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  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J3/00—Processes of treating or compounding macromolecular substances
  • C08J3/20—Compounding polymers with additives, e.g. colouring
  • C08J3/22—Compounding polymers with additives, e.g. colouring using masterbatch techniques
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  • 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
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  • 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
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J31/00—Catalysts comprising hydrides, coordination complexes or organic compounds
  • B01J31/02—Catalysts comprising hydrides, coordination complexes or organic compounds containing organic compounds or metal hydrides
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  • C08J3/24—Crosslinking, e.g. vulcanising, of macromolecules
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  • C08J3/00—Processes of treating or compounding macromolecular substances
  • C08J3/24—Crosslinking, e.g. vulcanising, of macromolecules
  • C08J3/246—Intercrosslinking of at least two polymers
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  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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  • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
  • C08J5/18—Manufacture of films or sheets
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  • 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
  • C08K5/00—Use of organic ingredients
  • C08K5/04—Oxygen-containing compounds
  • C08K5/09—Carboxylic acids; Metal salts thereof; Anhydrides thereof
  • C08K5/098—Metal salts of carboxylic acids
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  • 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 four or more carbon atoms
  • C08L23/0815—Copolymers of ethene with unsaturated hydrocarbons only containing four or more carbon atoms with aliphatic 1-olefins containing one carbon-to-carbon double bond
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  • 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
  • C08L23/26—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers modified by chemical after-treatment
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
  • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
  • H01M50/403—Manufacturing processes of separators, membranes or diaphragms
  • H01M50/406—Moulding; Embossing; Cutting
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
  • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
  • H01M50/409—Separators, membranes or diaphragms characterised by the material
  • H01M50/411—Organic material
  • H01M50/414—Synthetic resins, e.g. thermoplastics or thermosetting resins
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
  • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
  • H01M50/409—Separators, membranes or diaphragms characterised by the material
  • H01M50/411—Organic material
  • H01M50/414—Synthetic resins, e.g. thermoplastics or thermosetting resins
  • H01M50/417—Polyolefins
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
  • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
  • H01M50/409—Separators, membranes or diaphragms characterised by the material
  • H01M50/431—Inorganic material
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
  • C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
  • C08J2323/04—Homopolymers or copolymers of ethene
  • C08J2323/06—Polyethene
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
  • C08J2323/26—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers modified by chemical after-treatment
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2203/00—Applications
  • C08L2203/18—Applications used for pipes
• • 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
  • C08L2207/06—Properties of polyethylene
  • C08L2207/062—HDPE
• • 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
  • C08L2207/06—Properties of polyethylene
  • C08L2207/066—LDPE (radical process)
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2310/00—Masterbatches
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2312/00—Crosslinking
  • C08L2312/08—Crosslinking by silane
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/05—Accumulators with non-aqueous electrolyte
  • H01M10/052—Li-accumulators
  • H01M10/0525—Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
  • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
  • Y02E60/10—Energy storage using batteries

Definitions

• the present invention relates to a polyolefin composition, a silane-crosslinkable molded article, and a silane-crosslinked molded article and its use.
• Silane-crosslinked polyolefins obtained using silanol condensation catalysts are widely used in applications such as coating materials for electric wires and cables, pipes, hoses, and tubes.
• silane-crosslinked polyolefins are obtained by graft polymerizing an organic silane compound onto a polyolefin in the presence of a radical generator, and then reacting with water in the presence of a silanol condensation catalyst. This reaction with water in the presence of a silanol condensation catalyst is called "silane-water crosslinking.”
• silane water crosslinking a radical generator is usually applied as a graft initiator to a polyolefin in a molding machine such as an extruder. This causes an organic silane compound such as an alkoxysilane to be graft-copolymerized to the polyolefin. Then, water is applied to the molded body molded by the molding machine to cause a crosslinking reaction.
• the crosslinking reaction occurs through hydrolysis and condensation of an organic silane compound by the action of a silanol condensation catalyst.
• the silanol condensation catalyst may be mixed in advance into the molded article, or may be allowed to penetrate into the molded article from the surface.
• Patent Document 1 discloses a silanol condensation catalyst-containing composition that contains a specific silanol condensation catalyst and polyethylene, which is an alternative to the organotin compounds that have been widely used in the past and poses less environmental concerns.
• the silanol condensation catalyst-containing composition described in Patent Document 1 above has low environmental impact and exhibits good catalytic performance in crosslinking reactions.
• the inventors' investigations have revealed that the silanol condensation catalyst-containing composition has a yellowish tinge, and therefore there is room for improvement in terms of yellowness.
• an object of the present invention is to provide a polyolefin composition containing a zinc compound, which has low environmental load, good crosslinking performance, and reduced yellowness.
• Another object of the present invention is to provide a silane-crosslinkable molded article containing the above polyolefin composition, a silane-crosslinked molded article obtained by crosslinking such a molded article, and uses thereof.
• the present invention also aims to achieve effects that cannot be obtained by conventional techniques, which are derived from the various components shown in the detailed description of the invention described below.
• one aspect of the present invention is as follows.
