U.S. patent application number 15/771823 was filed with the patent office on 2018-11-01 for graft copolymer, crosslinked particles, graft crosslinked particles, rubbery polymer, and thermoplastic resin composition using same.
The applicant listed for this patent is UMG ABS, LTD.. Invention is credited to Hiroyuki ATSUTA, Yuusuke FUKAMACHI, Takashi IWANAGA, Ichiro KAMATA, Hironori MATSUYAMA, Yoshitaka NAITO.
Application Number | 20180312693 15/771823 |
Document ID | / |
Family ID | 58630298 |
Filed Date | 2018-11-01 |
United States Patent
Application |
20180312693 |
Kind Code |
A1 |
IWANAGA; Takashi ; et
al. |
November 1, 2018 |
GRAFT COPOLYMER, CROSSLINKED PARTICLES, GRAFT CROSSLINKED
PARTICLES, RUBBERY POLYMER, AND THERMOPLASTIC RESIN COMPOSITION
USING SAME
Abstract
Provided is a graft copolymer that has an excellent
impact-resistance-imparting effect and that can provide a
thermoplastic resin composition excellent in weather resistance and
color developability. A graft copolymer (C) obtained by
graft-polymerizing one or two or more monomers (B), which are
selected from (meth)acrylic acid esters, aromatic vinyls, vinyl
cyanides, N-substituted maleimides, and maleic acid, onto a
composite rubber-like polymer (A), which is obtained by
polymerizing a mixture (Ac) containing a polyorganosiloxane (Aa)
and an acrylic acid ester (Ab) after forming a miniemulsion in
water solvent. A thermoplastic resin composition that contains the
graft copolymer (C) and a thermoplastic resin (D).
Inventors: |
IWANAGA; Takashi; (Ube-shi,
Yamaguchi, JP) ; NAITO; Yoshitaka; (Ube-shi,
Yamaguchi, JP) ; ATSUTA; Hiroyuki; (Ube-shi,
Yamaguchi, JP) ; KAMATA; Ichiro; (Ube-shi, Yamaguchi,
JP) ; MATSUYAMA; Hironori; (Ube-shi, Yamaguchi,
JP) ; FUKAMACHI; Yuusuke; (Ube-shi, Yamaguchi,
JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
UMG ABS, LTD. |
Tokyo |
|
JP |
|
|
Family ID: |
58630298 |
Appl. No.: |
15/771823 |
Filed: |
October 7, 2016 |
PCT Filed: |
October 7, 2016 |
PCT NO: |
PCT/JP2016/079919 |
371 Date: |
April 27, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C08L 2312/00 20130101;
C08L 33/12 20130101; C08L 51/085 20130101; C08F 220/14 20130101;
C08L 83/10 20130101; C08L 101/00 20130101; C08G 81/024 20130101;
C08F 20/20 20130101; C08F 283/12 20130101; C08F 212/10 20130101;
C08J 3/24 20130101; C08F 285/00 20130101; C08L 51/08 20130101; C08L
25/12 20130101; C08K 5/0025 20130101; C08F 2/44 20130101; C08J 3/07
20130101; C08F 2/22 20130101; C08F 283/12 20130101; C08F 220/40
20130101; C08F 283/12 20130101; C08F 220/1804 20200201; C08F 285/00
20130101; C08F 220/14 20130101; C08F 285/00 20130101; C08F 212/08
20130101; C08F 285/00 20130101; C08F 220/44 20130101; C08F 220/14
20130101; C08F 222/40 20130101; C08F 212/08 20130101; C08L 51/085
20130101; C08L 33/12 20130101; C08L 33/12 20130101; C08L 33/12
20130101; C08L 51/085 20130101; C08L 33/12 20130101; C08L 25/12
20130101; C08L 51/085 20130101; C08F 283/12 20130101; C08F 220/1804
20200201 |
International
Class: |
C08L 83/10 20060101
C08L083/10; C08G 81/02 20060101 C08G081/02; C08J 3/07 20060101
C08J003/07; C08J 3/24 20060101 C08J003/24; C08K 5/00 20060101
C08K005/00 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 28, 2015 |
JP |
2015-212024 |
Oct 28, 2015 |
JP |
2015-212025 |
Oct 28, 2015 |
JP |
2015-212026 |
Oct 28, 2015 |
JP |
2015-212027 |
Claims
1. A graft copolymer (C) obtained by graft-polymerizing one or two
or more monomers (B), which are selected from (meth)acrylic acid
esters, aromatic vinyls, vinyl cyanides, N-substituted maleimides,
and maleic acid, onto a composite rubber-like polymer (A), which is
obtained by polymerizing a mixture (Ac) containing a
polyorganosiloxane (Aa) and an acrylic acid ester (Ab) after
forming a miniemulsion in water solvent.
2. (canceled)
3. (canceled)
4. (canceled)
5. A thermoplastic resin composition comprising: the graft
copolymer (C) according to claim 1; and a thermoplastic resin
(D).
6. (canceled)
7. A molded article obtained by molding the thermoplastic resin
composition according to claim 5.
8. Crosslinked particles (A-I) obtained by polymerizing a monomer
mixture (i-I) containing a di(meth)acrylic acid ester (a) having a
number average molecular weight (Mn) of 800 to 9,000 and
represented by formula (1): ##STR00005## wherein X represents a
divalent residue constituted by at least one diol selected from
polyalkylene glycols, polyester diols, and polycarbonate diols, and
R.sup.1a and R.sup.1b each independently represent H or
CH.sub.3.
9. (canceled)
10. (canceled)
11. The crosslinked particles (A-I) according to claim 8, wherein
the monomer mixture (i-I) contains the di(meth)acrylic acid ester
(a), an aromatic vinyl (b), and a vinyl cyanide (c), and a
proportion of the aromatic vinyl (b) in 100% by mass of a total of
the aromatic vinyl (b) and the vinyl cyanide (c) is 60% to 90% by
mass.
12. (canceled)
13. (canceled)
14. Graft crosslinked particles (B-I) obtained by
graft-polymerizing a monomer onto the crosslinked particles (A-I)
according to claim 8.
15. (canceled)
16. (canceled)
17. A thermoplastic resin composition comprising: the crosslinked
particles (A-I) according to claim 8 and a thermoplastic resin
(D-I).
18. A molded article obtained by molding the thermoplastic resin
composition according to claim 17.
19. Crosslinked particles (A-II) having a volume average particle
size of 0.07 to 2.0 .mu.m and obtained by polymerizing a monomer
mixture (i-II) containing a di(meth)acrylic acid ester (a) and a
mono(meth)acrylic acid component (d), wherein a content of the
di(meth)acrylic acid ester (a) in 100% by mass of the monomer
mixture (i-II) is 20% to 80% by mass, the di(meth)acrylic acid
ester (a) having a number average molecular weight of 800 to 9,000
and being represented by formula (1): ##STR00006## wherein X
represents a divalent residue constituted by at least one diol
selected from polyalkylene glycols, polyester diols, and
polycarbonate diols, and R.sup.1a and R.sup.1b each independently
represent H or CH.sub.3.
20. (canceled)
21. (canceled)
22. (canceled)
23. (canceled)
24. Graft crosslinked particles (B-II) obtained by
graft-polymerizing one or more monomers selected from (meth)acrylic
acid esters, aromatic vinyls, vinyl cyanides, maleimides, and
maleic anhydride onto the crosslinked particles (A-II) according to
claim 19.
25. (canceled)
26. (canceled)
27. A thermoplastic resin composition comprising: the crosslinked
particles (A-II) according to claim 19 and a thermoplastic resin
(D-II).
28. A molded article obtained by molding the thermoplastic resin
composition according to claim 27.
29. A rubbery polymer (A-III) that is a miniemulsion polymerization
reaction product of an alkyl (meth)acrylate.
30. The rubbery polymer (A-III) according to claim 29, wherein the
rubbery polymer (A-III) is a miniemulsion polymerization reaction
product of a mixture (i-III) containing an alkyl (meth)acrylate, a
hydrophobe, and an emulsifier.
31. (canceled)
32. (canceled)
33. A graft copolymer (B-III) comprising: the rubbery polymer
(A-III) according to claim 29; and at least one monomer selected
from aromatic vinyl compounds, (meth)acrylic acid esters, and vinyl
cyanide compounds graft-polymerized onto the rubbery polymer
(A-III).
34. (canceled)
35. (canceled)
36. A thermoplastic resin composition comprising the graft
copolymer (B-III) according to claim 33.
37. A molded article obtained by molding the thermoplastic resin
composition according to claim 36.
38. A graft crosslinked particles (B-I) according to claim 14; and
a thermoplastic resin (D-I).
39. A graft crosslinked particles (B-II) according to claim 24; and
a thermoplastic resin (D-II).
Description
TECHNICAL FIELD
[0001] The present invention relates to first to fourth inventions
below.
[0002] The first invention relates to a graft polymer that has an
excellent impact-resistance-imparting effect and that can provide a
thermoplastic resin composition excellent in weather resistance and
color developability, a production method thereof, a thermoplastic
resin composition including the graft copolymer, and a molded
article thereof.
[0003] The second invention relates to crosslinked particles and
graft crosslinked particles that, as modifiers of a thermoplastic
resin, can improve the flowability, impact resistance, and abrasion
resistance of the resin without impairing its color developability
and mold shrinkage rate, a thermoplastic resin composition
including the crosslinked particles and/or the graft crosslinked
particles, and a molded article thereof.
[0004] The third invention relates to crosslinked particles and
graft crosslinked particles that, as modifiers of a thermoplastic
resin, can improve the flowability, impact resistance, and abrasion
resistance of the resin without impairing its color developability
and weather resistance, a thermoplastic resin composition including
the crosslinked particles and/or the graft crosslinked particles,
and a molded article thereof.
[0005] The fourth invention relates to a rubbery polymer and a
graft copolymer that can provide a molded article excellent in
impact resistance, color developability, and molded appearance and
production methods thereof. The fourth invention also relates to a
thermoplastic resin composition including the graft copolymer and a
molded article thereof.
BACKGROUND ART
Background Art of First Invention
[0006] Improving the impact resistance of a resin material offers
very big industrial advantages such as widening the application of
the material and enabling slimming or upsizing of molded articles.
Various techniques for improving the impact resistance of a resin
material have been studied.
[0007] Conventionally, as a technique for improving the impact
resistance of a resin material, incorporation of a graft polymer
including a rubber-like polymer as represented by an ABS resin into
the resin material has been known.
[0008] ABS resins include diene rubber as a rubber component and
thus have poor weather resistance, and outdoor use of resin
materials reinforced with ABS resins is limited. Various methods of
incorporating a graft polymer having a rubber component other than
diene rubber have been proposed. For example, the use of
polyacrylic acid ester rubber, polyorganosiloxane, or
polydimethylsiloxane-polyacrylic acid ester composite rubber as a
rubber component has been proposed. Of these,
polydimethylsiloxane-acrylic acid ester composite rubber is very
excellent in terms of the balance of impact resistance, weather
resistance, and economical efficiency.
[0009] Polydimethylsiloxane-polyacrylic acid ester composite rubber
is typically produced by adding an acrylic acid ester to an
emulsion of polydimethylsiloxane in one portion or multiple
portions to cause polymerization (PTL 1).
[0010] This method generates not only
polydimethylsiloxane-polyacrylic acid ester composite rubber but
also polydimethylsiloxane and polyacrylic acid ester that have not
been combined together and does not readily provide
polydimethylsiloxane-polyacrylic acid ester composite rubber having
a uniform composition. A resin material including a graft polymer
obtained using the resulting polydimethylsiloxane-polyacrylic acid
ester composite rubber has poor color developability due to the
great difference in refractive index between polydimethylsiloxane
and polyacrylic acid ester.
[0011] In PTL 2, a thermoplastic resin composition whose color
developability is improved by using polydimethylsiloxane-conjugated
diene-acrylic acid ester composite rubber is proposed. This
thermoplastic resin composition has insufficient weather resistance
because conjugated diene is included.
[0012] There has been a need for a graft copolymer that has an
excellent impact-resistance-imparting effect and that can provide a
thermoplastic resin composition that is very excellent in weather
resistance and color developability.
Background Art of Second Invention
[0013] Thermoplastic resins such as styrene-acrylonitrile copolymer
resins, .alpha.-methylstyrene-acrylonitrile copolymer resins, and
styrene-acrylonitrile-phenylmaleimide copolymer resins are widely
used as materials provided with impact resistance, which materials
include graft polymers obtained by graft-polymerizing monomers that
impart compatibility with these resins onto rubbery polymers and
are represented by acrylonitrile-butadiene-styrene (ABS) resins,
acrylonitrile-acrylic rubber-styrene (AAS) resins, etc.
[0014] ABS resins and AAS resins have poor abrasion resistance to
soft cloths such as gauze and cotton work gloves and are prone to
wear.
[0015] As a resin that provides impact resistance and also has
improved abrasion resistance, an acrylonitrile-ethylene
.alpha.-olefin-styrene (AES) resin which includes ethylene
.alpha.-olefin rubber as a rubbery polymer is known.
[0016] In PTL 3, a resin material for sliding that includes a
rubber-toughened styrene resin such as an AES resin and an
inorganic filler is proposed. However, AES resins include
crystalline ethylene components and thus have mold shrinkage rates
higher than those of ABS resins and other resins, and when an AES
resin is transferred to an existing mold used for ABS resins and
other resins, a small molded article is provided. In PTL 3, the
inorganic filler is included in a large amount, and thus impact
resistance is significantly reduced.
Background Art of Third Invention
[0017] Methacrylic resins, polycarbonate resins, polystyrene
resins, alicyclic olefin polymers, etc. are known as transparent
resins. These transparent resins are industrially mass-produced and
are widely used in various fields for their good transparency and
color developability in the case of being colored.
[0018] In interior and exterior parts applications, etc. in the
automotive field, etc., there has recently been a demand for being
usable without paint for a reduction in production cost.
Accordingly, transparent resins that exhibit good color
developability have increasingly been applied.
[0019] In particular, methacrylic resins among transparent resins
have characteristics outstanding in optical properties such as
transparency and surface gloss, mechanical properties, scratch
resistance, weather resistance, etc. However, methacrylic resins
are poor in impact resistance and abrasion resistance to soft
materials such as gauze, and thus, when used without paint, the
thickness of a molded article needs to be large. In addition,
abrasions occur during assembling or car washing.
[0020] As a method for improving the impact resistance and abrasion
resistance of a methacrylic resin, dispersion of a graft copolymer
such as an acrylonitrile-ethylene .alpha.-olefin-styrene (AES)
resin in the methacrylic resin is known (PTL 4). This method
improves impact resistance and abrasion resistance but reduces
transparency and color developability in the case of being
colored.
[0021] A transparent acrylic film including a rubber-containing
polymer made of a specific monomer component is proposed (PTL 5).
The impact resistance and abrasion resistance provided by the
rubber-containing polymer proposed here are insufficient.
Background Art of Fourth Invention
[0022] Thermoplastic resins such as styrene-acrylonitrile copolymer
resins, .alpha.-methylstyrene-acrylonitrile copolymer resins, and
styrene-acrylonitrile-phenylmaleimide copolymer resins are widely
used as materials provided with impact resistance, which materials
include graft copolymers obtained by graft-polymerizing monomers
that impart compatibility with these resins onto rubbery polymers
and are represented by ABS resins, ASA resins, etc. Of these, ASA
resins, which include, as a rubbery polymer, a component such as
alkyl (meth)acrylate rubber which is saturated rubber, can provide
good weather resistance.
[0023] However, ASA resins may disadvantageously result in poor
appearance due to, for example, a reduction in color developability
of a colored molded article or may provide low impact resistance.
For the purpose of improving the balance between poor appearance
and impact resistance, ASA resins composed of acrylic acid ester
rubbery polymers in which rubber particles having different
particle size distributions are combined are proposed (PTLs 6 to
8).
[0024] To offset the disadvantages of ASA resins, a thermoplastic
resin composition in which an AES resin including an
ethylene-propylene rubber component and an ASA resin are used in
combination is proposed (PTL 9).
[0025] The thermoplastic resin composition described above is
insufficient in any of impact resistance, weather resistance, color
developability, and molded appearance and cannot sufficiently meet
the recent strong need.
[0026] To improve impact resistance, a graft copolymer obtained by
seeded polymerization using a rubber having a uniform particle size
is proposed, but it is difficult to prepare rubber particles of 200
nm or more, and the impact-resistance-improving effect is not
sufficient (PTL 10).
[0027] PTL 1: Japanese Patent Publication H1-190746 A
[0028] PTL 2: Japanese Patent Publication 2002-80684 A
[0029] PTL 3: Japanese Patent Publication 2011-178831 A
[0030] PTL 4: Japanese Patent Publication 2005-132970 A
[0031] PTL 5: Japanese Patent Publication 2012-144714 A
[0032] PTL 6: Japanese Patent Publication S59-232138 A
[0033] PTL 7: Japanese Patent Publication H04-225051 A
[0034] PTL 8: Japanese Patent Publication H08-134312 A
[0035] PTL 9: Japanese Patent Publication 2004-346187 A
[0036] PTL 10: Japanese Patent Publication 2000-344841 A
SUMMARY OF INVENTION
[0037] An object of the first invention is to provide a graft
copolymer that has an excellent impact-resistance-imparting effect
and that can provide a thermoplastic resin composition excellent in
weather resistance and color developability, a production method
thereof, a thermoplastic resin composition including the graft
copolymer, and a molded article thereof.
[0038] Inventors of the first invention have found that the
problems described above can be solved by producing
polyorganosiloxane-polyacrylic acid ester composite rubber used for
a graft copolymer by a specific technique.
[0039] The first invention is summarized as described below.
[0040] [1] A graft copolymer (C) obtained by graft-polymerizing one
or two or more monomers (B), which are selected from (meth)acrylic
acid esters, aromatic vinyls, vinyl cyanides, N-substituted
maleimides, and maleic acid, onto a composite rubber-like polymer
(A), which is obtained by polymerizing a mixture (Ac) containing a
polyorganosiloxane (Aa) and an acrylic acid ester (Ab) after
forming a miniemulsion in water solvent.
[0041] [2] The graft copolymer (C) according to [1], wherein the
polyorganosiloxane (Aa) has a refractive index of 1.470 to
1.600.
[0042] [3] The graft copolymer (C) according to [1] or [2], wherein
the composite rubber-like polymer (A) has an average particle size
of 10 to 2000 nm.
[0043] [4] A method for producing the graft copolymer (C) according
to any one of [1] to [3], the method comprising: a step of
miniemulsifying the mixture (Ac) containing the polyorganosiloxane
(Aa) and the acrylic acid ester (Ab) in water solvent in the
presence of a hydrophobic stabilizer and an emulsifier; and a step
of polymerizing the resulting miniemulsion.
[0044] [5] A thermoplastic resin composition comprising: the graft
copolymer (C) according to any one of [1] to [3]; and a
thermoplastic resin (D).
[0045] [6] The thermoplastic resin composition according to [5],
wherein a refractive index difference between the composite
rubber-like polymer (A) in the graft copolymer (C) and the
thermoplastic resin (D) is 0.02 or less.
[0046] [7] A molded article obtained by molding the thermoplastic
resin composition according to [5] or [6].
[0047] An object of the second invention is to provide crosslinked
particles and graft crosslinked particles that, as modifiers of a
thermoplastic resin, can improve the flowability, impact
resistance, and abrasion resistance of the resin without impairing
its color developability and mold shrinkage rate, a thermoplastic
resin composition including the crosslinked particles and/or the
graft crosslinked particles, and a molded article thereof.
