WO2022224686A1 - 樹脂組成物及び成形品 - Google Patents
樹脂組成物及び成形品 Download PDFInfo
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- WO2022224686A1 WO2022224686A1 PCT/JP2022/013769 JP2022013769W WO2022224686A1 WO 2022224686 A1 WO2022224686 A1 WO 2022224686A1 JP 2022013769 W JP2022013769 W JP 2022013769W WO 2022224686 A1 WO2022224686 A1 WO 2022224686A1
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- resin
- styrene
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- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
- PWWSSIYVTQUJQQ-UHFFFAOYSA-N distearyl thiodipropionate Chemical compound CCCCCCCCCCCCCCCCCCOC(=O)CCSCCC(=O)OCCCCCCCCCCCCCCCCCC PWWSSIYVTQUJQQ-UHFFFAOYSA-N 0.000 description 1
- MCPKSFINULVDNX-UHFFFAOYSA-N drometrizole Chemical compound CC1=CC=C(O)C(N2N=C3C=CC=CC3=N2)=C1 MCPKSFINULVDNX-UHFFFAOYSA-N 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 229940012466 egg shell membrane Drugs 0.000 description 1
- SUPCQIBBMFXVTL-UHFFFAOYSA-N ethyl 2-methylprop-2-enoate Chemical compound CCOC(=O)C(C)=C SUPCQIBBMFXVTL-UHFFFAOYSA-N 0.000 description 1
- 125000001495 ethyl group Chemical group [H]C([H])([H])C([H])([H])* 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 238000010413 gardening Methods 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 229920001519 homopolymer Polymers 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 238000004898 kneading Methods 0.000 description 1
- 235000021190 leftovers Nutrition 0.000 description 1
- 239000006028 limestone Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- FPYJFEHAWHCUMM-UHFFFAOYSA-N maleic anhydride Chemical compound O=C1OC(=O)C=C1 FPYJFEHAWHCUMM-UHFFFAOYSA-N 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 125000005397 methacrylic acid ester group Chemical group 0.000 description 1
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 239000002480 mineral oil Substances 0.000 description 1
- 235000010446 mineral oil Nutrition 0.000 description 1
- SSDSCDGVMJFTEQ-UHFFFAOYSA-N octadecyl 3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoate Chemical compound CCCCCCCCCCCCCCCCCCOC(=O)CCC1=CC(C(C)(C)C)=C(O)C(C(C)(C)C)=C1 SSDSCDGVMJFTEQ-UHFFFAOYSA-N 0.000 description 1
- QADJHAOXTKCYFT-UHFFFAOYSA-N octyl 3-(3-octoxy-3-oxopropyl)sulfanylpropanoate Chemical compound CCCCCCCCOC(=O)CCSCCC(=O)OCCCCCCCC QADJHAOXTKCYFT-UHFFFAOYSA-N 0.000 description 1
- 235000006408 oxalic acid Nutrition 0.000 description 1
- DXGLGDHPHMLXJC-UHFFFAOYSA-N oxybenzone Chemical compound OC1=CC(OC)=CC=C1C(=O)C1=CC=CC=C1 DXGLGDHPHMLXJC-UHFFFAOYSA-N 0.000 description 1
- NFHFRUOZVGFOOS-UHFFFAOYSA-N palladium;triphenylphosphane Chemical compound [Pd].C1=CC=CC=C1P(C=1C=CC=CC=1)C1=CC=CC=C1.C1=CC=CC=C1P(C=1C=CC=CC=1)C1=CC=CC=C1.C1=CC=CC=C1P(C=1C=CC=CC=1)C1=CC=CC=C1.C1=CC=CC=C1P(C=1C=CC=CC=1)C1=CC=CC=C1 NFHFRUOZVGFOOS-UHFFFAOYSA-N 0.000 description 1
- FJKROLUGYXJWQN-UHFFFAOYSA-N papa-hydroxy-benzoic acid Natural products OC(=O)C1=CC=C(O)C=C1 FJKROLUGYXJWQN-UHFFFAOYSA-N 0.000 description 1
- 239000011049 pearl Substances 0.000 description 1
- FDPIMTJIUBPUKL-UHFFFAOYSA-N pentan-3-one Chemical compound CCC(=O)CC FDPIMTJIUBPUKL-UHFFFAOYSA-N 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
- 239000002530 phenolic antioxidant Substances 0.000 description 1
- 229960000969 phenyl salicylate Drugs 0.000 description 1
- 239000011574 phosphorus Substances 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 239000003505 polymerization initiator Substances 0.000 description 1
- 238000003918 potentiometric titration Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000010298 pulverizing process Methods 0.000 description 1
- 229920005604 random copolymer Polymers 0.000 description 1
- 239000000376 reactant Substances 0.000 description 1
- 239000012783 reinforcing fiber Substances 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 229960001860 salicylate Drugs 0.000 description 1
- 229960004889 salicylic acid Drugs 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 238000007873 sieving Methods 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- AKHNMLFCWUSKQB-UHFFFAOYSA-L sodium thiosulfate Chemical compound [Na+].[Na+].[O-]S([O-])(=O)=S AKHNMLFCWUSKQB-UHFFFAOYSA-L 0.000 description 1
- 235000019345 sodium thiosulphate Nutrition 0.000 description 1
- 239000012086 standard solution Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- CXVGEDCSTKKODG-UHFFFAOYSA-N sulisobenzone Chemical compound C1=C(S(O)(=O)=O)C(OC)=CC(O)=C1C(=O)C1=CC=CC=C1 CXVGEDCSTKKODG-UHFFFAOYSA-N 0.000 description 1
- 239000012756 surface treatment agent Substances 0.000 description 1
- LVEOKSIILWWVEO-UHFFFAOYSA-N tetradecyl 3-(3-oxo-3-tetradecoxypropyl)sulfanylpropanoate Chemical compound CCCCCCCCCCCCCCOC(=O)CCSCCC(=O)OCCCCCCCCCCCCCC LVEOKSIILWWVEO-UHFFFAOYSA-N 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- QORWJWZARLRLPR-UHFFFAOYSA-H tricalcium bis(phosphate) Chemical compound [Ca+2].[Ca+2].[Ca+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O QORWJWZARLRLPR-UHFFFAOYSA-H 0.000 description 1
- 235000019731 tricalcium phosphate Nutrition 0.000 description 1
- MZHULIWXRDLGRR-UHFFFAOYSA-N tridecyl 3-(3-oxo-3-tridecoxypropyl)sulfanylpropanoate Chemical compound CCCCCCCCCCCCCOC(=O)CCSCCC(=O)OCCCCCCCCCCCCC MZHULIWXRDLGRR-UHFFFAOYSA-N 0.000 description 1
- 238000010792 warming Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 239000010457 zeolite Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0001—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor characterised by the choice of material
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- 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
-
- 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
- C08K11/00—Use of ingredients of unknown constitution, e.g. undefined reaction products
-
- 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
- C08K11/00—Use of ingredients of unknown constitution, e.g. undefined reaction products
- C08K11/005—Waste materials, e.g. treated or untreated sewage sludge
-
- 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
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/24—Acids; Salts thereof
- C08K3/26—Carbonates; Bicarbonates
-
- 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
- C08L25/06—Polystyrene
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2025/00—Use of polymers of vinyl-aromatic compounds or derivatives thereof as moulding material
- B29K2025/04—Polymers of styrene
- B29K2025/06—PS, i.e. polystyrene
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2025/00—Use of polymers of vinyl-aromatic compounds or derivatives thereof as moulding material
- B29K2025/04—Polymers of styrene
- B29K2025/08—Copolymers of styrene, e.g. AS or SAN, i.e. acrylonitrile styrene
-
- 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
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/24—Acids; Salts thereof
- C08K3/26—Carbonates; Bicarbonates
- C08K2003/265—Calcium, strontium or barium carbonate
-
- 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
- C08K2201/00—Specific properties of additives
- C08K2201/002—Physical properties
- C08K2201/005—Additives being defined by their particle size in general
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
- C08L2205/025—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2207/00—Properties characterising the ingredient of the composition
- C08L2207/04—Thermoplastic elastomer
Definitions
- the present invention relates to resin compositions and molded articles thereof. More specifically, the present invention relates to a resin composition having a low styrene-based resin content and low environmental impact, and a molded article thereof.