• a polyolefin composition comprising a zinc compound represented by the following formula (1)′ and a polyolefin: Zn( OCOR1 )( OCOR2 )...(1)' (In formula (1)′, R 1 and R 2 are each independently a branched saturated hydrocarbon group having 9 to 11 carbon atoms.) [2] The polyolefin composition according to [1] above, wherein the tin content is less than 100 ppm by mass. [3] The polyolefin composition according to [1] or [2] above, wherein the zinc content is 0.10 mass% or more. [4] The polyolefin composition according to [3] above, wherein the zinc content is 3.0 mass% or less.
• polyolefin composition according to any one of [1] to [4], comprising at least one selected from the group consisting of polyethylene and polypropylene as the polyolefin.
• a silane-crosslinkable molded article comprising a silane-modified polyolefin and a zinc compound represented by the following formula (1)': Zn( OCOR1 )( OCOR2 )...(1)' (In formula (1)′, R 1 and R 2 are each independently a branched saturated hydrocarbon group having 9 to 11 carbon atoms.)
• R 1 and R 2 are each independently a branched saturated hydrocarbon group having 9 to 11 carbon atoms.
• a silane-crosslinked molded article obtained by crosslinking the silane-crosslinkable molded article according to [8] above.
• the silane-crosslinked molding according to [9] which is a wire coating material, a cable coating material, a pipe, a hose, a tube, a container, a sealing material, a film, or a sheet.
• the present invention provides a polyolefin composition containing a zinc compound that has low environmental impact, good crosslinking performance, and reduced yellowness. Therefore, the silane-crosslinked molded product obtained using the polyolefin composition also has excellent colorability and is very useful as a product such as a wire coating material.
• the polyolefin composition according to the present embodiment contains a zinc compound represented by the following formula (1) and a polyolefin. Zn( OCOR1 )( OCOR2 )...(1) (In formula (1), R 1 and R 2 are each independently a saturated hydrocarbon group.)
• the zinc compound represented by the above formula (1) preferably functions as a silanol condensation catalyst.
• the zinc compound represented by formula (1) is a compound with low environmental load concerns, has good catalytic performance, and exhibits excellent crosslinking performance.
• the yellowness of the resulting polyolefin composition is reduced. Therefore, by using the above polyolefin composition, a molded article made of silane-modified polyolefin with excellent crosslinking performance and a crosslinked silane-crosslinked molded article can be obtained, while at the same time reducing the yellowness.
• R1 and R2 are preferably each independently a branched saturated hydrocarbon group having 9 to 11 carbon atoms. That is, the polyolefin composition according to this embodiment preferably contains a zinc compound represented by the following formula (1)' and a polyolefin. Zn( OCOR1 )( OCOR2 )...(1)' (In formula (1)′, R 1 and R 2 are each independently a branched saturated hydrocarbon group having 9 to 11 carbon atoms.)
• the silanol condensation catalyst-containing composition described in Patent Document 1 has a particular odor, but the polyolefin composition according to this embodiment can reduce odor in addition to reducing yellowness. Therefore, by using the polyolefin composition, it is possible to reduce odor even in molded articles made of silane-modified polyolefins and silane-crosslinked molded articles.
• the reason why the polyolefin composition according to the present embodiment exhibits the above-mentioned effects is not clear, but is presumed to be as follows.
• the silanol condensation catalyst specifically disclosed in Patent Document 1 contains a predetermined amount of alkylamine as an active ingredient, but compared to this, the zinc compound represented by formula (1), particularly the zinc compound represented by formula (1)', has reduced yellowness and odor. Therefore, it is considered that by blending the zinc compound represented by formula (1) or formula (1)' as a silanol condensation catalyst, the yellowness and odor are reduced not only in the polyolefin composition but also in the molded article and silane-crosslinked molded article made of silane-modified polyolefin.
• the presence of the zinc compound represented by formula (1) or formula (1)' above makes it possible to achieve crosslinking performance equivalent to that of the silanol condensation catalyst-containing composition specifically disclosed in Patent Document 1. This is believed to be due to the fact that in the presence of water, the zinc compound represented by formula (1) or formula (1)' quickly changes the functional group bonded or coordinated to the zinc element to an OH group. It is believed that the rapid change in the functional group above results in high catalytic activity for the silanol condensation reaction with silane-modified polyolefins.
• the polyolefin composition containing the zinc compound in this embodiment exhibits excellent crosslinking performance equivalent to that of the silanol condensation catalyst-containing composition disclosed in Patent Document 1, while reducing yellowness and odor.
• the zinc compound in this embodiment acts as a catalyst component in the silanol condensation reaction in obtaining the silane-crosslinked polyolefin.
• the zinc compound is a zinc compound represented by the following formula (1), and is preferably a zinc compound represented by formula (1)'.
• Zn( OCOR1 )( OCOR2 )...(1) In formula (1), R 1 and R 2 are each independently a saturated hydrocarbon group.) Zn( OCOR1 )( OCOR2 )...(1)' (In formula (1)′, R 1 and R 2 are each independently a branched saturated hydrocarbon group having 9 to 11 carbon atoms.)