[0048] Inventors of the second invention have found that the
above-described problems can be solved by crosslinked particles
obtained by polymerization using a di(meth)acrylic acid ester
having a specific molecular weight as a crosslinking agent and,
furthermore, by graft crosslinked particles obtained by
graft-polymerizing a monomer onto the crosslinked particles.
[0049] The second invention is summarized as described below.
[0050] [8] Crosslinked particles (A-I) obtained by polymerizing a
monomer mixture (i-I) containing a di(meth)acrylic acid ester (a)
having a number average molecular weight (Mn) of 800 to 9,000 and
represented by formula (1):
##STR00001##
[0051] wherein X represents a divalent residue constituted by at
least one diol selected from polyalkylene glycols, polyester diols,
and polycarbonate diols, and R.sup.1a and R.sup.1b each
independently represent H or CH.sub.3.
[0052] [9] The crosslinked particles (A-I) according to [8],
wherein the X is a polytetramethylene glycol residue.
[0053] [10] The crosslinked particles (A-I) according to [8] or
[9], wherein a content of the di(meth)acrylic acid ester (a) in the
monomer mixture (i-I) is 0.1% to 90% by mass.
[0054] [11] The crosslinked particles (A-I) according to any one of
[8] to [10], wherein the monomer mixture (i-I) contains the
di(meth)acrylic acid ester (a), an aromatic vinyl (b), and a vinyl
cyanide (c), and a proportion of the aromatic vinyl (b) in 100% by
mass of a total of the aromatic vinyl (b) and the vinyl cyanide (c)
is 60% to 90% by mass.
[0055] [12] The crosslinked particles (A-I) according to any one of
[8] to [11], wherein the crosslinked particles (A-I) have an
average particle size of 0.07 to 5.0 .mu.m.
[0056] [13] A method for producing the crosslinked particles (A-I)
according to any one of [8] to [12], the method comprising: a step
of miniemulsifying the monomer mixture (i-I) containing the
di(meth)acrylic acid ester (a) in water solvent in the presence of
a hydrophobic stabilizer and an emulsifier; and a step of
polymerizing the resulting miniemulsion.
[0057] [14] Graft crosslinked particles (B-I) obtained by
graft-polymerizing a monomer onto the crosslinked particles (A-I)
according to any one of [8] to [12].
[0058] [15] The graft crosslinked particles (B-I) according to
[14], wherein the graft crosslinked particles (B-I) are obtained by
graft-polymerizing 10% to 60% by mass of the monomer onto 40% to
90% by mass of the crosslinked particles (A-I) (provided that a
total amount of the crosslinked particles (A-I) and the monomer is
100% by mass), the monomer includes at least an aromatic vinyl and
a vinyl cyanide, and a proportion of the aromatic vinyl in 100% by
mass of a total of the aromatic vinyl and the vinyl cyanide is 60%
to 99% by mass.
[0059] [16] The graft crosslinked particles (B-I) according to [14]
or [15], wherein the graft crosslinked particles (B-I) have a graft
rate of 23% to 100%.
[0060] [17] A thermoplastic resin composition comprising: the
crosslinked particles (A-I) according to any one of [8] to [12]
and/or the graft crosslinked particles (B-I) according to any one
of claims 14 to 16; and a thermoplastic resin (D-I).
[0061] [18] A molded article obtained by molding the thermoplastic
resin composition according to [17].
[0062] An object of the third invention is to provide crosslinked
particles and graft crosslinked particles that, as modifiers of a
thermoplastic resin, can improve the flowability, impact
resistance, and abrasion resistance of the resin without impairing
its color developability and weather resistance, a thermoplastic
resin composition including the crosslinked particles and/or the
graft crosslinked particles, and a molded article thereof.
[0063] Inventors of the third invention have found that the
above-described problems can be solved by crosslinked particles
obtained by polymerization using a di(meth)acrylic acid ester
having a specific molecular weight as a crosslinking agent and,
furthermore, by graft crosslinked particles obtained by
graft-polymerizing a monomer onto the crosslinked particles.
[0064] The third invention is summarized as described below.
[0065] [19] Crosslinked particles (A-II) having a volume average
particle size of 0.07 to 2.0 .mu.m and obtained by polymerizing a
monomer mixture (i-II) containing a di(meth)acrylic acid ester (a)
and a mono(meth)acrylic acid component (d), wherein a content of
the di(meth)acrylic acid ester (a) in 100% by mass of the monomer
mixture (i-II) is 20% to 80% by mass, the di(meth)acrylic acid
ester (a) having a number average molecular weight of 800 to 9,000
and being represented by formula (1):
##STR00002##
[0066] wherein X represents a divalent residue constituted by at
least one diol selected from polyalkylene glycols, polyester diols,
and polycarbonate diols, and R.sup.1a and R.sup.1b each
independently represent H or CH.sub.3.
[0067] [20] The crosslinked particles (A-II) according to [19],
wherein the monomer mixture (i-II) contains at least styrene as an
additional vinyl compound (e).
[0068] [21] The crosslinked particles (A-II) according to [19] or
[20], wherein the X is a polytetramethylene glycol residue.
[0069] [22] The crosslinked particles (A-II) according to any one
of [19] to [21], wherein a content of the mono(meth)acrylic acid
ester (d) in the monomer mixture (i-II) is 1% to 80% by mass.
[0070] [23] A method for producing the crosslinked particles (A-II)
according to any one of [19] to [22], the method comprising: a step
of miniemulsifying the monomer mixture (i-II) containing the
di(meth)acrylic acid ester (a) and the mono(meth)acrylic acid
component (d) in water solvent in the presence of a hydrophobic
stabilizer and an emulsifier; and a step of polymerizing the
resulting miniemulsion.
[0071] [24] Graft crosslinked particles (B-II) obtained by
graft-polymerizing one or more monomers selected from (meth)acrylic
acid esters, aromatic vinyls, vinyl cyanides, maleimides, and
maleic anhydride onto the crosslinked particles (A-II) according to
any one of [19] to [22].
[0072] [25] The graft crosslinked particles (B-II) according to
[24], wherein the graft crosslinked particles (B-II) are obtained
by graft-polymerizing 10% to 60% by mass of the monomer onto 40% to
90% by mass of the crosslinked particles (A-II) (provided that a
total amount of the crosslinked particles (A-II) and the monomer is
100% by mass), the monomer includes at least methyl methacrylate
and methyl acrylate, and a proportion of the methyl methacrylate in
100% by mass of a total of the methyl methacrylate and the methyl
acrylate is 90% to 99.9% by mass.
[0073] [26] The graft crosslinked particles (B-II) according to
[24] or [25], wherein the graft crosslinked particles (B-II) have a
graft rate of 23% to 100%.
[0074] [27] A thermoplastic resin composition comprising: the
crosslinked particles (A-II) according to any one of [19] to 22
and/or the graft crosslinked particles (B-II) according to any one
of [23] to [26]; and a thermoplastic resin (D-II).
[0075] [28] A molded article obtained by molding the thermoplastic
resin composition according to [27].
[0076] An object of the fourth invention is to provide a rubbery
polymer and a graft copolymer that can provide a thermoplastic
resin molded article excellent in impact resistance, color
developability, and molded appearance, production methods thereof,
a thermoplastic resin composition including the graft copolymer,
and a molded article thereof.
[0077] Inventors of the fourth invention have found that the above
object can be achieved by a graft copolymer obtained using a
rubbery polymer obtained by miniemulsion polymerization of a
mixture containing an alkyl (meth)acrylate, a hydrophobe, and an
emulsifier.
[0078] The fourth invention is summarized as described below.
[0079] [29] A rubbery polymer (A-III) that is a miniemulsion
polymerization reaction product of an alkyl (meth)acrylate.
[0080] [30] The rubbery polymer (A-III) according to [29], wherein
the rubbery polymer (A-III) is a miniemulsion polymerization
reaction product of a mixture (i-III) containing an alkyl
(meth)acrylate, a hydrophobe, and an emulsifier.
[0081] [31] The rubbery polymer (A-III) according to [30], wherein
the mixture (i-III) further contains a crosslinking agent.
[0082] [32] The rubbery polymer (A-III) according to any one of
[29] to [31], wherein when an average particle size (X) is
represented by X; a largest 10% frequency particle size (Y), which
is a particle size at which a cumulative frequency from a largest
value in a particle size distribution curve reaches 10%, is
represented by Y; and a smallest 10% frequency particle size (Z),
which is a particle size at which a cumulative frequency from a
smallest value in the particle size distribution curve reaches 10%,
is represented by Z, the average particle size (X), the largest 10%
frequency particle size (Y), and the smallest 10% frequency
particle size (Z) satisfy (2) or (3) below:
[0083] (2) The average particle size (X) satisfies X.ltoreq.300 nm,
the largest 10% frequency particle size (Y) satisfies
Y.ltoreq.1.6X, and the smallest 10% frequency particle size (Z)
satisfies Z.gtoreq.0.7X; or
[0084] (3) The average particle size (X) satisfies X=300 to 800 nm,
the largest 10% frequency particle size (Y) satisfies
Y.ltoreq.1.7X, and the smallest 10% frequency particle size (Z)
satisfies Z.gtoreq.0.6X.
[0085] [33] A graft copolymer (B-III) comprising: the rubbery
polymer (A-III) according to any one of [29] to [32]; and at least
one monomer selected from aromatic vinyl compounds, (meth)acrylic
acid esters, and vinyl cyanide compounds graft-polymerized onto the
rubbery polymer (A-III).
[0086] [34] A method for producing the rubbery polymer (A-III)
according to any one of [29] to [32], the method comprising: a step
of miniemulsifying the mixture (i-III) containing an alkyl
(meth)acrylate, a hydrophobe, and an emulsifier; and a step of
polymerizing the resulting miniemulsion.
[0087] [35] A method for producing the graft copolymer (B-III)
according to [33], the method comprising: a step of miniemulsifying
the mixture (i-III) containing an alkyl (meth)acrylate, a
hydrophobe, and an emulsifier; a step of polymerizing the resulting
miniemulsion; and a step of graft-polymerizing at least one monomer
selected from aromatic vinyl compounds, (meth)acrylic acid esters,
and vinyl cyanide compounds onto the resulting rubbery polymer
(A-III).
[0088] [36] A thermoplastic resin composition comprising the graft
copolymer (B-III) according to [33].
[0089] [37] A molded article obtained by molding the thermoplastic
resin composition according to [36].
Advantageous Effects of Invention
[0090] By incorporating the graft copolymer of the first invention
into a thermoplastic resin, a thermoplastic resin composition
excellent in weather resistance and color developability as well as
in impact resistance and a molded article thereof can be
achieved.
[0091] According to the crosslinked particles and the graft
crosslinked particles of the second invention, the flowability,
impact resistance, and abrasion resistance of a thermoplastic resin
can be improved without impairing its color developability and mold
shrinkage rate, and a thermoplastic resin composition excellent in
flowability, color developability, dimensional stability, shape
accuracy, impact resistance, and abrasion resistance and a molded
article thereof can be provided.
[0092] According to the crosslinked particles and the graft
crosslinked particles of the third invention, the flowability,
impact resistance, and abrasion resistance of a thermoplastic resin
can be improved without impairing its color developability and
weather resistance, and a thermoplastic resin composition excellent
in all characteristics: flowability, color developability, weather
resistance, impact resistance, and abrasion resistance, and a
molded article thereof can be provided.
[0093] According to the rubbery polymer and the graft copolymer of
the fourth invention, a thermoplastic resin composition and a
molded article that are excellent in impact resistance, molded
appearance, and color developability can be provided.
BRIEF DESCRIPTION OF DRAWING
[0094] FIG. 1 illustrates a method for evaluating abrasion
resistance in EXAMPLES.
DESCRIPTION OF EMBODIMENTS
[0095] An embodiment of the first invention will now be described
in detail.
[0096] In this description, "(meth)acrylic" means one or both of
"acrylic" and "methacrylic". The same applies to
"(meth)acrylate".
[0097] "Molded article" means a substance obtained by molding a
thermoplastic resin composition.
Embodiment of First Invention
[Graft Copolymer (C)]
[0098] A graft copolymer (C) of the first invention is obtained by
graft-polymerizing one or two or more monomers (B) selected from
(meth)acrylic acid esters, aromatic vinyls, vinyl cyanides,
N-substituted maleimides, and maleic acid onto a composite
rubber-like polymer (A) (hereinafter also referred to as "the
composite rubber-like polymer (A) of the first invention") obtained
by miniemulsifying a mixture (Ac) containing a polyorganosiloxane
(Aa) and an acrylic acid ester (Ab) in water solvent and then
polymerizing the polyorganosiloxane (Aa) and the acrylic acid ester
(Ab) in the miniemulsion.
[0099] By polymerizing the mixture (Ac) of the polyorganosiloxane
(Aa) and the acrylic acid ester (Ab) after being miniemulsified,
the composition of each of the resulting composite rubber-like
polymer (A) particles tends to be uniform. A thermoplastic resin
composition obtained by incorporating the graft copolymer (C)
produced using the composite rubber-like polymer (A) has improved
color developability.
[0100] In commonly used emulsion polymerization in which the
mixture (Ac) and a radical initiator are added in the presence of
water solvent and an emulsifier to cause polymerization and in
seeded polymerization as described in PTL 1 in which an acrylic
acid ester is added in the presence of an emulsion of a
polyorganosiloxane to cause polymerization, the composition of
composite rubber-like polymer particles is unlikely to be uniform,
and, in some cases, particles of the polyorganosiloxane alone or of
the polyacrylic acid ester alone are formed. A graft copolymer
obtained using such a composite rubber-like polymer provides a
thermoplastic resin composition having poor color
developability.
[0101] The first invention is characterized by producing the
composite rubber-like polymer (A) by a miniemulsion polymerization
method including two steps: a step of miniemulsifying the mixture
(Ac) of the polyorganosiloxane (Aa) and the acrylic acid ester (Ab)
and a subsequent polymerization step.
[0102] <Composite Rubber-Like Polymer (A)>
[0103] The composite rubber-like polymer (A) of the first invention
is obtained by polymerizing the mixture (Ac) containing the
polyorganosiloxane (Aa) and the acrylic acid ester (Ab) after
forming a miniemulsion in water solvent.
[0104] <<Polyorganosiloxane (Aa)>>
[0105] The polyorganosiloxane (Aa) in the first invention is a
polymer whose main chain is a siloxane unit which is a
silicon-oxygen bond, and the polyorganosiloxane (Aa) has two
organic groups (including hydrogen atoms) on a silicon atom.
[0106] Examples of the organic groups on the silicon atom of the
polyorganosiloxane (Aa) include, but are not limited to, a hydrogen
atom, an alkyl group, an aryl group, a vinyl group, an amino group,
an epoxy group, an alicyclic epoxy group, a mercapto group, and a
carboxyl group. As the organic groups, alkyl groups having 1 to 6
carbon atoms, a vinyl group, and an aryl group are particularly
preferred. The polyorganosiloxane (Aa) may have only one of these
organic groups or may have two or more of them.
[0107] The viscosity of the polyorganosiloxane (Aa) is not
particularly limited as long as the mixture (Ac) can be obtained by
mixing the polyorganosiloxane (Aa) with the acrylic acid ester
(Ab). When the viscosity of the polyorganosiloxane (Aa) is oily,
such as 10 to 10000 mm.sup.2/s, preferably 100 to 5000 mm.sup.2/s,
the production stability of the composite rubber-like polymer (A)
tends to be excellent. The viscosity of the polyorganosiloxane (Aa)
is a value measured at 25.degree. C. using a kinematic
viscometer.
[0108] The refractive index of the polyorganosiloxane (Aa) is not
particularly limited but preferably in the range of 1.470 to 1.600
for the following reasons. When the graft copolymer (C) of the
first invention is incorporated into a thermoplastic resin (D) to
obtain a thermoplastic resin composition, the thermoplastic resin
composition obtained has good color developability if the
refractive index of the thermoplastic resin (D) and the refractive
index of the composite rubber-like polymer (A) in the graft
copolymer (C) close to each other. The refractive index of the
below-described thermoplastic resin (D) used for a thermoplastic
resin composition of the first invention is in the range of 1.470
to 1.600 in many cases. Therefore, the refractive index of the
polyorganosiloxane (Aa) is preferably in the range of 1.470 to
1.600. Although it depends, for example, on the conditions for
producing the composite rubber-like polymer (A), when the
refractive index of the polyorganosiloxane (Aa) is in the range of
1.470 to 1.600, the composite rubber-like polymer (A) having a
refractive index of about 1.460 to 1.590, which is close to the
refractive index of the thermoplastic resin (D), can be
produced.
[0109] When the difference in refractive index between the
composite rubber-like polymer (A) of the first invention and the
thermoplastic resin (D) is 0.02 or less and the thermoplastic resin
(D) has transparency, a thermoplastic resin composition having
particularly good color developability is provided, and, in
addition, the transparency of the thermoplastic resin composition
also tends to be high unless a color is imparted, for example, by
the blending of a colorant. Also for the reason that the difference
in refractive index between the composite rubber-like polymer (A)
and the thermoplastic resin (D) is likely to be 0.02 or less, the
refractive index of the polyorganosiloxane (Aa) is preferably 1.470
to 1.600.
[0110] When the polyorganosiloxane (Aa) has one or more aryl groups
as organic groups, the refractive index of the polyorganosiloxane
(Aa) tends to be in the range of 1.470 to 1.600.
[0111] Examples of aryl groups include a phenyl group, a naphthyl
group, an alkyl nuclear-substituted phenyl group, an alkyl
nuclear-substituted naphthyl group, a halogen nuclear-substituted
phenyl group, and a halogen nuclear-substituted naphthyl group, and
preferred are a phenyl group and a nuclear-substituted phenyl
group. Examples of alkyl groups of the alkyl nuclear-substituted
phenyl group and the alkyl nuclear-substituted naphthyl group
include alkyl groups having 1 to 12 carbon atoms.
[0112] Examples of the polyorganosiloxane (Aa) having an aryl group
include industrially available products such as "KF-53", "KF-54",
"X-21-3265", "KF-54SS", "KF-56", "HIVAC-F-4", and "HIVAC-F-5"
available from Shin-Etsu Chemical Co., Ltd.
[0113] The refractive index of the polyorganosiloxane (Aa) can be
measured similarly to the refractive index of the composite
rubber-like polymer (A), which will be described in the section of
EXAMPLES below. For commercially available products, catalogue
values can be employed.
[0114] The polyorganosiloxane (Aa) may be used alone or as a
mixture of two or more.
[0115] <<Acrylic Acid Ester (Ab)>>
[0116] Examples of the acrylic acid ester (Ab) in the first
invention include acrylic acid alkyl esters having alkyl groups of
1 to 12 carbon atoms; and acrylic acid aryl esters having aromatic
hydrocarbon groups such as a phenyl group and a benzyl group. The
alkyl groups of the acrylic acid alkyl esters and the aryl groups
of the acrylic acid aryl ester may be substituted with substituents
such as a hydroxyl group.
[0117] Specific examples of the acrylic acid ester (Ab) include
methyl acrylate, ethyl acrylate, n-propyl acrylate, i-propyl
acrylate, n-butyl acrylate, i-butyl acrylate, t-butyl acrylate,
amyl acrylate, isoamyl acrylate, octyl acrylate, 2-ethylhexyl
acrylate, decyl acrylate, lauryl acrylate, stearyl acrylate, lauryl
acrylate, stearyl acrylate, cyclohexyl acrylate, pentyl acrylate,
phenyl acrylate, benzyl acrylate, 2-hydroxyethyl acrylate, and
2-hydroxypropyl acrylate. Of these, n-butyl acrylate, 2-ethylhexyl
acrylate, and ethyl acrylate are preferred.