- polystyrene resins are typical thermoplastic resins, and are widely used as thermoplastic resins for injection molding for the above applications because they are excellent in transparency and moldability and are inexpensive.
- inorganic fillers such as calcium carbonate, talc, and zeolite are blended into polystyrene resins in fields where physical properties such as heat resistance and rigidity are required (see, for example, Patent Documents 1 etc.).
- the present invention has been made in view of the above circumstances, and provides a resin composition that has a low styrene resin content and a low environmental load, has good moldability, and has a tensile modulus and tensile strength.
- An object of the present invention is to provide a resin composition from which a molded article having excellent elongation at break can be obtained, and the molded article thereof.
- a resin composition having a tensile modulus of 1,000 to 3,000 MPa and a tensile elongation at break of 5% or more, as measured according to ASTM-D638.
- the eggshell powder has an average particle size of 3 to 50 ⁇ m.
- a molded article having good moldability and excellent tensile elastic modulus and tensile elongation at break which is a resin composition having a low styrene resin content and low environmental load.
- a resin composition and a molded article thereof can be provided.
- the resin composition according to the present invention is a resin composition containing an inorganic filler containing calcium carbonate and a styrene resin containing a diene component, wherein the content of the inorganic filler is It is 50% by mass or more based on the total mass, and is characterized by having a tensile modulus of 1,000 to 3,000 MPa and a tensile elongation at break of 5% or more, measured according to ASTM-D638.
- the resin composition of the present invention it is possible to reduce the content of the styrene-based resin while achieving moldability suitable for injection molding. Furthermore, it is possible to provide a molded article excellent in tensile modulus and tensile elongation at break.
- the resin composition according to the present invention has a tensile modulus of 1,000 to 3,000 MPa as measured according to ASTM-D638.
- tensile modulus of the resin composition and “tensile elongation at break of the resin composition” refer to a test piece of the resin composition prepared according to ASTM-D638, and the tensile strength measured using the test piece. means modulus and tensile elongation at break. If the tensile modulus of the test piece is 1,000 to 3,000 MPa, the tensile modulus of the molded product obtained from the resin composition will be good, and the molded product will have an excellent balance between strength and flexibility. can be done.
- the tensile modulus may be from 1,000 to 2,600 MPa, from 1,000 to 1,900 MPa, or from 1,200 to 1,800 MPa.
- the tensile modulus is a value measured according to ASTM-D638, and specifically means a value measured under the following conditions. (Method for measuring tensile modulus) After molding the resin composition into a plate having a thickness of 0.40 mm, the plate is cut into the shape of No. 1 dumbbell to prepare 10 measurement samples. Then, according to ASTM-D638, the tensile modulus of the measurement sample is measured using an autograph at a measurement temperature of 23° C. and a humidity of 50% at a tensile speed of 5 mm/min. The tensile modulus of elasticity of all measurement samples is measured, and the average value is taken as the tensile modulus of the resin composition.
- the resin composition according to the present invention has a tensile elongation at break of 5% or more as measured according to ASTM-D638.
- the tensile elongation at break of the resin composition is 5% or more, the obtained molded article has a good tensile elongation at break, and a molded article having an excellent balance between strength and flexibility can be obtained.
- the tensile elongation at break may be 10% or more, or 15% or more. From the standpoint of formability, the tensile elongation at break may be from 5 to 100%.
- the tensile elongation at break is a value measured according to ASTM-D638, and specifically means a value measured under the following conditions.
- Method for measuring tensile elongation at break After molding the resin composition into a plate having a thickness of 0.40 mm, the plate is cut into the shape of No. 1 dumbbell to prepare 10 measurement samples. Then, according to ASTM-D638, the tensile elongation at break of the measurement sample is measured using an autograph at a measurement temperature of 23° C. and a humidity of 50% at a tensile speed of 5 mm/min. The tensile elongation at break of all measurement samples is measured, and the average value is taken as the tensile elongation at break of the resin composition.
- the melt flow rate (MFR) of the resin composition according to the present invention at 200°C under a load of 5 kg, evaluated according to the JIS K 7260 standard, is preferably 1.5 g/10 min or more, more preferably 2.0 g/10 min or more. is more preferred.
- MFR 200° C., 5 kg load
- the resin composition according to the present invention contains an inorganic filler containing calcium carbonate in an amount of 50% by mass or more relative to the total mass of the resin composition. Since the resin composition according to the present invention contains a diene-containing styrene-based resin as a thermoplastic resin component, moldability does not deteriorate even when the inorganic filler is contained in an amount of 50% by mass or more. In addition, a molded article having excellent tensile modulus and tensile elongation at break can be provided.
- the proportion of the inorganic filler is 50% by mass or more, preferably 50 to 70% by mass, more preferably 50 to 60% by mass, relative to the total mass of the resin composition.
- the inorganic filler contains calcium carbonate.
- the proportion of calcium carbonate in the inorganic filler is preferably 90% by mass or more, more preferably 93 to 100% by mass, and even more preferably 95 to 100% by mass, relative to the total mass of the inorganic filler. If the ratio of calcium carbonate in the inorganic filler is within the above range, a molded article having excellent tensile modulus and tensile elongation at break can be easily obtained.
- the inorganic filler may contain fillers other than calcium carbonate (other fillers).
- Other fillers include, for example, talc.
- Other fillers may be contained individually by 1 type, and may use 2 or more types together.
- other fillers can be contained in a range of less than 10% by mass with respect to the total mass of the inorganic fillers.
- the inorganic filler containing calcium carbonate according to the present invention may be a biomineral.
- biomineral refers to minerals produced by living organisms, including pearls, seashells, eggshells, bones, exoskeletons of crustaceans, and the like.
- eggshell powder or shell powder When using “biomineral” as the inorganic filler according to the present invention, it is preferable to use eggshell powder or shell powder.
- These eggshell powder and seashell powder are inorganic fillers containing calcium carbonate as a main component.
- the eggshell powder and shell powder are preferably powders derived from food waste from the viewpoint of further reducing the burden on the environment. Among these, it is more preferable to contain eggshell powder.