• R 1 and R 2 are each independently a saturated hydrocarbon group.
• the number of carbon atoms in the saturated hydrocarbon group is preferably 5 to 15, more preferably 7 to 13, and even more preferably 9 to 11. From the viewpoint of controlling the silanol condensation reaction, the number of carbon atoms is preferably 5 or more, more preferably 7 or more, and even more preferably 9 or more, and is preferably 15 or less, more preferably 13 or less, and even more preferably 11 or less.
• the saturated hydrocarbon group may be linear, branched, or cyclic, and from the viewpoint of controlling the silanol condensation reaction, it is preferable that at least one of R1 and R2 is branched, and it is more preferable that both R1 and R2 are branched. It is more preferable that at least one of R1 and R2 is a branched saturated hydrocarbon group having 5 to 15 carbon atoms, it is even more preferable that both R1 and R2 are branched saturated hydrocarbon groups having 5 to 15 carbon atoms, and it is even more preferable that both R1 and R2 are branched saturated hydrocarbon groups having 9 to 11 carbon atoms. Furthermore, in the saturated hydrocarbon group, R 1 and R 2 are preferably the same.
• the content of the zinc compound represented by the formula (1) or (1)' is preferably 0.3% by mass or more, and more preferably 0.3 to 15% by mass. From the viewpoint of expressing the function as a silanol condensation catalyst, the content is preferably 0.3% by mass or more, more preferably 0.4% by mass or more, even more preferably 0.5% by mass or more, and even more preferably 0.8% by mass or more. From the viewpoint of reducing the yellowness and odor of the resulting polyolefin composition, the content is preferably 15% by mass or less, more preferably 10% by mass or less, and even more preferably 5% by mass or less. When two or more zinc compounds represented by the formula (1) or (1)' are contained, it is preferable that the total content thereof is within the above range.
• the zinc content in the polyolefin composition according to this embodiment is preferably 0.10% by mass or more, and preferably 0.10 to 3.0% by mass.
• the above content is preferably 0.10% by mass or more, more preferably 0.11% by mass or more, and even more preferably 0.12% by mass or more.
• the above content is preferably 3.0% by mass or less, more preferably 2.0% by mass or less, and even more preferably 1.0% by mass or less.
• the content of the zinc compound represented by the formula (1) or formula (1)' is preferably 10 to 100% by mass.
• the content is preferably 10% by mass or more, more preferably 40% by mass or more, even more preferably 70% by mass or more, and even more preferably 85% by mass or more.
• the content is particularly preferably 90% by mass or more.
• the upper limit of the content is not particularly limited, and may be 100% by mass, that is, the silanol condensation catalyst may be composed only of the zinc compound represented by the formula (1) or formula (1)'. Note that, when two or more types of zinc compounds represented by the formula (1) or formula (1)' are included, it is preferable that the total content of them is within the above range.
• the silanol condensation catalyst in this embodiment may contain components other than the zinc compound represented by the above formula (1) or formula (1)'.
• examples of other components include other metal compounds and organic solvents, and conventionally known ones can be used.
• the polyolefin composition according to this embodiment has low environmental load concerns, good crosslinking performance, and reduced yellowness due to the presence of the zinc compound represented by formula (1) or formula (1)'. Therefore, for example, it may be substantially free of tin, which is conventionally known as a catalyst. Specifically, the tin content in the polyolefin composition according to this embodiment may be less than 100 ppm by mass.
• the zinc compound represented by formula (1) or formula (1)' in this embodiment may be manufactured or may be commercially available.
• Commercially available products that satisfy formula (1) or formula (1)' may be used, for example, from the K-KAT (registered trademark) series manufactured by King Industries.
• the polyolefin composition according to the present embodiment comprises a polyolefin.
• the polyolefin in the present embodiment is not particularly limited, and any conventionally known polyolefin can be used. However, the above polyolefin does not include silane-modified polyolefins described later, and is used to distinguish them from silane-modified polyolefins.
• examples of the polyolefin include polyethylene and polypropylene, and it is preferable that the polyolefin contains at least one selected from the group consisting of polyethylene and polypropylene.
• Polyethylene Any polyethylene can be used, including ethylene homopolymers such as high density polyethylene (HDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), etc., and ethylene- ⁇ -olefin copolymers such as ethylene-propylene copolymers, ethylene-1-butene copolymers, ethylene-1-pentene copolymers, ethylene-1-hexene copolymers, ethylene-1-octene copolymers, ethylene-propylene-1-hexene copolymers, etc.
• ethylene homopolymers are preferred, and low density polyethylene (LDPE) is more preferred.
• the polyethylene may be used alone or in combination of two or more kinds.
• the melt flow rate (MFR) of the polyethylene in this embodiment is not particularly limited, but is usually 0.1 to 80 g/10 min.
• the MFR of the polyethylene is usually 0.1 g/10 min or more, but from the viewpoint of moldability of the crosslinked silane-modified polyolefin and uniform dispersion during melt kneading with the silane-modified polyolefin, it is preferably 0.5 g/10 min or more, and more preferably 1 g/10 min or more.