[0118] The acrylic acid ester (Aa) may be used alone or as a
mixture of two or more.
[0119] The amount of the acrylic acid ester (Ab) used in the
production of the composite rubber-like polymer (A) of the first
invention is preferably 10% to 99% by mass, particularly preferably
20% to 95% by mass, relative to 100% by mass of the total of the
polyorganosiloxane (Aa) and the acrylic acid ester (Ab). When the
amount of the acrylic acid ester (Ab) used is in the above range,
the thermoplastic resin composition obtained by incorporating the
graft copolymer (C) of the first invention is provided with good
color developability and good impact resistance.
[0120] <Polyfunctional Compound>
[0121] A polyfunctional compound may optionally be added to the
mixture (Ac) containing the polyorganosiloxane (Aa) and the acrylic
acid ester (Ab) used to produce the composite rubber-like polymer
(A) of the first invention. Due to the addition of a polyfunctional
compound, the thermoplastic resin composition obtained by
incorporating the graft copolymer (C) of the first invention is
provided with good color developability and good impact
resistance.
[0122] The polyfunctional compound has two or more carbon-carbon
double bonds in its molecule and is not particularly limited.
Examples of polyfunctional compounds include divinylbenzene, allyl
(meth)acrylate, ethylene glycol di(meth)acrylate, propylene glycol
di(meth)acrylate, 1,3-butylene di(meth)acrylate, 1,4-butylene
glycol di(meth)acrylate, tetraethylene glycol di(meth)acrylate,
tetradecaethylene glycol di(meth)acrylate, triallyl cyanurate,
triallyl isocyanurate, and pentaerythritol tetra(meth)acrylate.
[0123] The polyfunctional compounds may be used alone or in a
combination of two or more.
[0124] The polyfunctional compound can be used so as to replace
part of the acrylic acid ester (Ab) in the mixture (Ac) containing
the polyorganosiloxane (Aa) and the acrylic acid ester (Ab). The
polyfunctional compound is preferably added so as to replace 0.1%
to 5% by mass, particularly 0.2% to 3% by mass, and especially 0.5%
to 2% by mass of the acrylic acid ester (Ab) (100% by mass) since
the thermoplastic resin composition obtained by incorporating the
graft copolymer (C) of the first invention is provided with good
impact resistance.
[0125] <<Method for Producing Composite Rubber-Like Polymer
(A)>>
[0126] The composite rubber-like polymer (A) of the first invention
is obtained by what is called miniemulsion polymerization in which
the mixture (Ac) containing the polyorganosiloxane (Aa), the
acrylic acid ester (Ab), and optionally a polyfunctional compound
is sheared in water solvent in the presence of an emulsifier,
preferably in the presence of an emulsifier and a hydrophobic
stabilizer, to form a miniemulsion and then the miniemulsion is
copolymerized in the presence of a radical initiator. The radical
initiator may be added before or after the miniemulsion is formed
and may be added in one portion, in multiple portions, or in a
continuous manner.
[0127] From the viewpoint of workability, stability, production
efficiency, etc., the amount of water solvent used in the
miniemulsification is preferably about 100 to 500 parts by mass
relative to 100 parts by mass of the mixture (Ac).
[0128] As a method for applying shear in forming the miniemulsion,
any known method can be used. The shear may be applied in one
portion, in multiple portions, in a continuous manner, or in a
circular manner. In general, the miniemulsion can be formed by
using a high shear device that forms droplets having diameters of
about 10 to 2000 nm.
[0129] Examples of usable high shear devices that form
miniemulsions include, but are not limited to, emulsification
devices including high-pressure pumps and interaction chambers and
devices that form miniemulsions with ultrasonic energy or a high
frequency. Examples of emulsification devices including
high-pressure pumps and interaction chambers include
"Microfluidizer" available from Powrex corp. Examples of devices
that form miniemulsions with ultrasonic energy or a high frequency
include "Sonic Dismembrator" available from Fisher Scient and
"ULTRASONIC HOMOGENIZER" available from Nihonseiki Kaisha Ltd.
[0130] Examples of emulsifiers include anionic surfactants,
nonionic surfactants, and amphoteric surfactants. Examples of
emulsifiers include anionic surfactants such as sulfates of higher
alcohols, alkylbenzene sulfonates, fatty acid sulfonates,
phosphates (e.g., ammonium monoglyceride phosphate), fatty acid
salts (e.g., dipotassium alkenyl succinate), and salts of amino
acid derivatives; commonly used nonionic surfactants such as
alkyl-ester-type polyethylene glycol surfactants, alkyl-ether-type
polyethylene glycol surfactants, and alkylphenyl-ether-type
polyethylene glycol surfactants; and amphoteric surfactants having
carboxylates, sulfates, sulfonates, phosphates, and the like as
anionic moieties and amine salts, quarternary ammonium salts, and
the like as cationic moieties. The emulsifiers may be used alone or
in a combination of two or more.
[0131] The addition amount of emulsifier is typically 10 parts by
mass or less, preferably, for example, 0.01 to 10 parts by mass,
relative to 100 parts by mass of the mixture (Ac).
[0132] When the miniemulsion is formed, adding a hydrophobic
stabilizer tends to further improve the production stability of the
miniemulsion. Examples of hydrophobic stabilizers include
unpolymerizable hydrophobic compounds, for example, hydrocarbons
having 10 to 30 carbon atoms, alcohols having 10 to 30 carbon
atoms, hydrophobic polymers having mass average molecular weights
(Mw) of less than 10000, tetraalkylsilanes, hydrophobic monomers,
for example, vinyl esters of alcohols having 10 to 30 carbon atoms,
carboxylic acid vinyl esters having 10 to 30 carbon atoms,
(meth)acrylic acid esters having 8 to 30 carbon atoms,
p-alkylstyrenes, hydrophobic chain transfer agents, and hydrophobic
peroxides. The hydrophobic stabilizers may be used alone or as a
mixture of two or more.
[0133] Specific examples of the hydrophobic stabilizer include
decane, undecane, dodecane, tridecane, tetradecane, pentadecane,
hexadecane, olive oil, polystyrenes having mass average molecular
weights (Mw) of 500 to 5000, siloxanes having mass average
molecular weights (Mw) of 500 to 5000, cetyl alcohol, stearyl
alcohol, palmityl alcohol, behenyl alcohol, p-methylstyrene,
2-ethylhexyl acrylate, decyl acrylate, stearyl acrylate, lauryl
methacrylate, stearyl methacrylate, lauryl mercaptan (normal
dodecyl mercaptan), and hydrophobic peroxides such as lauroyl
peroxide.
[0134] When a hydrophobic stabilizer is used, the amount thereof is
preferably 0.05 to 5 parts by mass relative to 100 parts by mass of
the mixture (Ac). When the addition amount of hydrophobic
stabilizer is not less than the above lower limit, the production
stability of the composite rubber-like polymer (A) can be further
improved. When the addition amount of hydrophobic stabilizer is not
more than the above upper limit, there is a tendency that the color
developability and impact resistance of a thermoplastic resin
composition obtained by incorporating the graft copolymer (C) of
the first invention can be good.
[0135] As a radical initiator used in the polymerization step
subsequent to the miniemulsification step, a known one can be used.
Examples of radical initiators include azo polymerization
initiators, photopolymerization initiators, inorganic peroxides,
organic peroxides, and redox initiators containing organic
peroxides, transition metals, and reducing agents in combination.
Of these, azo polymerization initiators, inorganic peroxides,
organic peroxides, and redox initiators, which are capable of
initiating polymerization upon heating, are preferred. The radical
initiators may be used alone or in a combination of two or
more.
[0136] Examples of azo polymerization initiators include
2,2'-azobis(4-methoxy-2,4-dimethylvaleronitrile),
2,2'-azobis(2,4-dimethylvaleronitrile),
2,2'-azobisisobutyronitrile, 2,2'-azobis(2-methylbutyronitrile),
1,1'-azobis(cyclohexane-1-carbonitrile),
1-[(1-cyano-1-methylethyl)azo]formamide, 4,4'-azobis(4-cyanovaleric
acid), dimethyl 2,2'-azobis(2-methyl propionate), dimethyl
1,1'-azobis(1-cychloexanecarboxylate),
2,2'-azobis[2-methyl-N-(2-hydroxyethyl)propionamide],
2,2'-azobis(N-butyl-2-methylpropionamide),
2,2'-azobis(N-cyclohexyl-2-methylpropionamide),
2,2'-azobis[2-(2-imidazolin-2-yl)propane], and
2,2'-azobis(2,4,4-trimethylpentane).
[0137] Examples of inorganic peroxides include potassium
persulfate, sodium persulfate, ammonium persulfate, and hydrogen
peroxide.
[0138] Examples of organic peroxides include peroxyester compounds.
Specific examples thereof include
.alpha.,.alpha.'-bis(neodecanoylperoxy)diisopropylbenzene, cumyl
peroxyneodecanoate, 1,1,3,3-tetramethylbutyl peroxyneodecanoate,
1-cyclohexyl-1-methylethyl peroxyneodecanoate, t-hexyl
peroxyneodecanoate, t-butyl peroxyneodecanoate, t-hexyl
peroxypivalate, t-butyl peroxypivalate, 1,1,3,3-tetramethylbutyl
peroxy-2-ethylhexanoate,
2,5-dimethyl-2,5-bis(2-ethylhexanoylperoxy)hexane,
1-cyclohexyl-1-methylethyl peroxy-2-ethylhexanoate, t-hexyl
peroxy-2-hexylhexanoate, t-butyl peroxy-2-hexylhexanoate, t-butyl
peroxyisobutyrate, t-hexyl peroxyisopropylmonocarbonate, t-butyl
peroxymaleic acid, t-butyl peroxy-3,5,5-trimethylhexanoate, t-butyl
peroxylaurate, 2,5-dimethyl-2,5-bis(m-toluoylperoxy)hexane, t-butyl
peroxyisopropylmonocarbonate, t-butyl
peroxy-2-ethylhexylmonocarbonate, t-hexyl peroxybenzoate,
2,5-dimethyl-2,5-bis(benzoylperoxy)hexane, t-butyl peroxyacetate,
t-butyl peroxy-m-toluoylbenzoate, t-butyl peroxybenzoate,
bis(t-butylperoxy) isophthalate,
1,1-bis(t-hexylperoxy)3,3,5-trimethylcyclohexane,
1,1-bis(t-hexylperoxy)cyclohexane,
1,1-bis(t-butylperoxy)3,3,5-trimethylcyclohexane,
1,1-bis(t-butylperoxy)cyclohexane,
1,1-bis(t-butylperoxy)cyclododecane, 2,2-bis(t-butylperoxy)butane,
n-butyl 4,4-bis(t-butylperoxy)valerate,
2,2-bis(4,4-di-t-butylperoxycyclohexyl)propane,
.alpha.,.alpha.'-bis(t-butylperoxide)diisopropylbenzene, dicumyl
peroxide, 2,5-dimethyl-2,5-bis(t-butylperoxy)hexane, t-butyl cumyl
peroxide, di-t-butylperoxide, cumene hydroperoxide,
diisopropylbenzene hydroperoxide, t-butyl hydroperoxide, benzoyl
peroxide, lauroyl peroxide, dimethylbis(t-butylperoxy)hexyne-3,
bis(t-butylperoxyisopropyl)benzene,
bis(t-butylperoxy)trimethylcyclohexane, butyl-bis(t-butylperoxy)
valerate, t-butyl peroxy-2-ethylhexanoate, dibenzoyl peroxide,
paramenthane hydroperoxide, and t-butyl peroxybenzoate.
[0139] As a redox initiator, a combination of an organic peroxide,
ferrous sulfate, a chelating agent, and a reducing agent is
preferred. Examples include a combination of cumene hydroperoxide,
ferrous sulfate, sodium pyrophosphate, and dextrose and a
combination of t-butyl hydroperoxide, sodium formaldehyde
sulfoxylate (Rongalite), ferrous sulfate, and disodium
ethylenediaminetetraacetate.
[0140] The addition amount of radical initiator is typically 5
parts by mass or less, preferably 3 parts by mass or less, for
example 0.001 to 3 parts by mass, relative to 100 parts by mass of
the acrylic acid ester (Ab) (in the case where a polyfunctional
compound is used, the total of the acrylic acid ester (Ab) and the
polyfunctional compound). As described above, the radical initiator
may be added before or after the miniemulsion is formed and may be
added in one portion, in multiple portions, or in a continuous
manner.
[0141] In the production of the composite rubber-like polymer (A),
a chain transfer agent may optionally be added. Examples of chain
transfer agents include mercaptans (e.g., octyl mercaptan, n- or
t-dodecyl mercaptan, n-hexadecyl mercaptan, n- or t-tetradecyl
mercaptan), allyl compounds (allyl sulfonic acid, methallyl
sulfonic acid, and sodium salts thereof), and .alpha.-methylstyrene
dimers. The chain transfer agents may be used alone or in a
combination of two or more. Preferred chain transfer agents are
mercaptans in terms of ease of control of molecular weight.
[0142] When a chain transfer agent is used, it may be added in one
portion, in multiple portions, or in a continuous manner. The
addition amount of chain transfer agent is typically 2.0 parts by
mass or less, preferably, for example, 0.01 to 2.0 parts by mass,
relative to 100 parts by mass of the acrylic acid ester (Ab) (in
the case where a polyfunctional compound is used, the total of the
acrylic acid ester (Ab) and the polyfunctional compound).
[0143] The polymerization step subsequent to the miniemulsification
step is typically performed at 40.degree. C. to 95.degree. C. for
about 0.5 to 8 hours following the miniemulsification step.
[0144] The particle size (average particle size) of the composite
rubber-like polymer (A) of the first invention produced through the
above-described miniemulsification step and the subsequent
polymerization step is preferably 10 to 2000 nm, more preferably 60
to 1000 nm, particularly preferably 80 to 600 nm. When the particle
size of the composite rubber-like polymer (A) is in the above
range, the thermoplastic resin composition obtained by
incorporating the graft copolymer (C) of the first invention tends
to have good impact resistance.
[0145] The particle size of the composite rubber-like polymer (A)
may be controlled by any method, for example, by adjusting the type
or amount of emulsifier used and the shear force during the
production of the miniemulsion.
[0146] Specifically, the average particle size of the composite
rubber-like polymer (A) is measured by the method described in the
section of EXAMPLES below.
[0147] <Monomer (B)>
[0148] The graft copolymer (C) of the first invention is obtained
by graft-polymerizing a monomer (B) onto the composite rubber-like
polymer (A) produced as described above.
[0149] The monomer (B) is one or two or more selected from
(meth)acrylic acid esters, aromatic vinyls, vinyl cyanides,
N-substituted maleimides, and maleic acid. The monomer (B) can be
selected according to the compatibility with the thermoplastic
resin (D) described below or to the intended use. For example, the
use of an aromatic vinyl tends to provide good moldability. The use
of a vinyl cyanide can improve chemical resistance, impact
resistance, and compatibility with the thermoplastic resin (D)
having polarity. The use of a methacrylic acid ester can provide a
molded article with improved surface hardness and surface
appearance. The use of an N-substituted maleimide can improve heat
resistance.
[0150] Examples of (meth)acrylic acid esters include methyl
(meth)acrylate, ethyl (meth)acrylate, n-propyl (meth)acrylate,
1-propyl (meth)acrylate, n-butyl (meth)acrylate, i-butyl
(meth)acrylate, t-butyl (meth)acrylate, amyl (meth)acrylate,
isoamyl (meth)acrylate, octyl (meth)acrylate, 2-ethylhexyl
(meth)acrylate, decyl (meth)acrylate, lauryl (meth)acrylate,
cyclohexyl (meth)acrylate, benzyl (meth)acrylate, and phenyl
(meth)acrylate.
[0151] Examples of aromatic vinyls include styrene,
.alpha.-methylstyrene, o-, m-, or p-methylstyrene, vinyl xylene,
p-t-butylstyrene, and ethylstyrene.
[0152] Examples of vinyl cyanides include acrylonitrile and
methacrylonitrile.
[0153] Examples of N-substituted maleimides include
N-cyclohexylmaleimide and N-phenylmaleimide.
[0154] Examples of maleic acid include maleic acid and maleic
anhydride.
[0155] When a combination of a methacrylic acid ester and an
acrylic acid ester is used as the monomer (B), better results in
terms of thermal stability are obtained as compared to when a
methacrylic acid ester is used alone. In this case, it is
preferable to use the methacrylic acid ester in an amount of 70% to
99.5% by mass and the acrylic acid ester in an amount of 0.5% to
30% by mass (provided that the total amount of the methacrylic acid
ester and the acrylic acid ester is 100% by mass).
[0156] When a combination of an aromatic vinyl and a vinyl cyanide
is used as the monomer (B), better results in terms of
compatibility with the thermoplastic resin (D) are obtained. In
this case, it is preferable to use the aromatic vinyl in an amount
of 60% to 99% by mass and the vinyl cyanide in an amount of 1% to
40% by mass (provided that the total amount of the aromatic vinyl
and the vinyl cyanide is 100% by mass).
[0157] The proportions of the composite rubber-like polymer (A) and
the monomer (B) used in graft polymerization are not particularly
limited, but, in general, the proportion of the composite
rubber-like polymer (A) is 10% to 80% by mass, preferably 40% to
75% by mass, and the proportion of the monomer (B) is 20% to 90% by
mass, preferably 25% to 60% by mass (provided that the total amount
of the composite rubber-like polymer (A) and the monomer (B) is
100% by mass). When the proportions of the composite rubber-like
polymer (A) and the monomer (B) are in the above ranges,
productivity and impact resistance of the graft copolymer (C) are
good, and, in addition, the color developability and impact
resistance of a thermoplastic resin composition obtained by
incorporating the graft copolymer (C) and a molded article thereof
tend to improve.
[0158] <Method for Producing Graft Copolymer (C)>
[0159] The method for graft-polymerizing the monomer (B) onto the
composite rubber-like polymer (A) is not particularly limited.
Since the composite rubber-like polymer (A) is prepared by
miniemulsion polymerization and provided in the form of emulsified
latex, the graft polymerization is preferably carried out also by
emulsion polymerization. Examples of emulsion graft polymerization
include a method in which the monomer (B) is added in one portion,
in a continuous manner, or in an intermittent manner in the
presence of an emulsion of the composite rubber-like polymer (A) to
cause radical polymerization. In the graft polymerization, a chain
transfer agent for molecular weight adjustment and graft rate
control, a known inorganic electrolyte for adjusting the viscosity
and pH of latex, etc. can be used. The type and addition amount of
these are not particularly limited. In the emulsion graft
polymerization, various emulsifiers can be used as required. As a
chain transfer agent, emulsifier, and radical initiator, for
example, those exemplified as those used in the production of the
composite rubber-like polymer (A) can be used.
[0160] The method for obtaining the graft copolymer (C) in the form
of granules from the emulsion of the graft copolymer (C) produced
as described above is not particularly limited. Examples include a
method in which the emulsion is put in hot water containing a
dissolved coagulant and allowed to coagulate and solidify and a
spray drying method. Examples of usable coagulants include
inorganic acids such as sulfuric acid, hydrochloric acid,
phosphoric acid, and nitric acid and metal salts such as calcium
chloride, calcium acetate, and aluminum sulfate.
[0161] [Thermoplastic Resin Composition]
[0162] The thermoplastic resin composition of the first invention
includes the graft copolymer (C) of the first invention and the
thermoplastic resin (D).