- “Derived from food waste” refers to materials derived from food waste, such as unsold food and leftovers generated in the food distribution process and consumption stage, as well as processing residues generated in the food manufacturing and cooking processes. good.
- chicken eggshell powder it is preferable to use chicken eggshell as a raw material. More than 200,000 tons of chicken egg shells are discarded annually, and their effective use is desired.
- Chicken eggshells generally contain 95% by mass or more of calcium carbonate.
- the resin composition according to the present invention preferably contains chicken eggshell powder as the inorganic filler containing calcium carbonate.
- the inorganic filler may be eggshell powder alone or a mixture of eggshell powder and commercially available calcium carbonate.
- commercially available calcium carbonate means one that is chemically produced using raw materials not derived from biominerals, such as limestone.
- the ratio of eggshell powder in the mixture is preferably 60 to 100% by mass, preferably 70 to 100%, from the viewpoint of utilization of natural waste materials. % by mass is more preferred.
- the mixture may contain other fillers than calcium carbonate.
- the average particle size of the eggshell powder is preferably 3 to 50 ⁇ m, more preferably 3 to 40 ⁇ m, even more preferably 4 to 30 ⁇ m.
- the upper limit of the average particle size of the eggshell powder is preferably 50 ⁇ m or less.
- the average particle size of the eggshell powder means a value measured with a particle size distribution measuring device according to the "sieving method".
- the specific gravity of the eggshell powder is preferably 2.0 to 3.0, more preferably 2.0 to 2.8, and particularly preferably 2.3 to 2.7.
- the eggshell powder as described above can be prepared using a conventionally known production method. That is, eggshell powder having a desired average particle size can be obtained by pulverizing eggshells by a known method and then classifying them. Specifically, after removing the eggshell membrane from the eggshell, the eggshell is dried. Then, it is pulverized with a pulverizer or the like to obtain eggshell powder. After that, by classifying using a sieve having an appropriate mesh size, eggshell powder can be obtained. Moreover, eggshell powder can also use a commercial item. Commercially available products include, for example, Green Techno 21 Co., Ltd., trade name: GT-26, Kewpie Egg Co., Ltd., trade name: Calhope (registered trademark), and the like.
- the content of the eggshell powder in the resin composition is 50% by mass or more, preferably 50 to 70% by mass, relative to the total mass of the resin composition. , 50 to 65 mass % is more preferred.
- the resin composition according to the present invention contains a styrenic resin containing a diene component.
- a styrene resin containing a diene component By including a styrene resin containing a diene component, the resin composition does not become brittle even when 50% by mass or more of the inorganic filler is added, and moldability is improved. In addition, moldability with excellent tensile modulus and tensile elongation at break can be obtained.
- containing a diene component means containing a styrene resin containing a monomer unit derived from a conjugated diene, containing a conjugated diene monomer, or a conjugated diene rubber or a copolymer containing a conjugated diene. It means including a rubbery polymer, or including one or more of these.
- styrene-based resin means containing one or more polymers containing monomer units derived from aromatic vinyl compounds.
- the "styrenic resin containing a diene component” according to the present invention is composed of a polymer containing one type of monomer unit derived from a conjugated diene and a monomer unit derived from an aromatic vinyl compound. It may also be a mixture of multiple polymers, as described below.
- a styrene-based resin containing a diene component may be simply referred to as a "styrene-based resin".
- the ratio of the diene component in the resin composition is preferably 3 to 15% by mass, more preferably 3 to 14% by mass, particularly preferably 4 to 12% by mass, relative to the total mass of the resin composition. If the ratio of the diene component in the resin composition is within the above range, the moldability tends to be good even if 50% by mass or more of the inorganic filler is blended. In addition, the tensile modulus and tensile elongation at break of the molded product are less likely to decrease. In addition, the ratio of the diene component in the resin composition may be a value calculated from the blending amount of the styrene-based resin, or may be a value measured by the following method.
- the diene component in the resin composition is measured by potentiometric titration using iodine monochloride, potassium iodide and sodium thiosulfate standard solutions, and the diene A method in which the content is defined as the ratio of the diene component in the resin composition is exemplified.
- the Japanese Society for Analytical Chemistry, Polymer Analysis Research Roundtable Edition, "New Edition Polymer Analysis Handbook", Kinokuniya Shoten (1995 edition), p. 659(3) rubber content can be employed.
- the ratio of the diene component in the styrene resin according to the present invention is preferably 5 to 40% by mass, more preferably 6 to 30% by mass, and particularly preferably 8 to 28% by mass, relative to the total mass of the styrene resin. . If the ratio of the diene component is within the above range, the ratio of the diene component in the resin composition can be easily adjusted to the above preferred range. Moreover, even if the content of the styrene-based resin in the resin composition is reduced, the moldability is less likely to deteriorate. In addition, the tensile modulus of elasticity and tensile elongation at break of the resulting molded product are less likely to decrease.
- the ratio of the diene component in the styrene-based resin can be determined by the same method as the calculation method and measurement method for the diene component in the resin composition.
- the ratio of the styrene-based resin containing the diene component in the resin composition is preferably 50% by mass or less with respect to the total mass of the resin composition. Moreover, from the viewpoint of the rigidity of the molded product, it is preferable that the styrene resin is contained in an amount of 30% by mass or more. That is, the proportion of the styrene-based resin in the resin composition is more preferably 35-50% by mass, and even more preferably 40-50% by mass.
- the styrenic resin according to the present invention may be a mixture of multiple resins.
- the styrene-based resin may contain a polystyrene resin and a styrene-based thermoplastic elastomer.
- polystyrene resin The polystyrene resin according to the present invention is a polymer of an aromatic vinyl compound, a copolymer of a compound copolymerizable with an aromatic vinyl compound and an aromatic vinyl compound, or polymerized in the presence of a rubbery polymer.
- aromatic vinyl compounds include styrene, ⁇ -methylstyrene, p-methylstyrene, o-methylstyrene, m-methylstyrene, ethylstyrene, pt-butylstyrene and the like. These aromatic vinyl compounds may be used singly or in combination of two or more. Among these, it is preferable that styrene is included.
- Compounds copolymerizable with aromatic vinyl compounds include, for example, methacrylic acid esters such as methyl methacrylate and ethyl methacrylate; unsaturated nitrile compounds such as acrylonitrile and methacrylonitrile; acid anhydrides such as maleic anhydride; is mentioned.
- the mass ratio of the copolymerizable compound is preferably 20% by mass or less, more preferably 15% by mass, based on the total amount (100% by mass) of the aromatic vinyl compound and the copolymerizable compound. It is below.
- rubbery polymers examples include conjugated diene rubbers, copolymers of conjugated dienes and aromatic vinyl compounds, and ethylene-propylene copolymer rubbers. More specific examples include polybutadiene, styrene-butadiene random copolymers, styrene-butadiene block copolymers, and partially or wholly hydrogenated polymers thereof.
- the weight average molecular weight (Mw) of the polystyrene resin is preferably 10,000 to 500,000, more preferably 100,000 to 300,000. If the Mw of the polystyrene resin is within the above range, the fluidity tends to be good. In addition, Mw of a polystyrene resin points out the value calculated by polystyrene conversion by GPC (gel permeation chromatography).
