~3のいずれか一項に記載の樹脂組成物。
- 前記(A)として、ポリブチレンテレフタレートを含有する、請求項1~4のいずれか一項に記載の樹脂組成物。
- 前記(A)、(B)および(C)の含有量の合計を100質量部としたときに、(A)を55~80質量部、(B)を2~5質量部、(C)を20~40質量部含む、請求項1~5のいずれか一項に記載の樹脂組成物。
- オレフィン由来の構造単位、α,β-不飽和カルボン酸エステル由来の構造単位および環状オキシ炭化水素構造を有する構造単位とを有する共重合体(D)の含有量が、前記(A)、(B)および(C)の含有量の合計100質量部に対して3質量部未満である、請求項1~6のいずれか一項に記載の樹脂組成物。
- 請求項1~7のいずれか一項に記載の樹脂組成物を含む成形体。
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