[0163] <Thermoplastic Resin (D)>
[0164] Examples of the thermoplastic resin (D) in the first
invention include, but are not limited to, acrylic resins (PMMA),
acrylonitrile-styrene copolymers (AS resins), polycarbonate resins,
polybutylene terephthalate (PBT resins), methyl
methacrylate-styrene copolymer resins (MS resins), polyethylene
terephthalate (PET resins), polyvinyl chloride, polystyrene,
polyacetal resins, modified polyphenylene ethers (modified PPE
resins), ethylene-vinyl acetate copolymers, polyarylate, liquid
crystal polyester resins, polyethylene resins, polypropylene
resins, fluorocarbon resins, and polyamide resins (nylon).
[0165] The thermoplastic resin (D) may be used alone or as a
mixture of two or more.
[0166] When a transparent resin among them is used, using a
transparent resin having a refractive index different from that of
the composite rubber-like polymer (A) in the thermoplastic resin
(D) by 0.02 or less not only provides particularly good color
developability but also provides a thermoplastic resin composition
also having high transparency unless colored. The refractive index
difference is preferably as small as possible, more preferably 0.01
or less.
[0167] Examples of transparent resins include, but are not limited
to, acrylic resins (refractive index: 1.48 to 1.53), polystyrenes
(refractive index: 1.59 to 1.60), aliphatic polycarbonates
(refractive index: 1.48 to 1.55), aromatic polycarbonates
(refractive index: 1.58 to 1.59), AS resins (refractive index: 1.52
to 1.58), MS resins (refractive index: 1.56 to 1.59), and rigid
polyvinyl chlorides (refractive index: 1.52 to 1.54).
[0168] The refractive index of the thermoplastic resin (D) can be
measured by the method described in the section of EXAMPLES
below.
[0169] <Amounts of Graft Copolymer (C) and Thermoplastic Resin
(D)>
[0170] In the thermoplastic resin composition of the first
invention, the amounts of the graft copolymer (C) and the
thermoplastic resin (D) are not particularly limited. In general,
the amount of the graft copolymer (C) is 5 to 70 parts by mass,
preferably 10 to 50 parts by mass, and the amount of the
thermoplastic resin (D) is 30 to 95 parts by mass, preferably 50 to
90 parts by mass, the amounts being relative to 100 parts by mass
of the total of the graft copolymer (C) and the thermoplastic resin
(D). When the amount of the graft copolymer (C) is less than the
above range and the amount of the thermoplastic resin (D) is over
the above range, the impact resistance of the resulting
thermoplastic resin composition is not sufficient. When the amount
of the graft copolymer (C) is over the above range and the amount
of the thermoplastic resin (D) is less than the above range, the
resulting thermoplastic resin composition tends not to be provided
with, for example, intrinsic functions of the thermoplastic resin
(D), such as hardness of acrylic resins and heat resistance of
aromatic polycarbonates.
[0171] <Additives>
[0172] In addition to the graft copolymer (C) and the thermoplastic
resin (D), other commonly used additives such as lubricants,
pigments, dyes, fillers (e.g., carbon black, silica, and titanium
oxide), heat stabilizers, oxidation degradation inhibitors,
weathering agents, release agents, plasticizers, and antistatic
agents can be blended with the thermoplastic resin composition of
the first invention during the production (mixing) or molding of
the thermoplastic resin composition to the extent that the physical
properties of the thermoplastic resin composition are not
impaired.
[0173] <Method for Producing Thermoplastic Resin
Composition>
[0174] The thermoplastic resin composition of the first invention
can be produced using the graft copolymer (C), the thermoplastic
resin (D), and optionally added various additives by a known method
using a known apparatus. For example, commonly used methods include
a melt mixing method.
[0175] Examples of apparatuses used in the melt mixing method
include extruders, Banbury mixers, rollers, and kneaders. Either
batch mixing or continuous mixing may be employed. The order of
mixing of components is also not particularly limited as long as
all the components are uniformly mixed.
[0176] [Molded Article]
[0177] A molded article of the first invention is obtained by
molding the thermoplastic resin composition of the first invention
and is excellent in weather resistance and color developability as
well as in impact resistance.
[0178] Examples of the method for molding the thermoplastic resin
composition of the first invention include injection molding,
injection compression molding, extrusion, blow molding, vacuum
molding, air-pressure forming, calender molding, and inflation
molding. Of these, injection molding and injection compression
molding are preferred because these methods can achieve high mass
productivity and provide molded articles with high dimensional
accuracy.
Embodiment of Second Invention
[0179] Hereinafter, "abrasion resistance" means resistance to
damage (abrasion, wear) that can occur when a surface of a molded
article is rubbed with a soft material such as cotton work gloves,
gauze, or a cloth.
[0180] "Residue" refers to a structural portion that is derived
from a compound used to produce a polymer (crosslinked particles
(A-I) in the second invention) and incorporated into the polymer.
For example, a residue X described below corresponds to the rest of
a polyalkylene glycol, a polyester diol, a polycarbonate diol, or a
polymer of one or more thereof from each of the two hydroxyl groups
of which one hydrogen atom is removed.
[0181] In the second invention, number average molecular weights
(Mn) of the crosslinked particles (A-I) and diols incorporated as
divalent residues X are values measured using gel permeation
chromatography (GPC) relative to polystyrene standards.
[0182] The same applies to the third invention described below.
[0183] [Crosslinked Particles (A-I)]
[0184] The crosslinked particles (A-I) of the second invention are
obtained by polymerizing a monomer mixture (i-I) containing a
di(meth)acrylic acid ester (a) represented by the following formula
(1) and having a number average molecular weight (Mn) of 800 to
9,000. Therefore, the crosslinked particles (A-I) are constituted
by a structural unit derived from the di(meth)acrylic acid ester
(a) and a structural unit derived from a monomer that is contained
in the monomer mixture (i-I) described below and is other than the
di(meth)acrylic acid ester (a). The structural unit derived from
the di(meth)acrylic acid ester (a) included in the crosslinked
particles (A-I) effectively serves to improve the impact resistance
and abrasion resistance of a thermoplastic resin composition of the
second invention described below.
##STR00003##
[0185] In the above formula (1), X represents a divalent residue
constituted by at least one diol selected from polyalkylene
glycols, polyester diols, and polycarbonate diols. R.sup.1a and
R.sup.1b each independently represent H or CH.sub.3.
[0186] X in the formula (1) is also referred to as a "diol residue
X". A diol compound that is used as a material for producing the
di(meth)acrylic acid ester (a) and constitutes the diol residue X
in the di(meth)acrylic acid ester (a) is also referred to as an "X
source". The same applies to the third invention described
below.
[0187] <Di(Meth)Acrylic Acid Ester (a)>
[0188] The number average molecular weight (Mn) of the
di(meth)acrylic acid ester (a) used to produce the crosslinked
particles (A-I) of the second invention is 800 to 9,000, preferably
1,300 to 7,000, more preferably 1,800 to 5,000. When the number
average molecular weight (Mn) of the di(meth)acrylic acid ester (a)
is less than 800, the impact resistance and abrasion resistance of
a thermoplastic resin composition including the crosslinked
particles (A-I) of the second invention obtained using the
di(meth)acrylic acid ester (a) are poor, and when the number
average molecular weight (Mn) is more than 9,000, the flowability
and color developability are poor.
[0189] The structure of the diol residue X included in the
di(meth)acrylic acid ester (a) may be a repetition of a single
structural unit or a repetition of two or more structural units.
When the structure of X is a repetition of two or more structural
units, the way the structural units align may be such that the
structural units are present randomly, that the structural units
are present as blocks, or that the structural units are present
alternately.
[0190] From the viewpoint of abrasion resistance, the diol residue
X is preferably a residue made of a repetition of
polytetramethylene glycol (polybutylene glycol).
[0191] To constitute the di(meth)acrylic acid ester (a) satisfying
the above number average molecular weight (Mn), the number average
molecular weight (Mn) of the X source is preferably in the range of
values obtained by subtracting the number average molecular weight
of two (meth)acrylic acid residues from the number average
molecular weight (Mn) of the di(meth)acrylic acid ester (a). The
number average molecular weight (Mn) of the X source is
specifically 660 to 8890, preferably 1160 to 6890, particularly
preferably 1660 to 4890.
[0192] The method for synthesizing the X source is not particularly
limited, and, typically, the X source is produced by condensation
polymerization of the above-described diol or ring-opening
polymerization of cyclic ethers using an acid catalyst.
[0193] Examples of the di(meth)acrylic acid ester (a) include
polyethylene glycol di(meth)acrylates including 12 or more
repeating units, such as dodecaethylene glycol di(meth)acrylate,
tridecaethylene glycol di(meth)acrylate, tetradecaethylene glycol
di(meth)acrylate, pentadecaethylene glycol di(meth)acrylate, and
hexadecaethylene glycol di(meth)acrylate; polypropylene glycol
di(meth)acrylates including 9 or more repeating units, such as
nonapropylene glycol di(meth)acrylate, decapropylene glycol
di(meth)acrylate, undecapropylene glycol di(meth)acrylate,
dodecapropylene glycol di(meth)acrylate, and tridecapropylene
glycol di(meth)acrylate; and polybutylene glycol di(meth)acrylates,
i.e., polytetramethylene glycol di(meth)acrylates including 7 or
more repeating units, such as heptabutylene glycol
di(meth)acrylate, octabutylene glycol di(meth)acrylate,
nonabutylene glycol di(meth)acrylate, decabutylene glycol
di(meth)acrylate, and undecabutylene glycol di(meth)acrylate. These
can be used alone or in a combination of two or more.
[0194] The method for producing the di(meth)acrylic acid ester (a)
is not particularly limited. For example, a method (dehydration
reaction) in which an X source is reacted with (meth)acrylic acid
in the presence of an acid catalyst to form a (meth)acrylic acid
ester precursor, and then water formed as a by-product is removed
from the system or a method (transesterification reaction) in which
an X source is reacted with a lower (meth)acrylic acid ester to
form a (meth)acrylic acid ester precursor, and then a lower alcohol
formed as a by-product is removed can be used.
[0195] <Monomer Mixture (i-I)>
[0196] The crosslinked particles (A-I) of the second invention are
obtained by polymerizing the monomer mixture (i-I) containing the
di(meth)acrylic acid ester (a). The crosslinked particles (A-I) of
the second invention are typically obtained by copolymerizing the
monomer mixture (i-I) containing the di(meth)acrylic acid ester (a)
and another monomer.
[0197] The content of the di(meth)acrylic acid ester (a) in the
monomer mixture (i-I) is preferably 0.1% to 90% by mass, more
preferably 2% to 70% by mass, still more preferably 10% to 50% by
mass. When the content of the di(meth)acrylic acid ester (a) in the
monomer mixture (i-I) is in the above range, the color
developability, impact resistance, and abrasion resistance of a
thermoplastic resin composition including the resulting crosslinked
particles (A-I) can be excellent.
[0198] Examples of the monomer that is contained in the monomer
mixture (i-I) and copolymerizes with the di(meth)acrylic acid ester
(a) include an aromatic vinyl (b), a vinyl cyanide (c), and other
monomers copolymerizable therewith.
[0199] Examples of the aromatic vinyl (b) include styrene,
.alpha.-methylstyrene, o-, m-, or p-methylstyrene, vinyl xylene,
p-t-butylstyrene, and ethylstyrene. These can be used alone or in a
combination of two or more. In particular, it is preferable to use
at least one of styrene and .alpha.-methylstyrene.
[0200] For the content of the aromatic vinyl (b) in the monomer
mixture (i-I), the proportion of the aromatic vinyl (b) is
preferably 60% to 90% by mass, more preferably 65% to 80% by mass,
in 100% by mass of the total of the aromatic vinyl (b) and the
vinyl cyanide (c). When the proportion of the aromatic vinyl (b) is
in the above range, the flowability, color developability, and
impact resistance of a thermoplastic resin composition including
the resulting crosslinked particles (A-I) can be excellent.
[0201] Examples of the vinyl cyanide (c) include acrylonitrile and
methacrylonitrile. One or more of these can be used.
[0202] For the content of the vinyl cyanide (c) in the monomer
mixture (i-I), the proportion of the vinyl cyanide (c) is
preferably 10% to 40% by mass, more preferably 20% to 35% by mass,
in 100% by mass of the total of the aromatic vinyl (b) and the
vinyl cyanide (c). When the proportion of the vinyl cyanide (c) is
in the above range, the impact resistance of a thermoplastic resin
composition including the resulting crosslinked particles (A-I) can
be excellent.
[0203] Examples of other monomers copolymerizable with the aromatic
vinyl (b) and the vinyl cyanide (c) include methacrylic acid esters
such as methyl methacrylate, ethyl methacrylate, n-propyl
methacrylate, 1-propyl methacrylate, n-butyl methacrylate, i-butyl
methacrylate, t-butyl methacrylate, amyl methacrylate, isoamyl
methacrylate, octyl methacrylate, 2-ethylhexyl methacrylate, decyl
methacrylate, lauryl methacrylate, cyclohexyl methacrylate, benzyl
methacrylate, and phenyl methacrylate; acrylic acid esters such as
methyl acrylate, ethyl acrylate, propyl acrylate, and butyl
acrylate; maleimide compounds such as N-cycloalkylmaleimides
including N-methylmaleimide, N-ethylmaleimide, N-n-propylmaleimide,
N-i-propylmaleimide, N-n-butylmaleimide, N-i-butylmaleimide,
N-t-butylmaleimide, and N-cyclohexylmaleimide, N-arylmaleimides
including N-phenylmaleimide, N-alkyl-substituted phenylmaleimide,
and N-chlorophenylmaleimide, and N-aralkylmaleimides; alkylene
glycol dimethacrylates such as ethylene glycol dimethacrylate,
1,3-butylene glycol dimethacrylate, 1,4-butylene glycol
dimethacrylate, and propylene glycol dimethacrylate; and
polyvinylbenzenes such as divinylbenzene and trivinylbenzene. These
can be used alone or in a combination of two or more.
[0204] <Method for Producing Crosslinked Particles (A-I)>
[0205] The method for producing the crosslinked particles (A-I) is
not particularly limited. The crosslinked particles (A-I) are
produced from the above-described monomer mixture (i-I) containing
the di(meth)acrylic acid ester (a) by a known method such as bulk
polymerization, solution polymerization, bulk-suspension
polymerization, suspension polymerization, or emulsion
polymerization. From the viewpoint of stability during production
and particle size control, the crosslinked particles (A-I) are
preferably produced by what is called miniemulsion polymerization
in which part or all of the monomer mixture (i-I) is sheared in
water solvent in the presence of an emulsifier, preferably in the
presence of an emulsifier and a hydrophobic stabilizer, to form a
miniemulsion and then copolymerized in the presence of a radical
initiator. The radical initiator may be added before or after the
miniemulsion is formed.
[0206] The radical initiator, the monomer mixture (i-I), and the
emulsifier may be added in one portion, in multiple portions, or in
a continuous manner.
[0207] From the viewpoint of workability, stability, production
efficiency, etc., the amount of water solvent used in the
miniemulsification is preferably about 100 to 500 parts by mass
relative to 100 parts by mass of the monomer mixture (i-I) so that
the solids concentration of the reaction system after the
polymerization will be about 5% to 50% by mass.
[0208] As a method for applying shear in forming the miniemulsion,
any known method can be used. The shear may be applied in one
portion, in multiple portions, in a continuous manner, or in a
circular manner, and, in general, the miniemulsion can be formed by
using a high shear device that forms droplets having diameters of
about 0.05 to 3.0 .mu.m.
[0209] Examples of usable high shear devices that form
miniemulsions include, but are not limited to, those exemplified,
in the section of the description of the first invention, as those
used to produce the composite rubber-like polymer (A).
[0210] By performing radical copolymerization after forming the
miniemulsion, the stability during production is improved; for
example, the di(meth)acrylic acid ester (a), which is a
high-molecular-weight product, is efficiently taken into a micelle,
and agglomerates after the polymerization are reduced.
[0211] Examples of emulsifiers include those exemplified, in the
section of the description of the first invention, as those used to
produce the composite rubber-like polymer (A). The emulsifiers may
be used alone or in a combination of two or more.
[0212] The addition amount of emulsifier is typically 10 parts by
mass or less, preferably, for example, 0.01 to 10 parts by mass,
relative to 100 parts by mass of the monomer mixture (i-I).
[0213] When the miniemulsion is formed, adding a hydrophobic
stabilizer tends to further improve the production stability of the
miniemulsion. Examples of hydrophobic stabilizers include those
exemplified, in the section of the description of the first
invention, as those used to produce the composite rubber-like
polymer (A). The hydrophobic stabilizers may be used alone or as a
mixture of two or more.
[0214] When a hydrophobic stabilizer is used, the amount thereof is
preferably 0.05 to 5 parts by mass relative to 100 parts by mass of
the monomer mixture (i-I). When the addition amount of hydrophobic
stabilizer is not less than the above lower limit, the production
stability of the crosslinked particles (A-I) can be further
improved, and when the addition amount of hydrophobic stabilizer is
not more than the above upper limit, there is a tendency that the
color developability and impact resistance of a thermoplastic resin
composition obtained by incorporating the crosslinked particles
(A-I) of the second invention can be good.
[0215] Examples of the radical initiator used in the polymerization
step subsequent to the miniemulsification step include those
exemplified, in the section of the description of the first
invention, as those used to produce the composite rubber-like
polymer (A). The radical initiators may be used alone or in a
combination of two or more.
[0216] The addition amount of radical initiator is preferably 5
parts by mass or less, more preferably 3 parts by mass or less, for
example, 0.001 to 3 parts by mass, relative to 100 parts by mass of
the monomer mixture (i-I). As described above, the radical
initiator may be added before or after the miniemulsion is formed
and may be added in one portion, in multiple portions, or in a
continuous manner.
[0217] In the production of the crosslinked particles (A-I), a
chain transfer agent may optionally be added. Examples of chain
transfer agents include those exemplified, in the section of the
description of the first invention, as those used to produce the
composite rubber-like polymer (A). The chain transfer agents may be
used alone or in a combination of two or more. Of these, mercaptans
are preferred in terms of ease of control of molecular weight.
[0218] When a chain transfer agent is used, it may be added in one
portion, in multiple portions, or in a continuous manner. The
addition amount of chain transfer agent is typically 2.0 parts by
mass or less, preferably, for example, 0.01 to 2.0 parts by mass,
relative to 100 parts by mass of the monomer mixture (i-I).
[0219] The polymerization step subsequent to the miniemulsification
step is typically performed at 40.degree. C. to 95.degree. C. for
about 0.5 to 8 hours following the miniemulsification step.
[0220] The particle size (average particle size) of the crosslinked
particles (A-I) of the second invention produced through the
miniemulsification step and the subsequent polymerization step is
preferably 0.07 to 5.0 .mu.m, more preferably 0.09 to 3.0 .mu.m,
still more preferably 0.1 to 1 .mu.m. When the particle size of the
crosslinked particles (A-I) is in the above range, the impact
resistance and abrasion resistance of a thermoplastic resin
composition including the resulting crosslinked particles (A-I) can
be excellent.
[0221] The particle size of the crosslinked particles (A-I) may be
controlled by any method, for example, by adjusting the type or
amount of emulsifier used and the shear force during the production
of the miniemulsion.
[0222] Specifically, the average particle size of the crosslinked
particles (A-I) is measured by the method described in the section
of EXAMPLES below.
[0223] [Graft Crosslinked Particles (B-I)]
[0224] Graft crosslinked particles (B-I) of the second invention is
obtained by graft-polymerizing a monomer onto the crosslinked
particles (A-I) of the second invention.