- the polystyrene resin may be impact-resistant polystyrene (hereinafter sometimes referred to as "HIPS") or general-purpose polystyrene (homopolystyrene, hereinafter sometimes referred to as "GPPS").
- HIPS impact-resistant polystyrene
- GPPS general-purpose polystyrene
- the polystyrene resin preferably contains at least one resin selected from HIPS and GPPS. Note that the polystyrene resin does not include a styrene-based thermoplastic elastomer, which will be described later.
- the ratio of the polystyrene resin to the total amount (100% by mass) of the polystyrene resin and the styrene-based thermoplastic elastomer is preferably 20 to 95% by mass. 40 to 80% by mass is more preferable. If the ratio of the polystyrene resin to the total amount is within the above range, it is easy to adjust the ratio of the diene component of the styrene-based resin. Also, the proportion of the polystyrene resin in the resin composition is preferably 10 to 40% by mass, more preferably 20 to 32% by mass, relative to the total mass of the resin composition.
- the styrenic thermoplastic elastomer according to the present invention is a block copolymer of an aromatic vinyl compound and a conjugated diene, and a hydrogenated product thereof.
- aromatic vinyl compound include those mentioned above for the polystyrene resin, and styrene is more preferable.
- styrene-based thermoplastic elastomer examples include styrene-butadiene (SB), styrene-isoprene (SI), styrene-butadiene-butylene (SBB), styrene-butadiene-isoprene (SBI), styrene-butadiene- Block copolymers such as styrene (SBS), styrene-butadiene-butylene-styrene (SBBS), styrene-isoprene-styrene (SIS), and styrene-butadiene-isoprene-styrene (SBIS), and hydrogenated blocks thereof
- SBS styrene-butadiene
- SI styrene-butadiene-butylene-styrene
- SIS styrene-isoprene-
- the weight average molecular weight (Mw) of the styrene-based thermoplastic elastomer is preferably 100,000 to 200,000, more preferably 120,000 to 180,000. If the Mw of the styrene-based thermoplastic elastomer is within the above range, the compatibility with the polystyrene resin tends to be good.
- the Mw of the styrene-based thermoplastic elastomer is measured by GPC under the same conditions as for the polystyrene resin described above.
- the ratio of the diene component in the styrene-based thermoplastic elastomer is preferably 10 to 80% by mass with respect to the total mass of the styrene-based thermoplastic elastomer, from the viewpoint of facilitating adjustment within the range of moldable tensile modulus. ⁇ 70% by mass is more preferred, and 15 to 60% by mass is even more preferred.
- the diene component in the styrene-based thermoplastic elastomer may be a value calculated from the charged amount of the conjugated diene, or may be a value measured by the method described above.
- the method for measuring the diene component of the styrenic thermoplastic elastomer includes the same method as the method for measuring the diene content in the resin composition described above.
- the ratio of the styrene-based thermoplastic elastomer to the total amount (100% by mass) of the polystyrene resin and the styrene-based thermoplastic elastomer is 10 to 70% by mass. is preferred, and 20 to 60% by mass is more preferred. If the ratio of the styrene-based thermoplastic elastomer to the total amount is within the above range, it is easy to adjust the ratio of the diene component in the styrene-based resin.
- the proportion of the styrene-based thermoplastic elastomer in the resin composition is preferably 5-40% by mass, more preferably 8-30% by mass, relative to the total mass of the resin composition.
- the styrenic resin may consist only of a styrenic thermoplastic elastomer.
- the diene component of the styrenic thermoplastic elastomer is adjusted so that the amount of the diene component in the resin composition is in the range of 3 to 15% by mass. is preferred.
- the resin composition according to the present invention has a tensile elongation at break of 5% or more despite containing 50% by mass or more of the inorganic filler with respect to the total mass of the resin composition. ,000 to 3,000 MPa.
- the ratio of the inorganic filler is increased and the ratio of the resin component is decreased, the resin is easily broken and sufficient elongation cannot be obtained. That is, a hard and brittle molded article is obtained.
- the inventors of the present application have found that by blending a styrene resin containing a certain amount of a diene component, sufficient elongation can be obtained even with a small amount of resin, and that the elastic modulus can be prevented from becoming too high. .
- the resin composition according to the present invention can contain thermoplastic resins other than styrene resins (other thermoplastic resins). preferably does not contain other thermoplastic resins.
- the resin composition according to the present invention may optionally contain ultraviolet absorbers, light stabilizers, antioxidants, lubricants, plasticizers, colorants, antistatic agents, flame retardants, other additives such as mineral oil, and glass fibers. , carbon fiber, aramid fiber, and other reinforcing fibers. These may be used individually by 1 type, and may use 2 or more types together.
- UV absorbers examples include 2-(5'-methyl-2'-hydroxyphenyl)benzotriazole, 2-(5'-t-butyl-2'-hydroxyphenyl)benzotriazole, 2-[2 '-hydroxy-3',5'-bis( ⁇ , ⁇ -dimethylbenzyl)phenyl]benzotriazole, 2-(3',5'-di-t-butyl-2'-hydroxyphenyl)benzotriazole, 2-(3'-t-butyl-5'-methyl-2'-hydroxyphenyl)-5-chlorobenzotriazole, 2-(3',5'-di-t-butyl-2'-hydroxy Phenyl)-5-chlorobenzotriazole, 2-(3′,5′-di-t-amyl-2′-hydroxyphenyl)benzotriazole, 2-[3′-(3′′,4′′, 5′′,6′′-tetrahydrophthalimidomethyl)-5′-methyl-2′-hydroxyphenyl
- light stabilizers include bis(2,2,6,6-tetramethyl-4-piperidyl) sebacate and bis(1,2,2,6,6-pentamethyl-4-piperidyl) sebacate.
- dimethyl succinate/1-(2-hydroxyethyl)-4-hydroxy-2,2,6,6-tetramethylpiperidine polycondensate poly[[6,(1,1,3,3-tetramethylbutyl ) amino-1,3,5-triazine-2,4-diyl][(2,2,6,6-tetramethyl-4-piperidyl)imino]-hexamethylene-[(2,2,6,6- tetramethyl-4-piperidyl)imino]], 1-[2-[3-(3,5-di-t-butyl-4-hydroxyphenyl)propionyloxy]ethyl]-4-[3-(3,5 -di-t-butyl-4-hydroxyphenyl)propionyloxy]-2,2,6,6-te
- antioxidants include triethylene glycol-bis[3-(3-t-butyl-5-methyl-4-hydroxyphenyl)propionate], 2,4-bis(n-octylthio)- 6-(4-hydroxy-3,5-di-t-butylanilino)-1,3,5-triazine, pentaerythrityltetrakis[3-(3,5-di-t-butyl-4-hydroxyphenyl)propione -to], octadecyl-3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate, 2,2-thiobis(4-methyl-6-t-butylphenol) and 1,3 ,5-trimethyl-2,4,6-tris(3,5-di-t-butyl-4-hydroxybenzyl)benzene and other phenolic antioxidants; ditridecyl-3,3'-thiodipropionate, Sulfur antioxidants such as dilauryl-3
- the resin composition according to the present invention can be produced by melt-kneading an inorganic filler containing calcium carbonate, a styrenic resin containing a diene component, and optionally other components.