• the MFR of the polyethylene is usually 80 g/10 min or less, but from the same viewpoint as above, it is preferably 60 g/10 min or less, more preferably 40 g/10 min or less, even more preferably 20 g/10 min or less, and particularly preferably 15 g/10 min or less.
• the MFR of polyethylene is a value measured at a temperature of 190°C and a load of 21.2 N based on JIS K 7210:1999.
• the density of the polyethylene in this embodiment is usually 0.850 to 0.970 g/cm 3 , and preferably 0.855 to 0.965 g/cm 3.
• the density of the polyethylene is a value measured based on JIS K 7112:1999.
• the polypropylene in the present embodiment may be a propylene homopolymer or a propylene-ethylene copolymer.
• the propylene-ethylene copolymer for example, any of propylene- ⁇ -olefin copolymers such as a propylene-1-butene copolymer and a propylene-ethylene-1-butene copolymer can be used.
• the polypropylene may be used alone or in combination of two or more kinds.
• the melt flow rate (MFR) of the polypropylene in this embodiment is not particularly limited, but is usually 0.1 to 120 g/10 min.
• the MFR of the polypropylene is usually 0.1 g/10 min or more, but from the viewpoint of moldability of the crosslinked silane-modified polyolefin and uniform dispersion during melt kneading with the silane-modified polypropylene, it is preferably 0.3 g/10 min or more, and more preferably 0.5 g/10 min or more.
• the MFR of the polypropylene is usually 120 g/10 min or less, but from the same viewpoint as above, it is preferably 100 g/10 min or less, more preferably 80 g/10 min or less, even more preferably 60 g/10 min or less, and particularly preferably 40 g/10 min or less.
• the MFR of polypropylene is a value measured at a temperature of 230°C and a load of 21.2 N based on JIS K 7210:1999.
• the density of the polypropylene in this embodiment is usually 0.850 to 0.930 g/cm 3 , and preferably 0.855 to 0.920 g/cm 3.
• the density of the polypropylene is a value measured based on JIS K 7112:1999.
• the polyolefin when the polyolefin is polyethylene or polypropylene, it is preferable to use one that satisfies at least one of the above MFR and density, and it is more preferable to use one that satisfies both MFR and density.
• This allows the polyolefin composition according to the present embodiment to be easily handled and produced, and also allows the polyolefin composition to be more uniformly mixed and dispersed in the silane-modified polyolefin.
• the polyolefin in this embodiment may be manufactured or may be commercially available.
• Examples of commercially available polyolefins include the Novatec (registered trademark) series, Newcon (registered trademark) series, Wintech (registered trademark) series, Wellnex (registered trademark) series, and Waymax (registered trademark) series manufactured by Japan Polypropylene Corporation, and the Zelas (registered trademark) series manufactured by Mitsubishi Chemical Corporation.
• the polyolefin composition according to this embodiment may further contain a silane-modified polyolefin.
• the silane-modified polyolefin in the present embodiment is not particularly limited as long as it is obtained by reacting a polyolefin with an unsaturated silane compound.
• the polyolefin to be reacted with the unsaturated silane compound may be, for example, the polyolefins exemplified in the above section "Polyolefins.”
• the unsaturated silane compound is not particularly limited, but is preferably a compound represented by the following formula (2):
• the unsaturated silane compound may be used alone or in combination of two or more kinds.
• R 3 Si(R 4 ) 3 ...(2) (In the above formula (2), R3 is an olefinically unsaturated hydrocarbon group, R4 is each independently a hydrocarbon group having 1 to 10 carbon atoms or an alkoxy group having 1 to 10 carbon atoms, and at least one of R4 is an alkoxy group having 1 to 10 carbon atoms.)
• R3 is an olefinically unsaturated hydrocarbon group, preferably an olefinically unsaturated hydrocarbon group having 2 to 10 carbon atoms, more preferably an olefinically unsaturated hydrocarbon group having 2 to 6 carbon atoms. More specific examples of R3 include alkenyl groups such as a vinyl group, a propenyl group, a butenyl group, and a cyclohexenyl group.
• R 4 are each independently a hydrocarbon group having 1 to 10 carbon atoms or an alkoxy group having 1 to 10 carbon atoms, preferably a hydrocarbon group having 1 to 6 carbon atoms or an alkoxy group having 1 to 6 carbon atoms, and more preferably a hydrocarbon group having 1 to 4 carbon atoms or an alkoxy group having 1 to 4 carbon atoms. At least one of R 4 is an alkoxy group having 1 to 10 carbon atoms, preferably an alkoxy group having 1 to 6 carbon atoms, and more preferably an alkoxy group having 1 to 4 carbon atoms.
• R4 is a hydrocarbon group having 1 to 10 carbon atoms
• the hydrocarbon group may be any of an alkyl group, an aliphatic group, an alicyclic group, and an aromatic group, but is preferably an alkyl group.
• Specific examples of R4 include alkyl groups such as methyl, ethyl, isopropyl, t-butyl, n-butyl, i-butyl, and cyclohexyl groups, and aryl groups such as phenyl groups.