[0225] Examples of the monomer graft-polymerized onto the
crosslinked particles (A-I) of the second invention include one or
two or more selected from aromatic vinyls, vinyl cyanides,
(meth)acrylic acid esters, maleimides, and maleic anhydride. When
the crosslinked particles (A-I) are graft-polymerized, the
crosslinked particles (A-I) advantageously have better
dispersibility in a thermoplastic resin (D-I) described below to
provide a thermoplastic resin composition that is more excellent in
flowability and impact resistance.
[0226] Examples of monomers such as aromatic vinyls and vinyl
cyanides, among the monomers graft-polymerized onto the crosslinked
particles (A-I), include those exemplified as monomers used in the
monomer mixture (i-I) for producing the crosslinked particles (A-I)
of the second invention. In particular, to provide a thermoplastic
resin composition excellent in flowability and impact resistance,
it is preferable to use an aromatic vinyl such as styrene and a
vinyl cyanide such as acrylonitrile in combination. In this case,
it is preferable to use the aromatic vinyl in an amount of 60% to
99% by mass and the vinyl cyanide in an amount of 1% to 40% by mass
(provided that the total amount of the aromatic vinyl and the vinyl
cyanide is 100% by mass).
[0227] The proportions of the crosslinked particles (A-I) and the
monomer used in graft polymerization are not particularly limited,
but, in general, the proportion of the crosslinked particles (A-I)
is 40% to 90% by mass, and the proportion of the monomer is 10% to
60% by mass (provided that the total amount of the crosslinked
particles (A-I) and the monomer is 100% by mass). When the
proportions of the crosslinked particles (A-I) and the monomer are
in the above ranges, the dispersibility in the thermoplastic resin
(D-I) described below is good, and a thermoplastic resin
composition having improved flowability and impact resistance is
provided.
[0228] For good dispersibility in the thermoplastic resin (D-I)
described below, the graft crosslinked particles (B-I) preferably
have a graft rate of 23% to 100%.
[0229] The graft rate G of the graft crosslinked particles (B-I) is
determined by the following formula (4).
G=100(P-E)/E (4)
[0230] P: mass of acetone insoluble fraction (mass (g) of acetone
insoluble fraction after being vacuum-dried, the acetone insoluble
fraction being obtained by washing of graft crosslinked particles
(B-I) with methanol, extraction with acetone, and centrifugal
separation into acetone soluble fraction and acetone insoluble
fraction)
[0231] E: mass (g) of graft crosslinked particles (B-I) before
graft polymerization
[0232] The method for producing the graft crosslinked particles
(B-I) is not particularly limited. The graft crosslinked particles
(B-I) are produced by a known method such as bulk polymerization,
solution polymerization, bulk-suspension polymerization, suspension
polymerization, or emulsion polymerization. When the crosslinked
particles (A-I) are prepared by miniemulsion polymerization and
provided in the form of emulsified latex, the graft polymerization
may also be carried out by emulsion polymerization. Examples of
emulsion graft polymerization include a method in which the monomer
is added in one portion, in a continuous manner, or in an
intermittent manner in the presence of an emulsion of the
crosslinked particles (A-I) to cause radical polymerization. In the
graft polymerization, a chain transfer agent for molecular weight
adjustment and graft rate control, a known inorganic electrolyte
for adjusting the viscosity and pH of latex, etc. can be used. The
type and addition amount of these are not particularly limited. In
the emulsion graft polymerization, various emulsifiers can be used
as required. As a chain transfer agent, emulsifier, and radical
initiator, for example, those exemplified as those used in the
production of the crosslinked particles (A-I) can be used.
[0233] The method for obtaining the graft crosslinked particles
(B-I) in the form of granules from the emulsion of the graft
crosslinked particles (B-I) produced as described above is not
particularly limited. Examples include a method in which the
emulsion is put in hot water containing a dissolved coagulant and
allowed to coagulate and solidify and a spray drying method.
Examples of usable coagulants include inorganic acids such as
sulfuric acid, hydrochloric acid, phosphoric acid, and nitric acid
and metal salts such as calcium chloride, calcium acetate, and
aluminum sulfate.
[0234] [Thermoplastic Resin Composition]
[0235] The thermoplastic resin composition of the second invention
includes the crosslinked particles (A-I) and/or the graft
crosslinked particles (B-I) of the second invention described above
and the thermoplastic resin (D-I).
[0236] <Thermoplastic Resin (D-I)>
[0237] Examples of the thermoplastic resin (D-I) in the second
invention include styrene resins such as AS (acrylonitrile-styrene)
resins containing the above-described aromatic vinyl (b) and the
vinyl cyanide (c) as principal components,
styrene-acrylonitrile-phenylmaleimide copolymer resins, ABS resins,
AES resins, and AAS resins; polyolefin resins such as polystyrene,
poly(meth)acrylate resins, polyethylene, and polypropylene; and
polycarbonate (PC), polyphenylene ether, modified polyphenylene
ether, polybutylene terephthalate, polyethylene terephthalate,
polyamide, polyester, polysulfone, polyetherketone,
polyethersulfone, fluorocarbon resins, silicone resins, polyester
elastomers, and polycaprolactone. One of these resins may be used
alone, or two or more of them may be used in combination.
[0238] <Proportions of Crosslinked Particles (A-I)/Graft
Crosslinked Particles (B-I)>
[0239] The content of the crosslinked particles (A-I) and/or the
graft crosslinked particles (B-I) in the thermoplastic resin
composition of the second invention is preferably 1% to 95% by
mass, more preferably 5% to 80% by mass, particularly preferably
10% to 50% by mass, provided that the total amount of the
crosslinked particles (A-I) and/or the graft crosslinked particles
(B-I) and the thermoplastic resin (D-I) is 100% by mass. When the
content of the crosslinked particles (A-I) and/or the graft
crosslinked particles (B-I) is in the above range, the color
developability, impact resistance, and abrasion resistance of the
thermoplastic resin composition are more excellent.
[0240] <Additives>
[0241] In addition to the crosslinked particles (A-I) and/or the
graft crosslinked particles (B-I) and the thermoplastic resin
(D-I), other commonly used additives such as lubricants, colorants
including pigments and dyes, fillers (e.g., carbon black, silica,
and titanium oxide), processing aids, heat stabilizers,
antioxidants, weathering agents, release agents, plasticizers, and
antistatic agents can be blended with the thermoplastic resin
composition of the second invention during the production (mixing)
or molding of the thermoplastic resin composition to the extent
that the physical properties of the thermoplastic resin composition
are not impaired.
[0242] <Method for Producing Thermoplastic Resin
Composition>
[0243] The thermoplastic resin composition of the second invention
can be produced using the crosslinked particles (A-I) and/or the
graft crosslinked particles (B-I), the thermoplastic resin (D-I),
and optionally added various additives by a known method using a
known apparatus. For example, commonly used methods include a melt
mixing method. Examples of apparatuses used in the melt mixing
method include extruders, Banbury mixers, rollers, and kneaders.
Either batch mixing or continuous mixing may be employed. The order
of mixing of components is also not particularly limited as long as
all the components are uniformly mixed.
[0244] [Molded Article]
[0245] A molded article of the second invention is obtained by
molding the thermoplastic resin composition of the second
invention. The molded article is excellent in color developability,
flowability, impact resistance, and abrasion resistance and is
excellent in dimensional stability and shape accuracy due to its
small mold shrinkage rate.
[0246] Examples of the method for molding the thermoplastic resin
composition of the second invention include injection molding,
injection compression molding, extrusion, blow molding, vacuum
molding, air-pressure forming, calender molding, and inflation
molding. Of these, injection molding and injection compression
molding are preferred because these methods can achieve high mass
productivity and provide molded articles with high dimensional
accuracy.
[0247] The molded article of the second invention obtained by
molding the thermoplastic resin composition of the second invention
is excellent in color developability, flowability, impact
resistance, and abrasion resistance and is excellent in dimensional
stability and shape accuracy due to its small mold shrinkage rate,
and thus is suitable for automotive interior and exterior parts,
office machines, household electrical appliances, building
materials, etc.
Embodiment of Third Invention
[0248] In the third invention, "abrasion resistance" and "residue"
each have the same meaning as in the second invention. Number
average molecular weights (Mn) of crosslinked particles (A-II) and
diols incorporated as divalent residues X are values measured using
gel permeation chromatography (GPC) relative to polystyrene
standards.
[0249] [Crosslinked Particles (A-II)]
[0250] The crosslinked particles (A-II) of the third invention are
obtained by polymerizing a monomer mixture (i-II) containing a
di(meth)acrylic acid ester (a) represented by the following formula
(1) and having a number average molecular weight of 800 to 9,000
and a mono(meth)acrylic acid ester (d). The content of the
di(meth)acrylic acid ester (a) in 100% by mass of the monomer
mixture (i-II) is 20% to 80% by mass. Therefore, the crosslinked
particles (A-II) of the third invention are constituted by a
structural unit derived from the di(meth)acrylic acid ester (a), a
structural unit derived from the mono(meth)acrylic acid component
(d), and a structural unit derived from an additional vinyl
compound (e) described below that is optionally used and are
characterized by having a volume average particle size of 0.07 to
2.0 .mu.m. The structural unit derived from the di(meth)acrylic
acid ester (a) constituting the crosslinked particles (A-II)
effectively serves to improve the impact resistance and abrasion
resistance of a thermoplastic resin composition of the third
invention described below.
##STR00004##
[0251] In the above formula (1), X represents a divalent residue
constituted by at least one diol selected from polyalkylene
glycols, polyester diols, and polycarbonate diols. R.sup.1a and
R.sup.1b each independently represent H or CH.sub.3.
[0252] The monomer mixture (i-II), which is a raw material of the
crosslinked particles (A-II) of the third invention, contains the
di(meth)acrylic acid ester (a) and the mono(meth)acrylic acid
component (d) as essential components and contains the additional
vinyl compound (e) that is optionally used.
[0253] Hereinafter, X in the formula (1) is also referred to as a
"diol residue X". A diol compound that is used as a material for
producing the di(meth)acrylic acid ester (a) and constitutes the
diol residue X in the di(meth)acrylic acid ester (a) is also
referred to as an "X source".
[0254] <Di(Meth)Acrylic Acid Ester (a)>
[0255] The di(meth)acrylic acid ester (a) used to produce the
crosslinked particles (A-II) of the third invention is the same as
the di(meth)acrylic acid ester (a) used to produce the crosslinked
particles (A-I) of the second invention. The number average
molecular weight (Mn), the diol residue X included in the
di(meth)acrylic acid ester (a), the number average molecular weight
(Mn) of an X source, the method for synthesizing the X source,
examples of the di(meth)acrylic acid ester (a), and the production
method thereof are the same as in the second invention.
[0256] The content of the di(meth)acrylic acid ester (a) in the
monomer mixture (i-II) (i.e., the total of the di(meth)acrylic acid
ester (a), the mono(meth)acrylic acid component (d), and the
additional vinyl compound (e) described below that is optionally
used) is 20% to 80% by mass, more preferably 25% to 70% by mass,
still more preferably 30% to 50% by mass. When the content of the
di(meth)acrylic acid ester (a) in the monomer mixture (i-II) is
less than 20% by mass, the impact resistance and abrasion
resistance of a thermoplastic resin composition including the
resulting crosslinked particles (A-II) are poor, and when the
content is more than 90% by mass, the color developability is
poor.
[0257] <Mono(Meth)Acrylic Acid Component (d)>
[0258] The mono(meth)acrylic acid component (d) is a (meth)acrylic
acid and/or a mono(meth)acrylic acid ester.
[0259] Examples include methyl (meth)acrylate, ethyl
(meth)acrylate, n-butyl (meth)acrylate, i-butyl (meth)acrylate,
t-butyl (meth)acrylate, cyclohexyl (meth)acrylate, 2-ethylhexyl
(meth)acrylate, stearyl (meth)acrylate, lauryl (meth)acrylate,
isobornyl (meth)acrylate, benzyl (meth)acrylate, phenyl
(meth)acrylate, glycidyl (meth)acrylate, hydroxyethyl
(meth)acrylate, and (meth)acrylic acid. Of these, (meth)acrylic
acid monoalkyl esters having alkyl groups of 1 to 8 carbon atoms
are preferred. These may be used alone or in a combination of two
or more.
[0260] The content of the mono(meth)acrylic acid component (d) in
the monomer mixture (i-II) is preferably 1% to 80% by mass, more
preferably 25% to 75% by mass, still more preferably 50% to 70% by
mass. When the content of the mono(meth)acrylic acid component (d)
is in the above range, a molded article having an excellent balance
of color developability, weather resistance, impact resistance, and
abrasion resistance can be obtained from a thermoplastic resin
composition including the resulting crosslinked particles
(A-II).
[0261] <Additional Vinyl Compound (e)>
[0262] The additional vinyl compound (e) that is optionally used is
not particularly limited as long as it is copolymerizable with the
di(meth)acrylic acid ester (a) and the mono(meth)acrylic acid
component (d). Examples include aromatic vinyls such as styrene,
.alpha.-methylstyrene, o-, m-, or p-methylstyrene, vinyl xylene,
p-t-butylstyrene, and ethyl styrene; vinyl cyanides such as
acrylonitrile and methacrylonitrile; maleimides such as
N-cyclohexylmaleimide and N-phenylmaleimide; maleic anhydride;
alkylene glycol dimethacrylates such as ethylene glycol
dimethacrylate, 1,3-butylene glycol dimethacrylate, 1,4-butylene
glycol dimethacrylate, and propylene glycol dimethacrylate; and
polyvinylbenzenes such as divinylbenzene and trivinylbenzene. These
may be used alone or as a mixture of two or more.
[0263] Of these, styrene is preferably used to achieve a refractive
index closer to that of a thermoplastic resin (D-II).
[0264] The content of the additional vinyl compound (e) in the
monomer mixture (i-II) is 0% to 70% by mass. When the proportion of
the additional vinyl compound (e) is in the above range, the
flowability a thermoplastic resin composition including the
resulting crosslinked particles (A-II) is excellent, and a molded
article having excellent color developability can be obtained.
[0265] When styrene is used as the additional vinyl compound (e),
the content of styrene in the monomer mixture (i-II) is preferably
3% to 30% by mass, particularly preferably 5% to 20% by mass, to
achieve a refractive index closer to that of the thermoplastic
resin (D-II).
[0266] <Method for Producing Crosslinked Particles
(A-II)>
[0267] The method for producing the crosslinked particles (A-II) is
not particularly limited. The crosslinked particles (A-II) are
produced from the above-described monomer mixture (i-II) containing
the di(meth)acrylic acid ester (a), the mono(meth)acrylic acid
component (d), and the additional vinyl compound (e) that is
optionally used by a known method such as bulk polymerization,
solution polymerization, bulk-suspension polymerization, suspension
polymerization, or emulsion polymerization. From the viewpoint of
stability during production and particle size control, the
crosslinked particles (A-I) are preferably produced by what is
called miniemulsion polymerization in which part or all of the
monomer mixture (i-II) is sheared in water solvent in the presence
of an emulsifier, preferably in the presence of an emulsifier and a
hydrophobic stabilizer, to form a miniemulsion and then
copolymerized in the presence of a radical initiator. The radical
initiator may be added before or after the miniemulsion is formed,
and the radical initiator, the monomer mixture (i-II) (i.e., the
di(meth)acrylic acid ester (a), the mono(meth)acrylic acid
component (d), and the additional vinyl compound (e)), and the
emulsifier may be added in one portion, in multiple portions, or in
a continuous manner.
[0268] From the viewpoint of workability, stability, production
efficiency, etc., the amount of water solvent used in the
miniemulsification is preferably about 100 to 500 parts by mass
relative to 100 parts by mass of the monomer mixture (i-II) so that
the solids concentration of the reaction system after the
polymerization will be about 5% to 50% by mass.
[0269] As a method for applying shear in forming the miniemulsion,
any known method can be used. The shear may be applied in one
portion, in multiple portions, in a continuous manner, or in a
circular manner, and, in general, the miniemulsion can be formed by
using a high shear device that forms droplets having diameters of
about 0.05 to 3.0 .mu.m. Examples of usable high shear devices that
form miniemulsions include, but are not limited to, those
exemplified, in the section of the description of the first
invention, as those used to produce the composite rubber-like
polymer (A).
[0270] By performing radical copolymerization after forming the
miniemulsion, the stability during production is improved; for
example, the di(meth)acrylic acid ester (a), which is a
high-molecular-weight product, is efficiently taken into a micelle,
and agglomerates after the polymerization are reduced.
[0271] Examples of emulsifiers include those exemplified, in the
section of the description of the first invention, as those used to
produce the composite rubber-like polymer (A). These emulsifiers
may be used alone or in a combination of two or more.
[0272] The addition amount of emulsifier is typically 10 parts by
mass or less, preferably, for example, 0.01 to 10 parts by mass,
relative to 100 parts by mass of the monomer mixture (i-II).
[0273] When the miniemulsion is formed, adding a hydrophobic
stabilizer tends to further improve the production stability of the
miniemulsion. Examples of hydrophobic stabilizers include those
exemplified, in the section of the description of the first
invention, as those used to produce the composite rubber-like
polymer (A). The hydrophobic stabilizers may be used alone or as a
mixture of two or more.
[0274] When a hydrophobic stabilizer is used, the amount thereof is
preferably 0.05 to 5 parts by mass relative to 100 parts by mass of
the monomer mixture (i-II). When the addition amount of hydrophobic
stabilizer is not less than the above lower limit, the production
stability of the crosslinked particles (A-II) can be further
improved, and when the addition amount of hydrophobic stabilizer is
not more than the above upper limit, there is a tendency that the
color developability and impact resistance of a thermoplastic resin
composition obtained by incorporating the crosslinked particles
(A-II) of the third invention can be good.
[0275] Examples of the radical initiator used in the polymerization
step subsequent to the miniemulsification step include those
exemplified, in the section of the description of the first
invention, as those used to produce the composite rubber-like
polymer (A). The radical initiators may be used alone or in a
combination of two or more.
[0276] The addition amount of radical initiator is preferably 5
parts by mass or less, more preferably 3 parts by mass or less, for
example, 0.001 to 3 parts by mass, relative to 100 parts by mass of
the monomer mixture (i-II). As described above, the radical
initiator may be added before or after the miniemulsion is formed
and may be added in one portion, in multiple portions, or in a
continuous manner.
[0277] In the production of the crosslinked particles (A-II), a
chain transfer agent may optionally be added. Examples of chain
transfer agents include those exemplified, in the section of the
description of the first invention, as those used to produce the
composite rubber-like polymer (A). The chain transfer agents may be
used alone or in a combination of two or more. Of these, mercaptans
are preferred in terms of ease of control of molecular weight.
[0278] When a chain transfer agent is used, it may be added in one
portion, in multiple portions, or in a continuous manner, and the
addition amount thereof is typically 2.0 parts by mass or less,
preferably, for example, 0.01 to 2.0 parts by mass, relative to 100
parts by mass of the monomer mixture (i-II).
[0279] The polymerization step subsequent to the miniemulsification
step is typically performed at 40.degree. C. to 95.degree. C. for
about 0.5 to 8 hours following the miniemulsification step.
[0280] <Particle Size>
[0281] The particle size (average particle size) of the crosslinked
particles (A-II) of the third invention is 0.07 to 2.0 .mu.m,
preferably 0.09 to 1.0 .mu.m, still more preferably 0.1 to 0.5
.mu.m. When the average particle size of the crosslinked particles
(A-II) in less than 0.07 .mu.m, the impact resistance of a
thermoplastic resin composition including the resulting crosslinked
particles (A-II) is poor, and when the average particle size is
more than 2.0 .mu.m, the color developability and abrasion
resistance of a thermoplastic resin composition including the
resulting crosslinked particles (A-II) are poor.