- a styrene resin containing a diene component more preferably a polystyrene resin and a styrene thermoplastic elastomer
- an inorganic filler containing calcium carbonate more preferably eggshell powder
- the resin composition according to the present invention contains 50% by mass or more of the inorganic filler containing calcium carbonate with respect to the total mass of the resin composition, the content of the resin material is small.
- the resin composition according to the present invention contains 50% by mass of the inorganic filler, it has good moldability. Therefore, it is suitable as a resin composition for injection molding. Needless to say, the application of the resin composition according to the present invention is not limited to injection molding.
- a molded article according to the present invention includes the resin composition described above. Preferably, it is obtained by injection molding the resin composition according to the present invention.
- the molded article according to the present invention is excellent in tensile modulus and tensile elongation at break.
- the molded article according to the present invention has a resin material content of 50% by mass or less, it has little environmental impact.
- the molded article according to the present invention can be applied to uses such as stationery, furniture, building materials, tableware, containers, gardening materials, and toys.
- ⁇ 2> The resin composition according to ⁇ 1>, wherein the inorganic filler contains at least one biomineral-derived powder selected from eggshell powder and shell powder.
- the inorganic filler contains at least one biomineral-derived powder selected from eggshell powder and shell powder.
- the biomineral-derived powder has an average particle size of 3 to 50 ⁇ m.
- the polystyrene resin contains at least one resin selected from HIPS and GPPS.
- An injection-molded article comprising the resin composition according to any one of ⁇ 1> to ⁇ 4>.
- Eggshell powder was prepared as inorganic filler 1 containing calcium carbonate.
- chicken eggshells were washed with water and then put into a hot air dryer for drying.
- the dried eggshells were placed in a stirring separation tank and stirred while applying high-pressure water to separate and remove the egg membrane inside the eggshells.
- the egg shells from which the egg membrane was separated and removed were put into the hot air dryer again and dried at 90 to 120° C. for 6 hours.
- the dried eggshells were pulverized using a pulverizer to obtain eggshell powder.
- the specific gravity of the obtained eggshell powder was 2.6 g/cm 3 when measured using a hydrometer (manufactured by Shimadzu Corporation, product name “Dry Automatic Density Meter Accupic II 1340”). Further, the obtained powder was classified to obtain an inorganic filler 1 (eggshell powder) having an average particle size of 10 ⁇ m.
- inorganic fillers 2 to 4 containing calcium carbonate Three types of eggshell powder with different average particle sizes were prepared in the same manner as inorganic filler 1, and these were designated as inorganic fillers 2-4. Table 1 shows the average particle size and specific gravity of each inorganic filler.
- an antioxidant for a rubbery polymer (trade name “Irganox (registered trademark) 1076” manufactured by Nihon Ciba-Geigy Co., Ltd.) was added.
- This raw material for polymerization was supplied at 12.5 kg/hr to a 14 L jacketed reactor (R-01) equipped with an anchor-shaped stirring blade with a blade diameter of 0.285 m.
- Polymerization was carried out by stirring at a reaction temperature of 140° C. and a rotational speed of 2.17 sec ⁇ 1 to obtain a polymer liquid.
- the polymer ratio of the obtained polymer liquid was 25%.
- This polymer liquid was introduced into two jacketed plug-flow reactors having an internal volume of 21 L arranged in series.
- the jacket temperature was adjusted so that the reaction temperature was 120 to 140° C. in the flow direction of the polymer liquid.
- the jacket temperature was adjusted so that the reaction temperature had a gradient of 130 to 160° C. in the flow direction of the polymer liquid.
- the polymer rate at the R-02 outlet was 50%, and the polymer rate at the R-03 outlet was 70%.
- the polymer rate is a value calculated by the following formula (1).
- Polymer rate (%) [(amount of polymer produced)/ ⁇ (amount of monomer charged) + (amount of solvent) ⁇ ] x 100 (1)
- the obtained polymer liquid was heated to 230° C., it was sent to a devolatilization tank with a degree of vacuum of 5 torr to separate and recover unreacted monomers and solvent.
- the reaction product was extracted from the devolatilization tank with a gear pump, passed through a die plate to form a strand, and then passed through a water tank to be pelletized to obtain high-impact polystyrene (HIPS).
- HIPS high-impact polystyrene
- the rubber component content of the obtained HIPS was 4.8% by mass.
- Mw of HIPS measured under the same conditions as GPPS was 210,000.
- thermoplastic elastomer 1 A reaction vessel was charged with 500.0 kg of cyclohexane and 75.0 g of tetrahydrofuran (THF), and 1,000 mL of a 10% by mass cyclohexane solution of n-butyllithium was added as a polymerization initiator solution and maintained at 30°C. 20.0 kg of styrene was added to anionically polymerize the styrene. At that time, the internal temperature rose to 35°C. After styrene was completely consumed, 33.4 kg of 1,3-butadiene and 86.6 kg of styrene were added at the same time.
- THF tetrahydrofuran
- thermoplastic elastomers 2 and 3 A styrene-butadiene copolymer was obtained in the same manner as for the styrene-based thermoplastic elastomer 1, except that the amounts of styrene and butadiene charged were changed. Table 2 shows the composition and diene amount of each styrenic thermoplastic elastomer.
- Example 1 Polystyrene resin 1 (GPPS) (20% by mass relative to the total mass of the resin composition) and styrene thermoplastic elastomer 1 (styrene-butadiene copolymer, diene content 16.7% by mass) (total mass of the resin composition 30% by mass with respect to the mass) and inorganic filler 1 (eggshell powder, average particle size 10 ⁇ m) (50% by mass with respect to the total mass of the resin composition), a twin-screw extruder (Toshiba Machine Co., Ltd.
- GPPS Polystyrene resin 1
- styrene thermoplastic elastomer 1 styrene-butadiene copolymer, diene content 16.7% by mass
- inorganic filler 1 eggshell powder, average particle size 10 ⁇ m
- Examples 2 to 7 and Comparative Examples 1 to 4 A resin composition was prepared in the same manner as in Example 1, except that the composition of the resin composition was as shown in Table 3. In addition, pellets were prepared in the same manner as in Example 1 and the MFR was measured. Furthermore, it was formed into a plate shape in the same manner as in Example 1, and the plate thickness, tensile modulus and tensile elongation at break were measured. Table 3 shows the results.
- the resin compositions of Examples 1 to 7, which satisfy the constitution of the present invention had good tensile modulus and tensile elongation at break even when they contained 50% by mass or more of the inorganic filler. . Moreover, moldability was also good.
- the resin compositions of Comparative Examples 1 to 4 which did not satisfy the constitution of the present invention were inferior in either tensile modulus or tensile elongation at break, and were also inferior in moldability. From the above results, it was found that the resin composition according to the present invention can provide a molded article having good moldability and excellent tensile elastic modulus and tensile elongation at break even when the styrene resin content is at least.