• R4 is an alkoxy group having 1 to 10 carbon atoms
• the alkoxy group may be linear, branched, or cyclic, but is preferably linear or branched.
• Specific examples of R4 include a methoxy group, an ethoxy group, an isopropoxy group, and a ⁇ -methoxyethoxy group.
• the unsaturated silane compound is represented by the above formula (2)
• at least one of the three R 4s is an alkoxy group having 1 to 10 carbon atoms, but it is preferable that two or more R 4s are alkoxy groups, and it is more preferable that all R 4s are alkoxy groups.
• vinyltrialkoxysilanes such as vinyltrimethoxysilane, vinyltriethoxysilane, and propenyltrimethoxysilane are more preferred. This is because the vinyl group allows modification to polyolefins, and the alkoxy group promotes the following crosslinking reaction.
• the above-mentioned crosslinking reaction is a process in which the alkoxy groups introduced by graft modification to the modified polyolefin with the unsaturated silane compound react with water in the presence of a silanol condensation catalyst to hydrolyze and generate silanol groups.
• the resulting silanol groups then undergo dehydration condensation, bonding the modified polyolefins together and causing a crosslinking reaction.
• the modification amount of the unsaturated silane compound in the silane-modified polyolefin in this embodiment i.e., the amount of the unsaturated silane compound introduced into the silane-modified polyolefin by graft modification, is preferably 0.1 to 5% by mass. From the viewpoint of heat resistance, the modification amount is preferably 0.1% by mass or more, more preferably 0.2% by mass or more, and even more preferably 0.3% by mass or more. From the viewpoint of moldability, the modification amount is preferably 5.0% by mass or less, more preferably 4.0% by mass or less, and even more preferably 3.0% by mass or less.
• the modification amount of the unsaturated silane compound is the mass ratio of the unsaturated silane compound introduced by graft modification to the polyolefin before modification.
• the silane-modified polyolefin of the present embodiment can be produced by graft-modifying a polyolefin with the above-mentioned unsaturated silane compound.
• the method of graft-modification is not particularly limited, and any conventionally known method can be used.
• solution modification, melt modification, solid-phase modification by irradiation with an electron beam or ionizing radiation, modification in a supercritical fluid, etc. are preferably used.
• melt modification is preferred because of its excellent equipment and cost competitiveness, and melt kneading modification using an extruder with excellent continuous productivity is more preferred.
• Equipment used for melt kneading modification includes, for example, single screw extruders, twin screw extruders, Banbury mixers, roll mixers, etc. Among these, single screw extruders and twin screw extruders are preferred due to their excellent continuous productivity.
• the grafting of unsaturated silane compounds onto polyolefins is carried out by a grafting reaction in which the carbon-hydrogen bonds of the polyolefin are cleaved to generate carbon radicals to which unsaturated functional groups are added.
• a method using high temperature or a method using a radical generator such as an organic or inorganic peroxide can be used. From the viewpoint of cost and operability, it is preferable to use an organic peroxide.
• the radical generator may be used alone or in combination of two or more kinds.
• radical generators used in producing silane-modified polyolefins
• organic peroxides include hydroperoxides, dialkyl peroxides, diacyl peroxides, peroxy esters, and ketone peroxides.
• radical generators include azo compounds.
• the hydroperoxide group includes cumene hydroperoxide, tert-butyl hydroperoxide, and the like.
• the dialkyl peroxide group includes dicumyl peroxide, di-tert-butyl peroxide, 2,5-dimethyl-2,5-di-tert-butylperoxyhexane, 2,5-dimethyl-2,5-di-tert-butylperoxyhexyne-3, and the like.
• the diacyl peroxide group includes lauryl peroxide, benzoyl peroxide, and the like.
• the peroxyester group includes tert-peroxyacetate, tert-butylperoxybenzoate, tert-butylperoxyisopropylcarbonate, and the like.
• the ketone peroxide group includes cyclohexanone peroxide.
• Examples of the azo compound include azobisisobutyronitrile and methyl azoisobutyrate.
• a commonly used melt extrusion modification procedure involves compounding and blending polyolefin, unsaturated silane compound, and organic peroxide, feeding the mixture into a kneader or extruder, extruding the mixture while heating, melting, and kneading it, and cooling the molten resin emerging from the tip of the die in a water tank or the like to obtain the silane-modified polyolefin.
• the blending ratio of the polyolefin and the unsaturated silane compound is not particularly limited, but for example, it is preferable that the blending ratio of the unsaturated silane compound is 0.5 to 10 parts by mass per 100 parts by mass of the polyolefin.
• the blending ratio is preferably 0.5 parts by mass or more.
• the blending ratio is preferably 10 parts by mass or less.
• the blending ratio of the unsaturated silane compound and the organic peroxide is not particularly limited, but for example, it is preferable that the blending ratio of the organic peroxide is 0.1 to 100 parts by mass per 100 parts by mass of the unsaturated silane compound.
• the blending ratio is preferably 0.1 parts by mass or more.
• the blending ratio is preferably 100 parts by mass or less.