[0282] Specifically, the average particle size of the crosslinked
particles (A-II) is measured by the method described in the section
of EXAMPLES below.
[0283] [Graft Crosslinked Particles (B-II)]
[0284] Graft crosslinked particles (B-II) of the third invention
are obtained by graft-polymerizing a monomer onto the crosslinked
particles (A-II) of the third invention.
[0285] Examples of the monomer graft-polymerized onto the
crosslinked particles (A-II) of the third invention include one or
two or more selected from aromatic vinyls, vinyl cyanides,
(meth)acrylic acid esters, maleimides, and maleic anhydride. When
the crosslinked particles (A-II) are graft-polymerized, the
crosslinked particles (A-II) advantageously have better
dispersibility in the thermoplastic resin (D-II) described below to
provide a thermoplastic resin molded article that is more excellent
in color developability and impact resistance.
[0286] Examples of the monomer graft-polymerized onto the
crosslinked particles (A-II) include the mono(meth)acrylic acid
components (d) exemplified in the section of the crosslinked
particles (A-II) of the third invention and (meth)acrylic acid
esters, aromatic vinyls, vinyl cyanides, maleimides, and maleic
anhydride exemplified in the additional vinyl compound (e), and one
or more of these can be used. Of these, (meth)acrylic acid esters
are suitable for use in order to provide a thermoplastic resin
molded article excellent in color developability and weather
resistance. In particular, it is preferable to use methyl
methacrylate and methyl acrylate in combination such that the
amount of methyl methacrylate is 90% to 99.9% by mass and the
amount of methyl acrylate is 0.1% to 10% by mass, relative to 100%
by mass of their total amount.
[0287] The proportions of the crosslinked particles (A-II) and the
monomer used in graft polymerization are not particularly limited,
but, in general, the proportion of the crosslinked particles (A-II)
is 40% to 90% by mass, and the proportion of the monomer is 10% to
60% by mass (provided that the total amount of the crosslinked
particles (A-II) and the monomer is 100% by mass). When the
proportions of the crosslinked particles (A-II) and the monomer are
in the above ranges, the dispersibility in the thermoplastic resin
(D-II) described below is good, and a thermoplastic resin
composition having improved color developability and impact
resistance is provided.
[0288] For good dispersibility in the thermoplastic resin (D-II)
described below, the graft crosslinked particles (B-II) preferably
have a graft rate of 23% to 100%.
[0289] The method for calculating the graft rate of the graft
crosslinked particles (B-II) is the same as the method for
calculating the graft rate of the graft crosslinked particles (B-I)
in the second invention.
[0290] The method for producing the graft crosslinked particles
(B-II) and the method for obtaining the graft crosslinked particles
(B-II) in the form of granules from an emulsion of the graft
crosslinked particles (B-II) produced are the same as those for the
graft crosslinked particles (B-I) of the second invention.
[0291] [Thermoplastic Resin Composition]
[0292] The thermoplastic resin composition of the third invention
includes the crosslinked particles (A-II) and/or the graft
crosslinked particles (B-II) of the third invention and the
thermoplastic resin (D-II).
[0293] <Thermoplastic Resin (D-II)>
[0294] Examples of the thermoplastic resin (D-II) in the third
invention include poly(meth)acrylate resins containing the
above-described mono(meth)acrylic acid ester (d) as a principal
component; polyolefin resins such as polyethylene and
polypropylene; polycarbonate (PC), polyphenylene ether, modified
polyphenylene ether, polybutylene terephthalate, polyethylene
terephthalate, polyamide, polyester, polysulfone, polyetherketone,
polyethersulfone, fluorocarbon resins, silicone resins, polyester
elastomers, polycaprolactone, aromatic polyester elastomers,
polyamide elastomers, AS-grafted polyethylene, AS-grafted
polypropylene; and styrene resins such as polystyrene, AS resins,
and ABS resins. These resins may be used alone or in a combination
of two or more.
[0295] <Proportions of Crosslinked Particles (A-II)/Graft
Crosslinked Particles (B-II)>
[0296] The content of the crosslinked particles (A-II) and/or the
graft crosslinked particles (B-II)) in the thermoplastic resin
composition of the third invention is preferably 1% to 90% by mass,
more preferably 10% to 70% by mass, still more preferably 20% to
50% by mass, provided that the total amount of the crosslinked
particles (A-II) and/or the graft crosslinked particles (B-II) and
the thermoplastic resin (D-II) is 100% by mass. When the content of
the crosslinked particles (A-II) and/or the graft crosslinked
particles (B-II) is in the above range, a thermoplastic resin
composition excellent in color developability, abrasion resistance,
and impact resistance is provided.
[0297] <Additives>
[0298] Similarly to the thermoplastic resin composition of the
second invention, in addition to the crosslinked particles (A-II)
and/or the graft crosslinked particles (B-II) and the thermoplastic
resin (D-II), other commonly used additives can be blended with the
thermoplastic resin composition of the third invention during the
production (mixing) or molding of the thermoplastic resin
composition to the extent that the physical properties of the
thermoplastic resin composition are not impaired.
[0299] <Method for Producing Thermoplastic Resin
Composition>
[0300] The thermoplastic resin composition of the third invention
is produced similarly to the thermoplastic resin composition of the
second invention by using the crosslinked particles (A-II) and/or
the graft crosslinked particles (B-II), the thermoplastic resin
(D-II), and optionally added various additives.
[0301] [Molded Article]
[0302] A molded article of the third invention is obtained by
molding the thermoplastic resin composition of the third invention
and is excellent in flowability during molding, color
developability, weather resistance, impact resistance, and abrasion
resistance.
[0303] The method for molding the thermoplastic resin composition
of the third invention is the same as the method for molding the
thermoplastic resin composition of the second invention, and the
preferred molding method is also the same.
[0304] The molded article of the third invention obtained by
molding the thermoplastic resin composition of the third invention
is excellent in color developability, weather resistance, impact
resistance, and abrasion resistance and thus is suitable for
automotive interior and exterior parts, office machines, household
electrical appliances, building materials, etc.
Embodiment of Fourth Invention
[Rubbery Polymer (A-III)]
[0305] A rubbery polymer (A-III) of the fourth invention is
obtained by miniemulsion polymerization reaction of an alkyl
(meth)acrylate, preferably, a mixture (i-III) containing an alkyl
(meth)acrylate, a hydrophobe, and an emulsifier. The rubbery
polymer (A-III) is typically produced by miniemulsifying the
mixture (i-III) containing an alkyl (meth)acrylate, a hydrophobe,
and an emulsifier and polymerizing the resulting miniemulsion.
[0306] In the miniemulsion polymerization, monomer oil droplets of
about 100 to 1000 nm are prepared by applying a strong shear force
by using an ultrasonic oscillator or the like. In this process,
emulsifier molecules are preferentially adsorbed on the surface of
the monomer oil droplets, and free emulsifiers and micelles become
substantially absent in an aqueous medium. Therefore, in ideal
miniemulsion-type polymerization, monomer radicals are never to be
separated into an aqueous phase and an oil phase, and
polymerization proceeds with monomer oil droplets serving as nuclei
of particles. As a result, the monomer oil droplets formed are
converted as they are into polymer particles, making it possible to
obtain polymer nanoparticles having a narrow particle size
distribution. The polymer particles having a narrow particle size
distribution, even when having a particle size of 200 nm or more,
exhibit good color developability and good molded appearance.
[0307] By contrast, in the case of polymer particles having a
particle size of 200 nm or more prepared by standard emulsion
polymerization, their particle size distribution is difficult to
control, and the polymer particles have a wide particle size
distribution, thus resulting in poor color developability and poor
molded appearance.
[0308] <Method for Producing Rubbery Polymer (A-III)>
[0309] The miniemulsion polymerization for producing the rubbery
polymer (A-III) of the fourth invention may, but does not
necessarily, include, for example, a step of mixing a monomer
including an alkyl (meth)acrylate as an essential component, an
emulsifier, and a hydrophobe, and, furthermore, preferably a
radical polymerization initiator, a step of applying a shear force
to the resulting mixture (i-III) to prepare a pre-emulsion, and a
step of polymerizing the mixture (i-III) by heating to a
polymerization starting temperature. In the miniemulsion
polymerization, the monomer for polymerization and the emulsifier
are mixed, and the shearing step, for example, by ultrasonic
irradiation is then performed, whereby the shear force causes the
monomer to tear to form monomer oil microdroplets covered with the
emulsifier. After this, the monomer oil microdroplets are
polymerized as they are by heating to the polymerization starting
temperature of the radical polymerization initiator to obtain
polymer fine particles.
[0310] The shear force for forming a miniemulsion can be added by
any known method. Examples of usable high shear devices that form
miniemulsions include, but are not limited to, those exemplified,
in the section of the description of the first invention, as those
used to produce the composite rubber-like polymer (A).
[0311] From the viewpoint of workability, stability, production
efficiency, etc., the amount of water solvent used in the
miniemulsification is preferably about 100 to 500 parts by mass
relative to 100 parts by mass of the mixture (i-III) excluding
water so that the solids concentration of the reaction system after
the polymerization will be about 5% to 50% by mass.
[0312] <<Alkyl (Meth)Acrylate>>
[0313] Examples of the alkyl (meth)acrylate constituting the
rubbery polymer (A-III) include alkyl acrylates having alkyl groups
of 1 to 18 carbon atoms, such as methyl acrylate, ethyl acrylate,
n-propyl acrylate, n-butyl acrylate, and 2-ethylhexyl acrylate; and
alkyl methacrylates having alkyl groups of 1 to 18 carbon atoms,
such as hexyl methacrylate, 2-ethylhexyl methacrylate, and
n-dodecyl methacrylate.
[0314] Among the alkyl (meth)acrylates, n-butyl acrylate is
preferred because the impact resistance and gloss of a molded
article obtained from a thermoplastic resin composition are
improved. The alkyl (meth)acrylates may be used alone or in a
combination of two or more.
[0315] <<Hydrophobe>>
[0316] Examples of hydrophobes include hexadecane, olive oil,
polystyrenes having mass average molecular weights (Mw) of 500 to
5000, siloxanes having mass average molecular weights (Mw) of 500
to 5000, cetyl alcohol, stearyl alcohol, palmityl alcohol, and
behenyl alcohol. Other examples include water-insoluble monomers,
such as vinyl esters of carboxylic acids having 12 to 22 carbon
atoms, vinyl ethers of alcohols having 12 to 30 carbon atoms, and
alkyl acrylates having 12 to 22 carbon atoms. Specifically,
examples of hydrophobic monomers include hexyl acrylate,
p-methylstyrene, 2-ethylhexyl acrylate, decyl acrylate, stearyl
acrylate, lauryl methacrylate, and stearyl methacrylate. Examples
of hydrophobic chain transfer agents include lauryl mercaptan
(normal dodecyl mercaptan). Examples of hydrophobic peroxides
include lauroyl peroxide. These may be used alone or in a
combination of two or more. Of these, hexadecane is preferably, but
not necessarily, used as a hydrophobe.
[0317] The use of a hydrophobe suppresses the increase in
ununiformity of particle size due to Ostwald ripening and enables
the synthesis of monodisperse latex particles.
[0318] The addition amount of hydrophobe is preferably 0.1 to 10
parts by mass, more preferably 1 to 3 parts by mass, relative to
100 parts by mass of the alkyl (meth)acrylate.
[0319] <<Emulsifier>>
[0320] As an emulsifier used when the rubbery polymer is produced,
known emulsifiers, for example, carboxylic-acid-based emulsifiers,
such as alkali metal salts of oleic acid, palmitin acid, stearic
acid, and rosin acid and alkali metal salts of alkenyl succinic
acid; and anionic emulsifiers selected from alkyl sulfuric acid
esters, sodium alkylbenzene sulfonates, sodium alkyl
sulfosuccinates, polyoxyethylene nonylphenyl ether sodium sulfate,
etc., can be used alone or in a combination of two or more.
[0321] The addition amount of emulsifier is preferably 0.01 to 1.0
part by mass, more preferably 0.05 to 0.5 parts by mass, relative
to 100 parts by mass of the alkyl (meth)acrylate.
[0322] <<Radical Polymerization Initiator>>
[0323] Examples of the radical polymerization initiator used in the
polymerization step subsequent to the miniemulsification step
include those exemplified, in the section of the description of the
first invention, as those used to produce the composite rubber-like
polymer (A). The radical polymerization initiators may be used
alone or in a combination of two or more.
[0324] The addition amount of radical polymerization initiator is
typically 5 parts by mass or less, preferably 3 parts by mass or
less, for example, 0.001 to 3 parts by mass, relative to 100 parts
by mass of the alkyl (meth)acrylate.
[0325] The radical polymerization initiator may be added before or
after the miniemulsion is formed and may be added in one portion,
in multiple portions, or in a continuous manner.
[0326] <<Rubber Component>>
[0327] In producing the rubbery polymer (A-III), another rubber
component may be incorporated into the mixture (i-III) to produce
the rubbery polymer (A-III) made of a composite rubber. In this
case, examples of the other rubber component include diene rubbers,
such as polybutadiene, and polyorganosiloxanes. By polymerizing the
alkyl (meth)acrylate in the presence of such a rubber component,
the rubbery polymer (A-III) made of diene/alkyl (meth)acrylate
composite rubber or polyorganosiloxane/alkyl (meth)acrylate
composite rubber combined with alkyl (meth)acrylate rubber such as
butyl acrylic rubber is obtained. The composite rubber related to
the fourth invention is not limited thereto, and the rubber
components to be combined can be used alone or in a combination of
two or more.
[0328] <<Crosslinking Agent>>
[0329] In producing the rubbery polymer (A-III), the polymerization
is preferably performed with a crosslinking agent being added to
the mixture (i-III) in order to introduce a crosslinked structure
into a polyalkyl (meth)acrylate component obtained from the alkyl
(meth)acrylate described above. In the case of the crosslinked
rubbery polymer (A-III) obtained using a crosslinking agent,
crosslinked portions thereof also function as graft crosslinking
points for a vinyl monomer to be grafted in the production of a
graft copolymer (B-III) of the fourth invention.
[0330] Examples of the crosslinking agent used in this case include
allyl (meth)acrylate, butylene di(meth)acrylate, ethylene glycol
di(meth)acrylate, propylene glycol di(meth)acrylate, 1,3-butylene
glycol di(meth)acrylate, 1,4-butylene glycol di(meth)acrylate,
triallyl cyanurate, and triallyl isocyanurate. The crosslinking
agents may be used alone or in a combination of two or more.
[0331] The amount of crosslinking agent used is not particularly
limited, but preferably, the amount of crosslinking agent is 0.1 to
5.0 parts by mass relative to 100 parts by mass of the total of the
crosslinking agent and the alkyl (meth)acrylate.
[0332] <Average Particle Size and Particle Size
Distribution>
[0333] The rubbery polymer (A-III) of the fourth invention obtained
by the miniemulsion polymerization described above preferably
satisfies (2) or (3) below, wherein an average particle size (X) is
represented by X; a largest 10% frequency particle size (Y), which
is a particle size at which the cumulative frequency from the
largest value in a particle size distribution curve reaches 10%, is
represented by Y; and a smallest 10% frequency particle size (Z),
which is a particle size at which the cumulative frequency from the
smallest value in the particle size distribution curve reaches 10%,
is represented by Z.
[0334] (2) The average particle size (X) satisfies X.ltoreq.300 nm,
the largest 10% frequency particle size (Y) satisfies
Y.ltoreq.1.6X, and the smallest 10% frequency particle size (Z)
satisfies Z.gtoreq.0.7X.
[0335] (3) The average particle size (X) satisfies X=300 to 800 nm,
the largest 10% frequency particle size (Y) satisfies
Y.ltoreq.1.7X, and the smallest 10% frequency particle size (Z)
satisfies Z.gtoreq.0.6X.
[0336] When the rubbery polymer (A-III) of the fourth invention has
a uniform particle size satisfying the particle size distribution
(2) or (3) above, a thermoplastic resin molded article particularly
excellent in impact resistance, molded appearance, and color
developability can be obtained by incorporating the graft copolymer
(B-III) produced using the rubbery polymer (A-III) into a
thermoplastic resin composition. When miniemulsion polymerization
is used, the rubbery polymer (A-III) satisfying the average
particle size and particle size distribution described above can be
readily produced.
[0337] The average particle size (X) of the rubbery polymer (A-III)
of the fourth invention is more preferably 200 to 400 nm. For the
particle size distribution of the rubbery polymer (A-III) of the
fourth invention, more preferably, the largest 10% frequency
particle size (Y) satisfies Y.ltoreq.1.4X, and the smallest 10%
frequency particle size (Z) satisfies Z.gtoreq.0.8X.
[0338] The average particle size and particle size distribution of
the rubbery polymer (A-III) of the fourth invention are measured by
the methods described in the section of EXAMPLES below.
[0339] [Graft Copolymer (B-III)]
[0340] The graft copolymer (B-III) of the fourth invention includes
the rubbery polymer (A-III) of the fourth invention and at least
one monomer selected from aromatic vinyl compounds, (meth)acrylic
acid esters, and vinyl cyanide compounds (hereinafter referred to
as the "graft monomer component") graft-polymerized onto the
rubbery polymer (A-III).
[0341] The graft monomer component may include a vinyl monomer
other than aromatic vinyl compounds, (meth)acrylic acid esters, and
vinyl cyanide compounds.
[0342] Of these graft monomer components, the use of a mixture of
an aromatic vinyl compound, preferably styrene, and a vinyl cyanide
compound, preferably acrylonitrile, advantageously provides the
graft copolymer (B-III) with excellent thermal stability. In this
case, the proportions of the aromatic vinyl compound such as
styrene and the vinyl cyanide compound such as acrylonitrile are
preferably such that the proportion of the aromatic vinyl compound
is 50% to 90% by mass and the proportion of the vinyl cyanide
compound is 10% to 50% by mass (provided that the total amount of
the aromatic vinyl compound and the vinyl cyanide compound is 100%
by mass).
[0343] The graft copolymer (B-III) is preferably obtained by
emulsion graft polymerization of 10% to 90% by mass of the rubbery
polymer (A-III) and 90% to 10% by mass of the graft monomer
component (provided that the total amount of the rubbery polymer
(A-III) and the graft monomer component is 100% by mass). This is
because a molded article having an excellent appearance is
provided. More preferably, the proportion of the rubbery polymer
(A-III) is 30% to 70% by mass, and the proportion of the graft
monomer component is 70% to 30% by mass.
[0344] Examples of the method for graft-polymerizing the graft
monomer component onto the rubbery polymer (A-III) include a method
in which the graft monomer component is added to a latex of the
rubbery polymer (A-III) obtained by miniemulsion polymerization and
polymerization is performed in a single-stage or multistage manner.
When polymerization is performed in a multistage manner, the
polymerization is preferably performed by adding the graft monomer
component in multiple portions or in a continuous manner in the
presence of a rubber latex of the rubbery polymer (A-III). By such
a polymerization method, good polymerization stability is provided,
and a latex having the desired particle size and particle size
distribution can be stably obtained. Examples of polymerization
initiators used for the graft polymerization include those which
are the same as the above-described radical polymerization
initiators used for miniemulsion polymerization of the alkyl
(meth)acrylate.
[0345] When the graft monomer component is polymerized onto the
rubbery polymer (A-III), an emulsifier can be added in order to
stabilize the latex and control the average particle size the
resulting graft copolymer (B-III). Examples of emulsifiers used
here include, but are not limited to, those which are the same as
the above-described emulsifiers used for miniemulsion
polymerization of the alkyl (meth)acrylate. Preferred emulsifiers
are anionic emulsifiers and nonionic emulsifiers.