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Abstract
Description
すなわち、本発明は以下の態様を有する。
[1]炭酸カルシウムを含む無機充填剤と、ジエン成分を含むスチレン系樹脂とを含む、樹脂組成物であって、前記無機充填剤の含有量が、前記樹脂組成物の総質量に対して50質量%以上であり、ASTM-D638に従って測定される、引張弾性率が1,000~3,000MPaであり、引張破断伸びが5%以上である、樹脂組成物。
[2]前記無機充填剤が、卵殻粉末を含む、[1]に記載の樹脂組成物。
[3]前記卵殻粉末の平均粒子径が、3~50μmである、[2]に記載の樹脂組成物。
[4]前記スチレン系樹脂が、ポリスチレン樹脂と、スチレン系熱可塑性エラストマーとを含む、[1]から[3]のいずれか一項に記載の樹脂組成物。
[5]前記ポリスチレン樹脂が、汎用ポリスチレン及び耐衝撃性ポリスチレンから選択される少なくとも1つの樹脂を含む、[4]に記載の樹脂組成物。
[6]前記スチレン系熱可塑性エラストマーが、スチレン-ブタジエン共重合体を含む、[4]または[5]に記載の樹脂組成物。
[7]前記樹脂組成物の総質量に対する前記ジエン成分の含有量が、3~15質量%である、[1]から[6]のいずれか一項に記載の樹脂組成物。
[8]前記樹脂組成物のMFR(200℃、5kg荷重)が、1.5g/10min以上である、[1]から[7]のいずれか一項に記載の樹脂組成物。
[9]射出成形用である、[1]から[8]のいずれか一項に記載の樹脂組成物。
[10][1]から[9]のいずれか一項に記載の樹脂組成物を含む、成形品。
[樹脂組成物]
本発明に係る樹脂組成物は、炭酸カルシウムを含む無機充填剤と、ジエン成分を含むスチレン系樹脂とを含む、樹脂組成物であって、前記無機充填剤の含有量が、前記樹脂組成物の総質量に対して50質量%以上であり、ASTM-D638に従って測定される、引張弾性率が1,000~3,000MPaであり、引張破断伸びが5%以上であることを特徴とする。本発明に係る樹脂組成物によれば、射出成形に適した成形性を達成しつつ、スチレン系樹脂の含有量を低くすることができる。さらに、引張弾性率及び引張破断伸びに優れる成形品を提供できる。
前記引張弾性率は、1,000~2,600MPaであってもよく、1,000~1,900MPaであってもよく、1,200~1,800MPaであってもよい。なお、前記引張弾性率はASTM-D638に従って測定した値であり、具体的には以下の条件で測定した値のことを意味する。
(引張弾性率の測定方法)
樹脂組成物を厚み0.40mmの板状に成形したのち、ダンベル1号の形状で切り抜いて測定サンプルを10枚調製する。その後、ASTM-D638に従って、オートグラフを用いて、測定温度23℃、湿度50%の条件下、引張速度5mm/minで測定サンプルの引張弾性率を測定する。全ての測定サンプルの引張弾性率を測定し、その平均値を樹脂組成物の引張弾性率とする。
(引張破断伸びの測定方法)
樹脂組成物を厚み0.40mmの板状に成形したのち、ダンベル1号の形状で切り抜いて測定サンプルを10枚調製する。その後、ASTM-D638に従って、オートグラフを用いて、測定温度23℃、湿度50%の条件下、引張速度5mm/minで測定サンプルの引張破断伸びを測定する。全ての測定サンプルの引張破断伸びを測定し、その平均値を樹脂組成物の引張破断伸びとする。
本発明に係る樹脂組成物は、炭酸カルシウムを含む無機充填剤を、樹脂組成物の総質量に対して50質量%以上含有する。本発明に係る樹脂組成物は、熱可塑性樹脂成分として、ジエン成分を含むスチレン系樹脂を含んでいるため、無機充填剤を50質量%以上含有させても成形性が悪化しない。また、引張弾性率及び引張破断伸びに優れる成形品を提供できる。無機充填材の割合は、樹脂組成物の総質量に対して、50質量%以上であり、50~70質量%が好ましく、50~60質量%がより好ましい。
卵殻粉末の比重は2.0~3.0であることが好ましく、2.0~2.8であることがより好ましく、2.3~2.7であることが特に好ましい。
また、卵殻粉末は市販品を用いることもできる。市販品としては、例えば、(株)グリーンテクノ21製、商品名:GT-26、キューピータマゴ(株)製、商品名:カルホープ(登録商標)等が挙げられる。
本発明に係る樹脂組成物は、ジエン成分を含むスチレン系樹脂を含む。ジエン成分を含むスチレン系樹脂を含むことにより、前述の無機充填材を50質量%以上配合しても、樹脂組成物が脆くならず、成形性も良好となる。また、引張弾性率及び引張破断伸びに優れる成形性を得ることができる。ここで、「ジエン成分を含む」とは、共役ジエンに由来する単量体単位を含むスチレン系樹脂を含むこと、共役ジエンのモノマーを含むこと、または共役ジエンゴムや共役ジエンを含む共重合体のゴム質重合体を含むこと、あるいはこれらを1つ以上含むことを意味する。また、「スチレン系樹脂」とは、芳香族ビニル化合物に由来する単量体単位を含むポリマーを、1つ以上含んでいることを意味する。本発明に係る「ジエン成分を含むスチレン系樹脂」は、1種類の、共役ジエンに由来する単量体単位と、芳香族ビニル化合物に由来する単量体単位とを含むポリマーから構成されていてもよく、後述する通り、複数のポリマーの混合物であってもよい。以下、ジエン成分を含むスチレン系樹脂を、単に「スチレン系樹脂」と記載することもある。
スチレン系樹脂の配合量から算出する方法としては、例えば、あらかじめジエン成分量が判明しているスチレン系樹脂を用いる場合、[(スチレン系樹脂中のジエン成分量(質量%))×(スチレン系樹脂の配合量(質量%))]/樹脂組成物の総質量(100質量%)から算出することができる。
樹脂組成物中のジエン成分を測定する方法としては、例えば、一塩化ヨウ素、ヨウ化カリウムおよびチオ硫酸ナトリウム標準液を用いた電位差滴定で、樹脂組成物中のジエン含有量を測定し、このジエン含有量を樹脂組成物中のジエン成分の割合とする方法が挙げられる。具体的な測定方法としては、例えば、日本分析化学会高分子分析研究懇談会編、「新版高分子分析ハンドブック」、紀伊國屋書店(1995年度版)、P.659(3)ゴム含量に記載されている方法を採用することができる。
本発明に係るポリスチレン樹脂は、芳香族ビニル化合物の重合体、芳香族ビニル化合物と共重合可能な化合物と芳香族ビニル化合物との共重合体、または、これらをゴム質重合体の存在下で重合した重合体を意味する。
芳香族ビニル化合物としては、例えば、スチレン、α-メチルスチレン、p-メチルスチレン、o-メチルスチレン、m-メチルスチレン、エチルスチレン、p-t-ブチルスチレン等が挙げられる。これら芳香族ビニル化合物は、1種単独で用いられてもよく、2種以上を併用してもよい。このうち、スチレンを含むことが好ましい。