• melt extrusion modification conditions it is preferable to extrude at a temperature of about 150 to 300°C using a single screw extruder or twin screw extruder.
• the silane-modified polyolefin in this embodiment may be manufactured or may be commercially available. Commercially available products include, for example, those in the Linklon series manufactured by Mitsubishi Chemical Corporation.
• one aspect of the polyolefin composition according to this embodiment is one obtained by melt-kneading a polyolefin, a zinc compound represented by formula (1) or formula (1)', and the silane-modified polyolefin.
• the silane-modified polyolefin is obtained by melt-kneading a polyolefin, an unsaturated silane compound, and a radical generator, which are raw materials for the silane-modified polyolefin, and simultaneously producing the silane-modified polyolefin by graft modification and melt-kneading the polyolefin and the zinc compound represented by formula (1) or formula (1)'.
• melt-kneading with a silanol condensation catalyst master batch containing the polyolefin and the zinc compound represented by formula (1) or formula (1)' may be performed.
• the mode of its melt-kneading such as the order of its mixing, is not limited in any way.
• the polyolefin composition according to the present embodiment may contain optional components such as other additives and other resins other than polyolefins depending on various purposes, within the scope that does not significantly impair the effects of the present invention.
• additives include antioxidants, lubricants, colorants, heat stabilizers, light stabilizers, UV absorbers, neutralizing agents, antifogging agents, antiblocking agents, slip agents, flame retardants, dispersants, antistatic agents, conductivity imparting agents, metal deactivators, molecular weight regulators, antibacterial agents, fluorescent brighteners, crystal nucleating agents, etc. Depending on the purpose, these may be used alone or in combination of two or more types.
• antioxidants examples include phenol-based antioxidants, phosphite-based antioxidants, and thioether-based antioxidants. When an antioxidant is used, it is generally used in the range of 0.1 to 30 parts by mass per 100 parts by mass of the total polyolefin in this embodiment.
• Lubricants include oleamide, erucamide, silicone oil, fluorine-based resins, etc. When a lubricant is used, it is usually used in the range of 0.1 to 10 parts by mass per 100 parts by mass of the total polyolefin in this embodiment.
• resins include styrene-based thermoplastic elastomers, polyester resins, polyamide resins, styrene resins, acrylic resins, polycarbonate resins, polyvinyl chloride resins, various elastomers (excluding those that fall under the category of polyolefins in this embodiment), and the like.
• the other resins listed above may be used alone or in combination of two or more.
• the other resins are typically used in an amount of 50 parts by mass or less per 100 parts by mass of the total of the polyolefins in this embodiment.
• the polyolefin composition according to the present embodiment can be produced by kneading the zinc compound represented by the above formula (1) or (1)' and the above polyolefin, if necessary, together with the above silane-modified polyolefin and the above other components, in a twin-screw kneader or the like under conditions of 120 to 230° C. Furthermore, the resulting mixture may be pelletized as necessary.
• the polyolefin composition according to the present embodiment is preferably, for example, made into a masterbatch, more preferably a catalyst masterbatch, and even more preferably a silanol condensation catalyst masterbatch.
• masterbatch refers to a state in which a polyolefin composition containing a high concentration of an active ingredient such as a silanol condensation catalyst is granulated, or a resin mass is crushed to form pellets.
• the catalyst master batch in this embodiment is made of the polyolefin composition according to this embodiment.
• the polyolefin composition according to this embodiment as a catalyst master batch for producing a crosslinked body, it is possible to provide a silane crosslinked molded body with good hue, i.e., reduced yellowness, and preferably also with reduced odor.
• the yellowness of the polyolefin composition according to the present embodiment in a state not containing the silane-modified polyolefin is preferably 20 or less, more preferably 15 or less, and even more preferably 10 or less, taking into consideration the influence on a molded article obtained by adding the silane-modified polyolefin and melt-kneading it, and the lower the better.
• the yellowness is a value measured in accordance with JIS Z 8722:2009 after pelletizing the polyolefin composition not containing the silane-modified polyolefin.
• the molded article according to the present embodiment is a molded product of a polyolefin composition containing a silane-modified polyolefin.
• the molded article may be a product obtained by melt-kneading a polyolefin, a zinc compound represented by formula (1) or formula (1)', and a silane-modified polyolefin, and molding the mixture by various molding methods. Examples of the various molding methods include extrusion molding, injection molding, and press molding.
• the molded article according to this embodiment may be a silane-crosslinkable molded article containing a silane-modified polyolefin and a zinc compound represented by formula (1), and the zinc compound represented by formula (1) is preferably a zinc compound represented by formula (1)'.
• Another aspect of the molded article according to this embodiment may be one obtained by melt-kneading the raw materials for the silane-modified polyolefin, namely, a polyolefin, an unsaturated silane compound, and a radical generator, and simultaneously producing the silane-modified polyolefin by graft modification and melt-kneading the polyolefin and the zinc compound represented by formula (1) or formula (1)', followed by molding.
• a silanol condensation catalyst master batch containing the polyolefin and the zinc compound represented by formula (1) or formula (1)' may be melt-kneaded and molded.