[0346] The amount of emulsifier used when the graft monomer
component is polymerized is not particularly limited but is
preferably 0.1 to 10 parts by mass, more preferably 0.2 to 5 parts
by mass, relative to 100 parts by mass of the resulting graft
copolymer (B-III).
[0347] Examples of the method for collecting the graft copolymer
(B-III) from the latex of the graft copolymer (B-III) obtained by
emulsion polymerization include, but are not limited to, the
following method.
[0348] The latex of the graft copolymer (B-III) is placed in hot
water in which a coagulant is dissolved to solidify the graft
copolymer (B-III). The solidified graft copolymer (B-III) is then
redispersed in water or warm water to form a slurry, and an
emulsifier residue remaining in the graft copolymer (B-III) is
eluted into water and washed. The slurry is then dehydrated with a
dehydrator or the like, and the resulting solid is dried with a
flash dryer or the like to thereby collect the graft copolymer
(B-III) as powder or particles.
[0349] Examples of coagulants include inorganic acids (e.g.,
sulfuric acid, hydrochloric acid, phosphoric acid, and nitric acid)
and metal salts (e.g., calcium chloride, calcium acetate, and
aluminum sulfate). The coagulant is appropriately selected
according to the type of emulsifier. For example, when a carboxylic
acid salt (e.g., a fatty acid salt or rosin acid soap) alone is
used as an emulsifier, any coagulant may be used. When an
emulsifier that shows stable emulsifying power even in the acidic
region, such as sodium alkylbenzene sulfonate, is used as an
emulsifier, an inorganic acid is insufficient, and it is necessary
to use a metal salt.
[0350] The average particle size of the graft copolymer (B-III) of
the fourth invention produced as described above using the rubbery
polymer (A-III) having the above-described preferred average
particle size and particle size distribution is typically 150 to
600 nm, preferably 180 to 500 nm.
[0351] The average particle size of the graft copolymer (B-III) is
measured by the method described in the section of EXAMPLES
below.
[0352] [Thermoplastic Resin Composition]
[0353] A thermoplastic resin composition of the fourth invention
contains the graft copolymer (B-III) of the fourth invention. The
content of the graft copolymer (B-III) in 100 parts by mass of the
thermoplastic resin composition is preferably 20 to 60 parts by
mass. When the content of the graft copolymer (B-III) in the
thermoplastic resin composition is less than 20 parts by mass, the
amount of rubber is small, and the impact resistance of a molded
article obtained tends to be low. When the content of the graft
copolymer (B-III) in the thermoplastic resin composition is more
than 60 parts by mass, the pigmentability and physical property
balance of a molded article obtained tend to be poor.
[0354] In view of the balance of impact resistance, color
developability, and other physical properties, the content of the
graft copolymer (B-III) in 100 parts by mass of the thermoplastic
resin composition of the fourth invention is more preferably 30 to
40 parts by mass.
[0355] The thermoplastic resin composition of the fourth invention
may optionally contain any other thermoplastic resin and
additives.
[0356] Examples of other thermoplastic resins include one or two or
more of polyvinyl chloride, polystyrene, acrylonitrile-styrene
copolymers, styrene-acrylonitrile-N-phenylmaleimide copolymers,
.alpha.-methylstyrene-acrylonitrile copolymers, polymethyl
methacrylate, methyl methacrylate-styrene copolymers,
polycarbonate, polyamide, polyesters such as polyethylene
terephthalate and polybutylene terephthalate, and polyphenylene
ether-polystyrene composites. Of these, acrylonitrile-styrene
copolymers are preferred from the viewpoint of impact resistance
and flowability.
[0357] Examples of additives include colorants such as pigments and
dyes, fillers (e.g., carbon black, silica, and titanium oxide),
flame retardants, stabilizers, reinforcing agents, processing aids,
heat stabilizers, antioxidants, weathering agents, release agents,
plasticizers, and antistatic agents.
[0358] The thermoplastic resin composition of the fourth invention
is produced by mixing and dispersing the graft copolymer (B-III)
and, optionally, any other thermoplastic resin and additives by
using a V-type blender, a Henschel mixer, or the like and
melt-kneading the resulting mixture by using, for example, a
kneading machine such as an extruder, a Banbury mixer, a pressure
kneader, or a roller.
[0359] The order of mixing of components is not particularly
limited as long as all the components are uniformly mixed.
[0360] [Molded Article]
[0361] A molded article of the fourth invention is obtained by
molding the thermoplastic resin composition of the fourth invention
and is excellent in impact resistance, molded appearance, and color
developability.
[0362] The method for molding the thermoplastic resin composition
of the fourth invention is the same as the method for molding the
thermoplastic resin composition of the second invention, and the
preferred molding method is also the same.
[0363] The molded article of the fourth invention obtained by
molding the thermoplastic resin composition of the fourth invention
is excellent in impact resistance, molded appearance, and color
developability thus is suitable for automotive interior and
exterior parts, office machines, household electrical appliances,
building materials, etc.
[0364] Examples of industrial applications of the molded article of
the fourth invention obtained by molding the thermoplastic resin
composition of the fourth invention include automotive parts,
particularly, various exterior and interior parts used without
paint, building material parts such as wall materials and window
frames, tableware, toys, household electrical appliance parts such
as cleaner housings, television housings, and air-conditioner
housings, interior materials, ship materials, and communication
device housings.
EXAMPLES
[0365] Examples will be specifically described below. It should be
noted that the present invention is not limited to the following
examples. Hereinafter, "%" means "% by mass", and "parts" means
"parts by mass".
Examples and Comparative Examples of First Invention
[Methods of Measurements, Evaluations, and Operations]
[0366] Methods of various measurements, evaluations, and operations
therefor in the following Examples and Comparative Examples are as
described below.
[0367] <Average Particle Size>
[0368] For the composite rubber-like polymer (A), the volume
average particle size (MV) measured using a Microtrac ("Nanotrac
150" available from Nikkiso Co., Ltd.) and pure water as a
measurement solvent was used as an average particle size.
[0369] <Refractive Index>
[0370] The refractive index of the composite rubber-like polymer
(A) and the thermoplastic resin (D) was measured at 23.degree. C.
using an Abbe refractometer "KPR-30A" available from Shimadzu
Corporation. The refractive index of the composite rubber-like
polymer (A) was measured after the composite rubber-like polymer
(A) was recovered from an emulsion of the composite rubber-like
polymer (A) by precipitation with isopropyl alcohol and dried.
[0371] <Melt Kneading 1-1>
[0372] The graft copolymer (C) and the thermoplastic resin (D) were
mixed together, and 0.8 parts of carbon black ("#966B" available
from Mitsui Chemicals, Inc.) was mixed with 100 parts of the total
amount of the graft copolymer (C) and the thermoplastic resin (D).
Using a twin-screw extruder ("PCM30" available from Ikegai Corp.)
having a diameter of 30 mm and equipped with a vacuum vent, melt
kneading was performed at a cylinder temperature of 200.degree. C.
to 260.degree. C. and a reduced pressure of 93.325 kPa to obtain a
black-colored thermoplastic resin composition. After the melt
kneading, pelletization was performed using a pelletizer ("Model SH
pelletizer" available from Soukensya).
[0373] <Melt Kneading 1-2>
[0374] The graft copolymer (C) and the thermoplastic resin (D) were
mixed together, and using a twin-screw extruder ("PCM30" available
from Ikegai Corp.) having a diameter of 30 mm and equipped with a
vacuum vent, melt kneading was performed at a cylinder temperature
of 200.degree. C. to 260.degree. C. and a reduced pressure of
93.325 kPa to obtain a transparent thermoplastic resin composition.
After the melt kneading, pelletization was performed using a
pelletizer ("Model SH pelletizer" available from Soukensya).
[0375] <Injection Molding 1-1>
[0376] Using the pellets of the thermoplastic resin compositions
obtained in Melt Kneading 1-1 and/or Melt Kneading 1-2, a molded
article 80 mm long, 10 mm wide, and 4 mm thick was molded with an
injection molding machine ("IS55FP-1.5A" available from Toshiba
Machine Co., Ltd.) under the conditions of a cylinder temperature
of 200.degree. C. to 270.degree. C. and a mold temperature of
60.degree. C. and used as a molded article for Charpy impact
testing.
[0377] <Injection Molding 1-2>
[0378] Using the pellets of the thermoplastic resin compositions
obtained in Melt Kneading 1-1 and/or Melt Kneading 1-2, molded
articles 100 mm long, 100 mm wide, and 2 mm thick were molded with
an injection molding machine ("IS55FP-1.5A" available from Toshiba
Machine Co., Ltd.) under the conditions of a cylinder temperature
of 200.degree. C. to 270.degree. C. and a mold temperature of
60.degree. C. and used as a molded article for color developability
evaluation, a molded article for transparency evaluation, and a
molded article for weather resistance evaluation.
[0379] <Color Developability>
[0380] The molded article for color developability evaluation
molded using the black-colored thermoplastic resin composition
obtained in Melt Kneading 1-1 was measured for lightness L* by the
SCE method using a spectrocolorimeter ("CM-3500d" available from
Konica Minolta Optics, Inc). The measured L* is defined as "L*
(ma)". The lower the L*, the blacker the molded article and the
better the color developability.
[0381] "Lightness (L*)" means a lightness value (L*) among color
values in the L*a*b* color system employed in JIS Z 8729.
[0382] The "SCE method" means a method for measuring color by using
a spectrocolorimeter in accordance with JIS Z 8722 with specular
reflection being removed by light trapping.
[0383] <Transparency>
[0384] The haze value (Hz) of the molded article for transparency
evaluation molded using the transparent thermoplastic resin
composition obtained in Melt Kneading 1-2 was measured with a haze
meter (available from Murakami Color Research Laboratory Co., Ltd).
The smaller the haze, the higher the transparency.
[0385] <Weather Resistance>
[0386] In the case of the molded article for weather resistance
evaluation molded using the black-colored thermoplastic resin
composition obtained in Melt Kneading 1-1, the molded article for
weather resistance evaluation was treated for 1500 hours using a
Sunshine Weather Meter (available from Suga Test Instruments Co.,
Ltd.) under the conditions of a black panel temperature of
63.degree. C. and a cycle of 60 minutes (rainfall: 12 minutes). The
degree of change in color (.DELTA.E) before and after the treatment
was measured with a spectrocolorimeter ("CM-3500d" available from
Konica Minolta Optips, Inc.) and evaluated. The smaller the
.DELTA.E, the better the weather resistance.
[0387] In the case of the molded article for weather resistance
evaluation molded using the transparent thermoplastic resin
composition obtained in Melt Kneading 1-2, the molded article for
weather resistance evaluation was treated for 1500 hours using a
Sunshine Weather Meter (available from Suga Test Instruments Co.,
Ltd.) under the conditions of a black panel temperature of
63.degree. C. and a cycle of 60 minutes (rainfall: 12 minutes). The
change in haze (.DELTA.Hz) before and after the treatment was
measured with a haze meter (available from Murakami Color Research
Laboratory Co., Ltd). The smaller the .DELTA.Hz, the better the
weather resistance.
[0388] <Impact Resistance>
[0389] The Charpy impact strength of the molded article for Charpy
impact testing was measured by performing a Charpy impact test
(unnotched) under the condition of 23.degree. C. in accordance with
ISO 179 standard. The Charpy impact strength of a molded article
obtained using an acrylonitrile-styrene copolymer resin, i.e., a
thermoplastic resin (D2) described below was measured by a notched
Charpy impact test.
[0390] [Production of Graft Copolymers]
Production Example 1-1: Graft Polymer (C1)
<<Production of Composite Rubber-Like Polymer
(A1)>>
[0391] Twenty four parts of polymethylphenyl siloxane "HIVAC-F-5"
(refractive index: 1.575, viscosity: 160 mm.sup.2/s) available from
Shin-Etsu Chemical Co., Ltd., 75 parts of n-butyl acrylate, 1 part
of allyl methacrylate were mixed together to obtain a mixture
(Ac1). While stirring the mixture obtained, 310 parts of deionized
water, 1 part of dipotassium alkenyl succinate, 0.1 parts of
t-butyl hydroperoxide, and 2.5 parts of hexadecane, ultrasonic
irradiation was performed at an amplitude of 35 .mu.m for 20
minutes using an "ULTRASONIC HOMOGENIZER US-600" available from
Nihonseiki Kaisha Ltd. to obtain a miniemulsion of the mixture
(Ac1).
[0392] The miniemulsion of the mixture (Ac1) was loaded into a
reaction vessel equipped with a reagent injector, a condenser, a
jacket heater, and a stirring device. The reaction vessel was
purged with nitrogen, and the temperature was then raised to
55.degree. C. Next, 0.3 parts of Rongalite, 0.0001 parts of ferrous
sulfate heptahydrate, 0.0003 parts of disodium
ethylenediaminetetraacetate, and 10 parts of deionized water were
added to initiate polymerization. After polymerization exotherm was
observed, the jacket temperature was set at 75.degree. C., and the
polymerization was continued until polymerization exotherm was not
observed anymore. The resultant was further maintained for 1 hour
to obtain an emulsion of a composite rubber-like polymer (A1). The
volume average particle size of the emulsion of the composite
rubber-like polymer (A1) was 122 nm.
[0393] <<Production of Graft Copolymer (C1)>>
[0394] To the emulsion (solid content: 50 parts) of the composite
rubber-like polymer (A1), an aqueous solution of 0.0002 parts of
ferrous sulfate heptahydrate, 0.0006 parts of disodium
ethylenediaminetetraacetate, and 0.25 parts of Rongalite in 10
parts of ion-exchanged water was added. Next, while adding dropwise
49.2 parts of methyl methacrylate, 0.8 parts of methyl acrylate,
and 0.2 parts of t-butyl hydroperoxide over 100 minutes, graft
polymerization was performed at 75.degree. C. Next, 150 parts of an
aqueous solution in which calcium acetate was dissolved in a
proportion of 5% were heated to 60.degree. C., and while stirring
the aqueous solution, the emulsion obtained was gradually added
dropwise thereto to be coagulated. The coagulation obtained was
separated, washed, and then dried to obtain a dry powder of a graft
copolymer (C1).
Production Example 1-2: Graft Polymer (C2)
[0395] A composite rubber-like polymer (A2) and a graft polymer
(C2) were obtained by performing the reaction under the same
reaction conditions as in Production Example 1-1 except that 66.3
parts of polymethylphenyl siloxane "KF-54" (refractive index:
1.505, viscosity: 400 mm.sup.2/s) available from Shin-Etsu Chemical
Co., Ltd., 32.7 parts of n-butyl acrylate, and 1 part of allyl
methacrylate were used in place of 24 parts of polymethylphenyl
siloxane "HIVAC F-5" available from Shin-Etsu Chemical Co., Ltd.,
75 parts of n-butyl acrylate, and 1 part of allyl methacrylate. The
volume average particle size of the composite rubber-like polymer
(A2) was 125 nm.
Production Example 1-3: Graft Polymer (C3)
[0396] A composite rubber-like polymer (A3) and a graft polymer
(C3) were obtained by performing the reaction under the same
reaction conditions as in Production Example 1-1 except that
ultrasonic irradiation was performed at an amplitude of 20 .mu.m
for 20 minutes using an "ULTRASONIC HOMOGENIZER US-600" available
from Nihonseiki Kaisha Ltd. The volume average particle size of the
composite rubber-like polymer (A3) was 282 nm.
Production Example 1-4: Graft Polymer (C4)
<<Production of Composite Rubber-Like Polymer
(A4)>>
[0397] Twenty four parts of polymethylphenyl siloxane "HIVAC F-5"
available from Shin-Etsu Chemical Co., Ltd., 75 parts of n-butyl
acrylate, 1 part of allyl methacrylate, and 0.1 parts of t-butyl
hydroperoxide were mixed together. The resulting mixture, 310 parts
of deionized water, and 1 part of dipotassium alkenyl succinate
were loaded into a reaction vessel equipped with a reagent
injector, a condenser, a jacket heater, and a stirring device. The
reaction vessel was purged with nitrogen, and the temperature was
then raised to 55.degree. C. Next, 0.3 parts of Rongalite, 0.0001
parts of ferrous sulfate heptahydrate, 0.0003 parts of disodium
ethylenediaminetetraacetate, and 10 parts of deionized water were
added to initiate polymerization. After polymerization exotherm was
observed, the jacket temperature was set at 75.degree. C., and the
polymerization was continued until polymerization exotherm was not
observed anymore. The resultant was further maintained for 1 hour
and filtered through a 200-mesh wire net to obtain an emulsion of a
composite rubber-like polymer (A4). When the reaction vessel after
the reaction was inspected, a large amount of oily deposit was
observed, demonstrating that the polymethylphenyl siloxane "HIVAC
F-5" was not sufficiently combined in the composite rubber-like
polymer (A4). The volume average particle size of the composite
rubber-like polymer (A4) was 102 nm.
[0398] <<Production of Graft Polymer (C4)>>
[0399] A graft polymer (C4) was obtained in the same manner as in
Production Example 1-1 except that the composite rubber-like
polymer (A4) was used in place of the composite rubber-like polymer
(A1).
Production Example 1-5: Graft Polymer (C5)
<<Production of Composite Rubber-Like Polymer
(A5)>>
[0400] While stirring 24 parts of polymethylphenyl siloxane "HIVAC
F-5" available from Shin-Etsu Chemical Co., Ltd., 310 parts of
deionized water, and 1 part of dipotassium alkenyl succinate,
ultrasonic irradiation was performed at an amplitude of 35 .mu.m
for 20 minutes using an "ULTRASONIC HOMOGENIZER US-600" available
from Nihonseiki Kaisha Ltd.
[0401] Next, the resulting polymethylphenyl siloxane emulsion, 0.3
parts of Rongalite, 0.0001 parts of ferrous sulfate heptahydrate,
and 0.0003 parts of disodium ethylenediaminetetraacetate were
loaded into a reaction vessel equipped with a reagent injector, a
condenser, a jacket heater, and a stirring device, and the reaction
vessel was purged with nitrogen. After the temperature was raised
to 70.degree. C., polymerization was performed while adding
dropwise 75 parts of n-butyl acrylate, 1 part of allyl
methacrylate, and 0.1 parts of t-butyl hydroperoxide for 60
minutes. Next, the jacket temperature was set at 75.degree. C. and
further maintained for 1 hour to obtain an emulsion of a composite
rubber-like polymer (A5). The volume average particle size of the
emulsion of the composite rubber-like polymer (A5) was 142 nm.
[0402] <<Production of Graft Polymer (C5)>>
[0403] A graft polymer (C5) was obtained in the same manner as in
Production Example 1-1 except that the composite rubber-like
polymer (A5) was used in place of the composite rubber-like polymer
(A1).
Production Example 1-6: Graft Polymer (C6)
[0404] A composite rubber-like polymer (A6) and a graft polymer
(C6) were obtained by performing the reaction under the same
conditions as in Production Example 1-5 except that the addition
amount of dipotassium alkenyl succinate was 0.7 parts and the
amplitude of the "ULTRASONIC HOMOGENIZER US-600" available from
Nihonseiki Kaisha Ltd. was 20 .mu.m. The volume average particle
size of the composite rubber-like polymer (A6) was 302 nm.
[0405] <Graft Polymer (C7)>
[0406] "MUX-60" available from UMG ABS, Ltd. was used as a graft
polymer (C7) in which methyl methacrylate was graft-polymerized
onto a composite rubber-like polymer of polybutadiene and n-butyl
polyacrylate.