前記共重合可能な化合物の質量割合としては、前記芳香族ビニル化合物と前記共重合可能な化合物との合計量(100質量%)に対して、20質量%以下が好ましく、より好ましくは15質量%以下である。
本発明に係るスチレン系熱可塑性エラストマーは、芳香族ビニル化合物と、共役ジエンとのブロック共重合体、及びその水添物である。芳香族ビニル化合物としては、前述のポリスチレン樹脂と同じものが挙げられ、スチレンがより好ましい。
本発明に係るスチレン系熱可塑性エラストマーとしては、例えば、スチレン-ブタジエン(SB)、スチレン-イソプレン(SI)、スチレン-ブタジエン-ブチレン(SBB)、スチレン-ブタジエン-イソプレン(SBI)、スチレン-ブタジエン-スチレン(SBS)、スチレン-ブタジエン-ブチレン-スチレン(SBBS)、スチレン-イソプレン-スチレン(SIS)、及びスチレン-ブタジエン-イソプレン-スチレン(SBIS)等のブロック共重合体、ならびにこれらを水添したブロック共重合体が挙げられる。これらは1種単独で用いられてもよく、2種以上を併用してもよい。このうち、スチレン系熱可塑性エラストマーとしては、スチレン-ブタジエン共重合体を含むことが好ましい。
1つの態様において、スチレン系樹脂は、スチレン系熱可塑性エラストマーのみから構成されていてもよい。スチレン系樹脂がスチレン系熱可塑性エラストマーのみから構成されている場合、樹脂組成物中のジエン成分量が3~15質量%の範囲となるように、スチレン系熱可塑性エラストマーのジエン成分を調整することが好ましい。
本発明に係る樹脂組成物は、炭酸カルシウムを含む無機充填材と、ジエン成分を含むスチレン系樹脂と、必要に応じてその他の成分とを溶融混錬することによって製造することができる。具体的には、ジエン成分を含むスチレン系樹脂(より好ましくは、ポリスチレン樹脂及びスチレン系熱可塑性エラストマー)と、炭酸カルシウムを含む無機充填材(より好ましくは卵殻粉末)とを、それぞれ二軸押出機に投入して、200~250℃の温度で溶融混錬した後、ストランド状に押出することでペレット状の樹脂組成物を調製することができる。なお、本発明に係る樹脂組成物は、炭酸カルシウムを含む無機充填材を、樹脂組成物の総質量に対して50質量%以上含むため、樹脂材料の含有量が少ない。
上記の通り、本発明に係る樹脂組成物は、無機充填材を50質量%含んでいるものの、成形性が良好である。よって、射出成形用樹脂組成物として好適である。なお、当然ながら、本発明に係る樹脂組成物は、その用途が射出成形用途に限定されるわけではない。
本発明に係る成形品は、前述の樹脂組成物を含む。好ましくは、本発明に係る樹脂組成物を射出成形して得られるものである。本発明に係る成形品は、引張弾性率及び引張破断伸びに優れている。また、本発明に係る成形品は、樹脂材料の割合が50質量%以下であるため、環境への負荷が少ない。本発明に係る成形品は、文房具、家具、建材、食器、容器、園芸資材、玩具等の用途に応用できる。
<1>炭酸カルシウムを含む無機充填材と、ポリスチレン樹脂及びスチレン系熱可塑性エラストマーからなる、ジエン成分を含むスチレン系樹脂と、を含む樹脂組成物であって、前記樹脂組成物の総質量に対する、前記無機充填材の割合が50~60質量%であり、前記スチレン系樹脂の割合が40~50質量%であり、かつ前記ジエン成分の割合が3~15質量%であって、ASTM-D638に従って測定される、引張弾性率が1,000~3,000MPaであり、引張破断伸びが5%以上である、樹脂組成物。
<2>前記無機充填材は、卵殻粉末及び貝殻粉末から選択される少なくとも1つのバイオミネラル由来の粉末を含む、<1>に記載の樹脂組成物。
<3>前記バイオミネラル由来の粉末の平均粒子径が3~50μmである、<2>に記載の樹脂組成物。
<4>前記ポリスチレン樹脂が、HIPS及びGPPSから選択される少なくとも1つの樹脂を含む、<1>から<3>のいずれかに記載の樹脂組成物。
<5><1>から<4>のいずれかに記載の樹脂組成物を含む、射出成形品。
炭酸カルシウムを含む無機充填材1として、卵殻粉末を調製した。
まず、鶏の卵殻を水洗浄した後、熱風乾燥機に投入して、乾燥処理を行った。乾燥処理後の卵殻を撹拌分離槽に投入し、高圧水を当てながら撹拌して卵殻の内側の卵膜を分離除去した。その後、卵膜を分離除去した卵殻を熱風乾燥機に再度投入して、90~120℃で6時間乾燥処理した。乾燥処理後の卵殻を、粉砕機を用いて粉砕し、卵殻粉末を得た。得られた卵殻粉末の比重を、比重計((株)島津製作所製、製品名「乾式自動密度計アキュピックII 1340」)を用いて測定したところ2.6g/cm3であった。さらに得られた粉末を分級し、平均粒子径10μmの無機充填材1(卵殻粉末)を得た。
無機充填材1と同様の方法で、平均粒子径の異なる卵殻粉末を3種類調製し、これを無機充填材2~4とした。表1に各無機充填材の平均粒子径及び比重を示す。
内容積200Lの重合缶に、純水70.4kg、第三リン酸カルシウム300gを加えて攪拌した。その後、スチレン80.0kg、ベンゾイルパーオキサイド267.2gを加えて密封し、100℃で6時間反応させた。反応終了後、反応物を冷却、中和、脱水、及び乾燥して、ポリスチレンのホモポリマー(GPPS)を得た。得られたGPPSのMwを、GPCを用いて以下の条件で測定したところ、167,000であった。
<GPCの測定条件>
装置:Shodex(株)製、製品名「Shodex SYSTEM-21」
カラム:PLgel MIXED-B
測定温度:40℃
溶媒:テトラヒドロフラン
流量:1.0mL/分
検出方法:RI
サンプル濃度:0.2質量%
注入量:100μL
検量線:標準ポリスチレン(Polymer Laboratories製)
ゴム質重合体としてローシスポリブタジエンゴム(旭化成(株)製、商品名「ジエン55AS」)を使用し、このゴム質重合体(重合原料の総質量に対して5.3質量%)と、スチレンとを、溶剤としてエチルベンゼン(重合原料の総質量に対して5質量%)に溶解して重合原料とした。また、ゴム質重合体の酸化防止剤(日本チバガイギー(株)製、商品名「イルガノックス(登録商標)1076」)0.1質量部を添加した。この重合原料を、翼径0.285mの錨型撹拌翼を備えた14Lのジャケット付き反応器(R-01)に12.5kg/hrで供給した。反応温度140℃、回転数2.17sec-1で撹拌して重合させ、ポリマー液を得た。得られたポリマー液のポリマー率は25%であった。このポリマー液を、直列に配置した2基の内容積21Lのジャケット付きプラグフロー型反応器に導入した。1基目のプラグフロー型反応器(R-02)では、反応温度がポリマー液の流れ方向に向かって120~140℃となるようにジャケット温度を調整した。2基目のプラグフロー型反応器(R-03)では、反応温度がポリマー液の流れ方向に向かって130~160℃の勾配を持つようにジャケット温度を調整した。R-02出口でのポリマー率は50%、R-03出口でのポリマー率は70%であった。ここで、ポリマー率とは、下記式(1)によって算出される値である。