• the silane-crosslinked molded article according to the present embodiment is a crosslinked molded article described in the above ⁇ Molded Article>, such as a molded article made of a polyolefin composition containing a silane-modified polyolefin or a silane-crosslinkable molded article containing a silane-modified polyolefin and a zinc compound represented by formula (1) or formula (1)'.
• the molded article can be crosslinked by exposing it to a water atmosphere to promote a crosslinking reaction between silanol groups.
• the material can be left standing in air containing moisture, air containing water vapor can be blown into the material, the material can be immersed in a water bath, or the material can be sprayed with a mist of warm water.
• the hydrolyzable alkoxy groups in the silane-modified polyolefin react with water in the presence of the zinc compound represented by formula (1) or formula (1)' in the polyolefin composition to generate silanol groups through hydrolysis.
• the crosslinking reaction then proceeds through dehydration condensation between the generated silanol groups, and the silane-modified polyolefins bond together to generate silane-crosslinked polyolefins, resulting in a silane-crosslinked molded product.
• the rate at which the crosslinking reaction proceeds depends on the conditions of exposure to the water atmosphere, but typically, the temperature ranges from 20 to 130° C. and the exposure time ranges from 10 minutes to 2 weeks. Particularly preferred conditions are a temperature range of 60 to 110° C. and a time range of 1 hour to 160 hours.
• the relative humidity of the air is selected from the range of 1 to 100%.
• the gel fraction (degree of crosslinking) of the silane-crosslinked molded article which is a silane-crosslinked polyolefin, is the mass proportion of the insoluble portion after extraction at the boiling point of xylene.
• the silane crosslinked molded article according to this embodiment is subjected to Soxhlet extraction with xylene, and then extracted with boiling xylene for 10 hours, and the insoluble matter sample, i.e., the mass after drying is measured, and the ratio to the mass before extraction is calculated, whereby the gel fraction can be calculated. More specifically, it is measured by the method described in the Examples section below.
• the gel fraction is preferably 50% or more from the viewpoint of ensuring that the silane-crosslinked polyolefin exhibits excellent properties over a long period of time.
• There is no particular upper limit to the gel fraction but it is usually 100% (completely crosslinked) or less, and 90% or less is preferable from the viewpoint of suppressing the progression of crosslinking during molding.
• the above gel fraction can be adjusted by changing the graft ratio (amount of modification) of the unsaturated silane compound of the silane-modified polyolefin, the type and amount of the zinc compound represented by formula (1) or formula (1)', which is a silanol condensation catalyst, the conditions (temperature, time) for crosslinking, etc.
• the silane cross-linked molded article according to this embodiment can be suitably used in various shapes and forms, such as wire coating materials, cable coating materials, pipes, hoses, tubes, various containers, sealing materials, films, sheets, etc.
• the silane cross-linked molded article according to this embodiment is preferably used as a coolant tube or a coolant tube member.
• the silane cross-linked molded article according to this embodiment is also preferably used as a lithium ion battery separator or a lithium ion battery separator member.
• the present invention also relates to the use of the silane-crosslinked molding.
• examples of uses of the silane-crosslinked molded article according to this embodiment include use as a coolant tube, use as a coolant tube component, use as a lithium ion battery separator, and use as a lithium ion battery separator component.
• Aspect 1 of the present invention is a polyolefin composition
• a silanol condensation catalyst contains a zinc compound represented by the following formula (1):
• the polyolefin composition has a content of the zinc compound of 0.3 mass% or more.
• Zn( OCOR1 )( OCOR2 )...(1) In formula (1), R 1 and R 2 are each independently a saturated hydrocarbon group.
• a second aspect of the present invention is the polyolefin composition of the first aspect, wherein R 1 and R 2 in the formula (1) are each independently a saturated hydrocarbon group having 5 to 15 carbon atoms.
• a third aspect of the present invention relates to the polyolefin composition according to the second aspect, wherein R 1 and R 2 in the formula (1) are each independently a branched saturated hydrocarbon group having 5 to 15 carbon atoms.
• Aspect 4 of the present invention is a polyolefin composition according to any one of aspects 1 to 3, in which the content of the zinc compound in the silanol condensation catalyst is 10 to 100 mass %.
• Aspect 5 of the present invention is a polyolefin composition according to any one of aspects 1 to 4, in which the polyolefin comprises at least one selected from the group consisting of polyethylene and polypropylene.
• Aspect 6 of the present invention is a masterbatch of any one of the polyolefin compositions of aspects 1 to 5.
• the polyolefin composition of any one of aspects 1 to 6 further contains a silane-modified polyolefin.
• Aspect 8 of the present invention is a molded article obtained by molding the polyolefin composition of aspect 7.
• Aspect 9 of the present invention is a silane-crosslinked molded body obtained by crosslinking the molded body of aspect 8.
• the silane cross-linked molded article of aspect 9 is a wire coating material, a cable coating material, a pipe, a hose, a tube, a container, a sealing material, a film, or a sheet.