ポリマー率(%)=[(生成したポリマー量)/{(仕込んだモノマー量)+(溶剤量)}]×100 ・・・(1)
得られたポリマー液を230℃に加熱後、真空度5torrの脱揮槽に送り、未反応の単量体、溶剤を分離、回収した。その後、反応物を脱揮槽からギヤポンプで抜き出し、ダイプレートを通してストランドとした後、水槽を通してペレット化し、耐衝撃性ポリスチレン(HIPS)を得た。得られたHIPSのゴム成分含有量は4.8質量%であった。また、GPPSと同様の条件で測定したHIPSのMwは210,000であった。
反応容器中にシクロヘキサン500.0kg、テトラヒドロフラン(THF)75.0gを入れ、この中に重合開始剤溶液として、n-ブチルリチウムの10質量%シクロヘキサン溶液1,000mLを加え、30℃に保った。スチレン20.0kgを加えて、スチレンをアニオン重合させた。その際、内温は35℃まで上昇した。スチレンが完全に消費された後、1,3-ブタジエン33.4kgとスチレン86.6kgを同時に添加し、スチレンと1,3-ブタジエンが完全に消費された後、反応系の内温を75℃に下げ、さらにスチレン60.0kgを一括添加し、重合を完結させた。最後にすべての重合活性末端を水により失活させて、ポリスチレンブロック、スチレンとブタジエンのテーパードブロックを持つスチレン-ブタジエン共重合体を含む重合液を得た。この重合液を脱気して、押出機を用いてペレット状のブロック共重合体を得た。得られたスチレン-ブタジエン共重合体の、モノマーの仕込み量から計算したジエン量は16.7質量%であった。
スチレン及びブタジエンの仕込み量を変更した以外は、前記スチレン系熱可塑性エラストマー1と同様の方法で、スチレン-ブタジエン共重合体を得た。表2に、各スチレン系熱可塑性エラストマーの組成とジエン量とを示す。
ポリスチレン樹脂1(GPPS)(樹脂組成物の総質量に対して20質量%)と、スチレン系熱可塑性エラストマー1(スチレン-ブタジエン共重合体、ジエン量16.7質量%)(樹脂組成物の総質量に対して30質量%)と、無機充填材1(卵殻粉末、平均粒径10μm)(樹脂組成物の総質量に対して50質量%)とを、二軸押出機(東芝機械(株)製、製品名「TEM35-B」)を用いて、200℃、200rpm、吐出20kg/hで溶融混錬し、ストランド状に押出しペレット化した。得られたペレットのMFRを以下の条件で測定したところ、4.8g/10minであった。また、得られたペレットを、熱プレス(テスター産業(株)製、製品名「SA-303」)を用いて厚み0.40mmの板状に成形し、引張弾性率及び引張破断伸びを以下の方法で評価した。結果を表3に示す。なお、表3中のプレス板厚みの値は、マイクロメータを用いて板状成形品の厚みを測定した値である。
200℃、5kg荷重の条件で、JIS K 7260の規格に従って測定した。
樹脂組成物の板状成形品を、ダンベル1号の形状で切り抜いて測定サンプルを10枚調製した。その後、ASTM-D638に従って、オートグラフ((株)島津製作所製、製品名「AGS-X」)を用いて、測定温度23℃、湿度50%の条件下、引張速度5mm/minで測定サンプルの引張弾性率を測定した。全ての測定サンプルの引張弾性率を測定し、その平均値を以下の評価基準に沿って評価した。なお、B評価以上を合格とした。
(評価基準)
A:引張弾性率が1,200MPa以上1,800MPa未満のもの。
B:引張弾性率が1,000MPa以上1,200MPa未満、又は1,800MPa以上3,000MPa未満のもの。
C:引張弾性率が1,000MPa未満、又は3,000MPa以上のもの。
樹脂組成物の板状成形品を、ダンベル1号の形状で切り抜いて測定サンプルを10枚調製した。その後、ASTM-D638に従って、オートグラフ((株)島津製作所製、製品名「AGS-X」)を用いて、測定温度23℃、湿度50%の条件下、引張速度5mm/minで測定サンプルの引張破断伸びを測定した。全ての測定サンプルの引張破断伸びを測定し、その平均値を以下の評価基準に沿って評価した。なお、B評価以上を合格とした。
(評価基準)
A:引張破断伸びが10%以上のもの。
B:引張破断伸びが5%以上10%未満のもの。
C:引張破断伸びが5%未満のもの。
樹脂組成物を(株)日本製鋼製の射出成形機を用い、温度200℃、金型温度70℃の条件でISOダンベル形状に成形し、以下の評価基準に沿って成形性を評価した。
A:問題なく成形できるもの。
B:スプールやランナー部で折れるもの、又は、成形体が軟らかくて、しなるもの。
樹脂組成物の組成を表3に示す通りとした以外は、実施例1と同様の方法で樹脂組成物を調製した。また、実施例1と同様の方法でペレットを作成してMFRを測定した。さらに実施例1と同様の方法で板状に成形し、板厚み、引張弾性率、及び引張破断伸びを測定した。結果を表3に示す。
Claims (10)
- 炭酸カルシウムを含む無機充填剤と、ジエン成分を含むスチレン系樹脂とを含む、樹脂組成物であって、
前記無機充填剤の含有量が、前記樹脂組成物の総質量に対して50質量%以上であり、
ASTM-D638に従って測定される、引張弾性率が1,000~3,000MPaであり、引張破断伸びが5%以上である、樹脂組成物。 - 前記無機充填剤が、卵殻粉末を含む、請求項1に記載の樹脂組成物。
- 前記卵殻粉末の平均粒子径が、3~50μmである、請求項2に記載の樹脂組成物。
- 前記スチレン系樹脂が、ポリスチレン樹脂と、スチレン系熱可塑性エラストマーとを含む、請求項1から3のいずれか一項に記載の樹脂組成物。
- 前記ポリスチレン樹脂が、汎用ポリスチレン及び耐衝撃性ポリスチレンから選択される少なくとも1つの樹脂を含む、請求項4に記載の樹脂組成物。
- 前記スチレン系熱可塑性エラストマーが、スチレン-ブタジエン共重合体を含む、請求項4または5に記載の樹脂組成物。
- 前記樹脂組成物の総質量に対する前記ジエン成分の含有量が、3~15質量%である、請求項1から6のいずれか一項に記載の樹脂組成物。
- 前記樹脂組成物のMFR(200℃、5kg荷重)が、1.5g/10min以上である、請求項1から7のいずれか一項に記載の樹脂組成物。
- 射出成形用である、請求項1から8のいずれか一項に記載の樹脂組成物。
- 請求項1から9のいずれか一項に記載の樹脂組成物を含む、成形品。
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