• zinc neodecanoate corresponds to the zinc compound represented by formula (1) or formula (1)', in which R1 and R2 in formula (1) or formula (1)' are both branched alkyl groups having 10 carbon atoms.
• K-KAT registered trademark
• XK-640 King Industries, containing 50 to 60% by mass of bismuth carboxylate, less than 1.5% by mass of mineral oil, and 38.5 to 50% by mass of other components
• K-KAT registered trademark
• K-670 King Industries, containing 10 to less than 20% by mass of alkylamine, 1 to less than 3% by mass of zinc compound, and 80 to less than 90% by mass of other components
• Ingredients A-1 Irganox (registered trademark) 1010 (manufactured by BASF); antioxidant; A-2: Irganox (registered trademark) MD1024 (manufactured by BASF); metal deactivator; A-3: Sumilizer (registered trademark) WXRC (manufactured by Sumitomo Chemical); antioxidant; A-4: Viton (registered trademark) Freeflow RC (manufactured by DuPont); lubricant
• MFR Melt flow rate
• Odor 80 g of the polyolefin composition was placed in a 500 mL Erlenmeyer flask with a stopper, the flask was stoppered, and the flask was left to stand for 24 hours in a thermostatic chamber at 23°C and 50% RH. After that, within 10 minutes after opening the stopper, five inspectors checked the odor and gave each an average score based on the following criteria, and the average score of the five inspectors is shown in Table 1. It should be noted that if the odor average is 4.0 points or less, it can be said to be good (passed), and the lower the score, the more suitable it is.
• Example 1-1a The raw material composition shown in Table 1, i.e., 50 parts by mass of PO-1, 50 parts by mass of PO-2, 5 parts by mass of C-1, 2 parts by mass of A-1, 1 part by mass of A-2, 1 part by mass of A-3, and 0.3 parts by mass of A-4, was mixed in a blender. Thereafter, the mixture was charged into a twin-screw kneader (TEX25- ⁇ III, manufactured by JSW Co., Ltd.) set at a temperature of 180° C., and the strands coming out of the nozzle were cooled and solidified in a water tank, and then cut into pellets to obtain a masterbatch polyolefin composition A. The MFR, color, and odor of the obtained polyolefin composition A were measured according to the above-mentioned methods. The results are shown in Table 1. In addition, the blanks in the raw material composition in Table 1 mean that no raw material was blended.
• TEX25- ⁇ III manufactured by JSW Co.,
• Example 1-1b Five parts by mass of polyolefin composition A was added as a catalyst master batch to 100 parts by mass of silane-modified polyolefin Linklon XLE830N, and dry-blended. This was then placed in an injection molding machine and molded into a sheet having a thickness of 2 mm under conditions of 220° C., thereby obtaining a molded article of polyolefin composition A′ further containing silane-modified polyolefin.
• Example 2-1 A sheet-like molded product of the polyolefin composition A' containing the silane-modified polyolefin obtained in Example 1-1b was left to stand in a thermohygrostat at 85° C. and 85% RH for 16 hours to obtain a sheet-like silane-crosslinked molded product A.
• the gel fraction of the obtained sheet-like silane-crosslinked molded product A was measured according to the above-mentioned method. The results are shown in Table 1.
• Example 1-1a Polyolefin compositions B to K were obtained in the same manner as in Example 1-1a, except that the raw material compositions were as shown in Table 1.
• the MFR, hue, and odor of the obtained polyolefin compositions B to K were measured in the same manner as in Example 1-1a.
• the results are shown in Table 1.
• the zinc content of Comparative Example 1-1a is marked as "-". This is because the structure of the silanol condensation catalyst C-4 used could not be identified and therefore could not be calculated.
• the tin content in each of the polyolefin compositions A to K of Examples 1-1a to 1-10a was less than 100 ppm by mass.
• Example 1-1b ⁇ Examples 1-2b to 1-10b, Comparative Example 1-1b>
• polyolefin composition A the polyolefin compositions B to K obtained in Examples 1-2a to 1-10a and Comparative Example 1-1a were used, and molded bodies of polyolefin compositions B' to K' containing silane-modified polyolefin were obtained in the same manner as in Example 1-1b.
• Example 2-1 ⁇ Examples 2-1 to 2-10, Comparative Example 2-1>
• the sheet-shaped molded bodies of the polyolefin compositions B' to K' containing the silane-modified polyolefin obtained in Examples 1-2b to 1-10b and Comparative Example 1-1b were used to obtain sheet-shaped silane-crosslinked molded bodies B to K in the same manner as in Example 2-1.
• the gel fraction of each of the obtained sheet-like silane-crosslinked molded articles B to K was measured in the same manner as in Example 2-1. The results are shown in Table 1.
• the olefin compositions A to J according to this embodiment had better evaluation results in terms of hue (yellowness) and odor compared to the olefin composition K, and the yellowness in particular was very low.
• the sheet-like silane-crosslinked molded products A to J which were obtained by crosslinking silane-modified polyolefins using the olefin compositions A to J, all showed a high level of gel fraction, confirming that the olefin compositions A to J have good crosslinking performance.

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