Production Example 1-7: Graft Polymer (C8)
[0407] A composite rubber-like polymer (A8) and a graft polymer
(C8) were obtained by performing the reaction under the same
conditions as in Production Example 1-1 except that in producing a
composite rubber-like polymer, 50 parts of polymethylphenyl
siloxane "HIVAC F-5" available from Shin-Etsu Chemical Co., Ltd.,
49 parts of n-butyl acrylate, and 1 part of allyl methacrylate were
used in place of 24 parts of polymethylphenyl siloxane "HIVAC F-5"
available from Shin-Etsu Chemical Co., Ltd., 75 parts of n-butyl
acrylate, and 1 part of allyl methacrylate, and in producing a
graft copolymer, 49.2 parts of methyl methacrylate and 0.8 parts of
methyl acrylate were changed to 35 parts of styrene and 15 parts of
acrylonitrile. The volume average particle size of the composite
rubber-like polymer (A8) was 155 nm.
Production Example 1-8: Graft Polymer (C9)
[0408] A composite rubber-like polymer (A9) and a graft polymer
(C9) were obtained by performing the reaction under the same
conditions as in Production Example 1-1 except that in producing a
composite rubber-like polymer, 14 parts of polydimethylsiloxane
"KF-96-500cs" (refractive index: 1.403, viscosity: 500 mm.sup.2/s)
available from Shin-Etsu Chemical Co., Ltd., 35 parts of n-butyl
acrylate, and 1 part of allyl methacrylate were used in place of 24
parts of polymethylphenyl siloxane "HIVAC F-5" available from
Shin-Etsu Chemical Co., Ltd., 75 parts of n-butyl acrylate, and 1
part of allyl methacrylate, and in producing a graft copolymer,
49.2 parts of methyl methacrylate, 0.8 parts of methyl acrylate
were changed to 35 parts of styrene and 15 parts of acrylonitrile.
The volume average particle size of the composite rubber-like
polymer (A9) was 111 nm.
Production Example 1-9: Graft Polymer (C10)
[0409] A composite rubber-like polymer (A10) and a graft polymer
(C10) were obtained by performing the reaction under the same
conditions as in Production Example 1-5 except that in producing a
composite rubber-like polymer, 14 parts of polydimethylsiloxane
"KF-96-500cs" available from Shin-Etsu Chemical Co., Ltd., 35 parts
of n-butyl acrylate, and 1 part of allyl methacrylate were used in
place of 24 parts of polymethylphenyl siloxane "HIVAC F-5"
available from Shin-Etsu Chemical Co., Ltd., 75 parts of n-butyl
acrylate, and 1 part of allyl methacrylate, and in producing a
graft copolymer, 49.2 parts of methyl methacrylate, 0.8 parts of
methyl acrylate were changed to 35 parts of styrene and 15 parts of
acrylonitrile. The volume average particle size of the composite
rubber-like polymer (A10) was 138 nm.
Production Example 1-10: Graft Polymer (C11)
[0410] A graft polymer (C11) was obtained in the same manner as in
Production Example 1-1 except that the composite rubber-like
polymer (A8) was used in place of the composite rubber-like polymer
(A1).
Production Example 1-11: Graft Polymer (C12)
[0411] A composite rubber-like polymer (A12) and a graft polymer
(C12) were obtained by performing the reaction under the same
conditions as in Production Example 1-1 except that in producing a
composite rubber-like polymer, 8 parts of polymethylphenyl siloxane
"HIVAC F-5" available from Shin-Etsu Chemical Co., Ltd., 91 parts
of n-butyl acrylate, and 1 part of allyl methacrylate were used in
place of 24 parts of polymethylphenyl siloxane "HIVAC F-5"
available from Shin-Etsu Chemical Co., Ltd., 75 parts of n-butyl
acrylate, and 1 part of allyl methacrylate. The volume average
particle size of the composite rubber-like polymer (A12) was 132
nm.
[0412] [Production of Thermoplastic Resins]
Production Example 1-12: Thermoplastic Resin (D1)
[0413] Into a nitrogen-purged stainless steel reaction vessel
equipped with a stirrer, 150 parts of deionized water, 99 parts of
methyl methacrylate, 1 part of methyl acrylate, 0.2 parts of
2,2'-azobis(isobutyronitrile), 0.25 parts of n-octyl mercaptan,
0.47 parts of calcium hydroxyapatite, and 0.003 parts of potassium
alkenyl succinate were loaded. The inner temperature of the
reaction vessel was set at 75.degree. C., and the reaction was
allowed to proceed for 3 hours. The temperature was then raised to
90.degree. C., and the reaction was allowed to proceed for 1 hour.
The contents were extracted, washed with a centrifugal dehydrator,
and dried to obtain a powdery thermoplastic resin (D1).
Production Example 1-13: Thermoplastic Resin (D2)
[0414] Into a nitrogen-purged stainless steel reaction vessel
equipped with a stirrer, 120 parts of deionized water, 0.47 parts
of calcium hydroxyapatite, 0.003 parts of potassium alkenyl
succinate, 0.3 parts of 2,2'-azobis(isobutyronitrile), 30 parts of
acrylonitrile, 70 parts of styrene, and 0.35 parts of t-dodecyl
mercaptan were loaded. The starting temperature was set at
75.degree. C., and the reaction was allowed to proceed for 5 hours.
The temperature was then raised to 120.degree. C., and the reaction
was allowed to proceed for 2 hours. The contents were taken out,
washed with a centrifugal dehydrator, and dried to obtain a powdery
thermoplastic resin (D2).
Production Example 1-14: Thermoplastic Resin (D3)
[0415] Into a nitrogen-purged stainless steel reaction vessel
equipped with a stirrer, 150 parts of deionized water, 82 parts of
methyl methacrylate, 12 parts of N-phenylmaleimide, 6 parts of
styrene, 0.2 parts of 2,2'-azobis(isobutyronitrile), 0.25 parts of
n-octyl mercaptan, 0.67 parts of calcium hydroxyapatite, and 0.003
parts of potassium alkenyl succinate were loaded. The inner
temperature of the reaction vessel was set at 75.degree. C., and
the reaction was allowed to proceed for 3 hours. The temperature
was then raised to 90.degree. C., and the reaction was allowed to
proceed for 1 hour. The contents were extracted, washed with a
centrifugal dehydrator, and dried to obtain a powdery thermoplastic
resin (D3).
[0416] Table 1 summarizes the volume average particle sizes and
refractive indices of the composite rubber-like polymers (A) used
for the graft copolymers (C) and the refractive index of the
thermoplastic resins (D).
TABLE-US-00001 TABLE 1 Volume average particle size Refractive (nm)
index Remarks Graft copolymer (C1) Composite rubber-like polymer
(A1) 122 1.494 Present invention example Graft copolymer (C2)
Composite rubber-like polymer (A2) 125 1.492 Present invention
example Graft copolymer (C3) Composite rubber-like polymer (A3) 282
1.492 Present invention example Graft copolymer (C4) Composite
rubber-like polymer (A4) 102 1.471 Comparative example Graft
copolymer (C5) Composite rubber-like polymer (A5) 142 1.496
Comparative example Graft copolymer (C6) Composite rubber-like
polymer (A6) 302 1.492 Comparative example Graft copolymer (C8)
Composite rubber-like polymer (A8) 155 1.521 Present invention
example Graft copolymer (C9) Composite rubber-like polymer (A9) 111
1.446 Present invention example Graft copolymer (C10) Composite
rubber-like polymer (A10) 138 1.448 Comparative example Graft
copolymer (C11) Composite rubber-like polymer (A8) 155 1.521
Present invention example Graft copolymer (C12) Composite
rubber-like polymer (A12) 132 1.475 Present invention example
Thermoplastic resin (D1) -- -- 1.492 -- Thermoplastic resin (D2) --
-- 1.569 -- Thermoplastic resin (D3) -- -- 1.515 --
Examples 1-1 to 1-5, Comparative Examples 1-1 to 1-5
[0417] The graft copolymer (C) and the thermoplastic resin (D1) in
amounts shown in Table 2 were pelletized by the method of Melt
Kneading 1-1 described above, and molded articles were obtained by
injection molding. The molded articles obtained were evaluated for
color developability, weather resistance, and impact resistance.
The results are shown in Table 2.
TABLE-US-00002 TABLE 2 Com- Exam- Exam- Exam- Exam- Exam-
Comparative Comparative Comparative Comparative parative ple ple
ple ple ple example example example example example 1-1 1-2 1-3 1-4
1-5 1-1 1-2 1-3 1-4 1-5 Amount Graft C1 10 40 60 (parts) copolymer
(C) C2 40 C3 40 C4 40 C5 40 C6 40 C7 40 Thermoplastic D1 90 60 40
60 60 60 60 60 60 100 resin (D) Evaluation Color L* 3.8 4.2 4.3 3.8
4.0 7.2 6.2 8.1 4.0 3.5 results developability Weather .DELTA.E 0.5
1.0 1.1 0.9 1.1 1.0 1.1 1.3 9.6 0.5 resistance Impact kJ/m.sup.2 22
53 82 57 65 33 55 66 78 17 resistance
[0418] As shown in Examples 1-1 to 1-5, the graft copolymers (C) of
the first invention can provide thermoplastic resin compositions
and molded articles thereof excellent in weather resistance, color
developability, and impact resistance. By contrast, as shown in
Comparative Examples 1-1 to 1-3, the graft polymers polymerized
without going through miniemulsification of the mixture (Ac) and
the thermoplastic resin compositions including the graft polymers
have poor color developability. As shown in Comparative Example
1-4, the use of a graft polymer obtained by using polybutadiene
instead of polyorganosiloxane in a composite rubber-like polymer
results in poor weather resistance. Comparative Example 1-5 is poor
in impact resistance because the graft copolymer (C) is not
included.
Examples 1-6 and 1-7, Comparative Example 1-6
[0419] The graft copolymer (C) and the thermoplastic resin (D2) in
amounts shown in Table 3 were pelletized by the method of Melt
Kneading 1-1 described above, and molded articles were obtained by
injection molding. The molded articles obtained were evaluated for
color developability, weather resistance, and impact resistance.
The results are shown in Table 3.
TABLE-US-00003 TABLE 3 Exam- Exam- Comparative ple ple example 1-6
1-7 1-6 Amount Graft copolymer(C) C8 40 (parts) C9 40 C10 40
Thermoplastic D2 60 60 60 resin (D) Evalu- Color developability L*
4.8 5.5 7.2 ation Weather resistance .DELTA.E 1.5 1.7 1.6 results
Impact resistance kJ/m.sup.2 22 28 26
[0420] As shown in Examples 1-6 and 1-7, the graft copolymers (C)
of the first invention can provide thermoplastic resin compositions
and molded articles thereof excellent in weather resistance, color
developability, and impact resistance. By contrast, as shown in
Comparative Example 1-6, the thermoplastic resin composition
including a graft polymer polymerized without going through
miniemulsification of the mixture (Ac) has poor color
developability.
Examples 1-8 to 1-10, Comparative Example 1-7, Reference Example
1-1
[0421] The graft copolymer (C) and the thermoplastic resin (D1) or
the thermoplastic resin (D3) in amounts shown in Table 4 were
pelletized by the method of Melt Kneading 1-2 described above, and
molded articles were obtained by injection molding. The molded
articles obtained were evaluated for color developability,
transparency, weather resistance, and impact resistance. The
results are shown in Table 4.
TABLE-US-00004 TABLE 4 Comparative Reference Example Example
Example example Example 1-8 1-9 1-10 1-7 1-1 Amount (parts) Graft
copolymer (C) C1 40 C11 40 40 C12 40 C5 40 Thermoplastic resin (D)
D1 60 60 60 60 D3 60 Refractive index difference.asterisk-pseud.
0.002 0.006 0.017 0.004 0.029 Evaluation Color developability L*
4.2 4.8 5.2 6.2 5.3 results Transparency Hz (%) 0.9 3.3 8.2 9.1
11.3 Weather resistance .DELTA. Hz (%) 0.7 1.2 1.1 0.9 1.2 Impact
resistance kJ/m.sup.2 53 48 51 55 60 .asterisk-pseud.Refractive
index difference between graft copolymer (C) and thermoplastic
resin (D)
[0422] As shown in Examples 1-8 to 1-10, when the refractive index
difference between the graft copolymer (C) and the thermoplastic
resin (D) is 0.02 or less in the first invention, a thermoplastic
resin composition and a molded article thereof that are highly
transparent are provided. By contrast, as shown in Comparative
Example 1-7, in the thermoplastic resin composition including a
graft polymer polymerized without going through miniemulsification
of the mixture (Ac), the composition of the composite rubber-like
polymer (A) is not uniform, and the transparency is poor although
the refractive index difference between the graft copolymer (C) and
the thermoplastic resin (D) is 0.02 or less.
[0423] Reference Example 1-1 is poor in transparency because the
refractive index difference between the graft copolymer (C) and the
thermoplastic resin (D) is more than 0.02 but is good in color
developability, weather resistance, and impact resistance.
Examples and Comparative Examples of Second Invention
[Methods of Measurements and Evaluations]
[0424] Methods of various measurements, evaluations, and operations
therefor in the following Examples and Comparative Examples are as
described below.
[0425] <Measurement of Number Average Molecular Weight
(Mn)>
[0426] The number average molecular weight (Mn) in terms of
polystyrene was measured by GPC (GPC: "GPC/V2000" available from
Waters, column: "Shodex AT-G+AT-806MS" available from Showa Denko
K.K.) using o-dichlorobenzene (145.degree. C.) as a solvent.
[0427] <Measurement of Average Particle Size>
[0428] The volume average particle size (MV) measured using a
Microtrac ("Nanotrac 150" available from Nikkiso Co., Ltd.) and
pure water as a measurement solvent was used as an average particle
size.
[0429] It was confirmed by electron microscopic image analysis that
the average particle size of the crosslinked particles (A-I)
dispersed in the graft crosslinked particles (B-I) equated with the
average particle size of the crosslinked particles (A-I) and the
graft crosslinked particles (B-I) in a thermoplastic resin
composition.
[0430] <Melt Kneading 2-1>
[0431] The crosslinked particles (A-I) or the graft crosslinked
particles (B-I) and the thermoplastic resin (D-I) were mixed
together, and using a twin-screw extruder ("PCM30" available from
Ikegai Corp.) having a diameter of 30 mm and equipped with a vacuum
vent, melt kneading was performed at a cylinder temperature of
200.degree. C. to 260.degree. C. and a reduced pressure of 93.325
kPa to obtain a transparent thermoplastic resin composition. After
the melt kneading, pelletization was performed using a pelletizer
("Model SH pelletizer" available from Soukensya).
[0432] <Melt Kneading 2-2>
[0433] The crosslinked particles (A-I) or the graft crosslinked
particles (B-I), the thermoplastic resin (D-I), and, furthermore,
carbon black ("#966B" available from Mitsui Chemicals, Inc.) in an
amount of 0.8 parts relative to 100 parts of the total of the
crosslinked particles (A-I) or the graft crosslinked particles
(B-I) and the thermoplastic resin (D-I) were mixed together, and
using a twin-screw extruder ("PCM30" available from Ikegai Corp.)
having a diameter of 30 mm and equipped with a vacuum vent, melt
kneading was performed at a cylinder temperature of 200.degree. C.
to 260.degree. C. and a reduced pressure of 93.325 kPa to obtain a
black-colored thermoplastic resin composition. After the melt
kneading, pelletization was performed using a pelletizer ("Model SH
pelletizer" available from Soukensya).
[0434] <Measurement of Melt Volume Rate (MVR)>
[0435] The MVR of the thermoplastic resin composition obtained in
Melt Kneading 2-1 was measured in accordance with ISO 1133
standard. The MVR indicates the flowability of the thermoplastic
resin composition.
[0436] <Injection Molding 2-1>
[0437] Using the pellets of the thermoplastic resin composition
obtained in Melt Kneading 2-1, a molded article 80 mm long, 10 mm
wide, and 4 mm thick was molded with an injection molding machine
("IS55FP-1.5A" available from Toshiba Machine Co., Ltd.) under the
conditions of a cylinder temperature of 200.degree. C. to
270.degree. C. and a mold temperature of 60.degree. C. and used as
a molded article for Charpy impact testing or a molded article for
tensile testing.
[0438] <Injection Molding 2-2>
[0439] Using the pellets of the thermoplastic resin composition
obtained in Melt Kneading 2-2, molded articles 100 mm long, 100 mm
wide, and 2 mm thick were molded with an injection molding machine
("IS55FP-1.5A" available from Toshiba Machine Co., Ltd.) under the
conditions of a cylinder temperature of 200.degree. C. to
270.degree. C. and a mold temperature of 60.degree. C. and used as
a molded article for color developability evaluation and a molded
article for abrasion resistance evaluation.
[0440] <Evaluation of Impact Resistance>
[0441] The Charpy impact strength of the molded article for Charpy
impact testing was measured by performing a Charpy impact test
(notched) under the condition of 23.degree. C. in accordance with
ISO 179 standard.
[0442] <Evaluation of Color Developability>
[0443] The molded article for color developability evaluation was
measured for lightness L* by the SCE method using a
spectrocolorimeter ("CM-3500d" available from Konica Minolta
Optips, Inc). The measured L* is defined as "L* (ma)". The lower
the L*, the blacker the molded article and the better the color
developability.
[0444] "Lightness L*" means a lightness value (L*) among color
values in the L*a*b* color system employed in JIS Z 8729.
[0445] The "SCE method" means a method for measuring color by using
a spectrocolorimeter in accordance with JIS Z 8722 with specular
reflection being removed by light trapping.
[0446] <Evaluation of Abrasion Resistance>
[0447] As shown in FIG. 1, a rod-like jig 2 having a tip portion 1
formed in a substantially hemispherical shape was provided, and a
laminate sheet S made of eight pieces of gauze superposed on one
another was put on the tip portion 1. The tip portion 1 having the
laminate sheet S put thereon was brought into contact with a
surface of a molded article (test piece) M such that the rod-like
jig 2 was perpendicular to the surface, and the tip portion 1 was
slid on the surface of the molded article M in a horizontal
direction (an arrow X direction in the FIGURE) and reciprocated 100
times. During this process, a load of 1 kg was applied. After the
100 reciprocations, the lightness L* of the abraded surface of the
molded article M was measured by the SCE method using a
spectrocolorimeter similarly to the above-described evaluation of
color developability. The measured L* is defined as "L* (mc)".
[0448] (Assessment of Abrasion Resistance)
[0449] .DELTA.L*, which is a benchmark for assessing the prominence
of abrasions on the molded article M, was calculated from "L* (ma)"
obtained in the above-described evaluation of color developability
and "L* (mc)" by the following formula (5). Larger absolute values
of .DELTA.L*(mc-ma) indicate higher prominence of abrasions.
.DELTA.L*(mc-ma)=L*(mc)-L*(ma) (5)
Evaluations were made by using the absolute value of
.DELTA.L*(mc-ma) according to the following criteria. In the case
of A and B, it was determined to have abrasion resistance.
[0450] A: The absolute value of .DELTA.L*(mc-ma) is 2.0 or less.
Abrasions are not prominent, and the design of a molded article is
not impaired.
[0451] B: The absolute value of .DELTA.L*(mc-ma) is more than 2.0
and 5.0 or less. Abrasions are less prominent, and the design of a
molded article is not impaired.
[0452] D: the absolute value of .DELTA.L*(mc-ma) is more than 5.0.
Abrasions are prominent, and the design of a molded article is
impaired.
[0453] <Measurement of Mold Shrinkage Rate>
[0454] According to ASTM D 955, the molded article for tensile
testing was measured for its mold shrinkage rate from a mold
dimension. The mold shrinkage rate is preferably 0.7% or less.
[0455] [Production of Di(Meth)Acrylic Acid Ester (a)]
Production Example 2-1: Di(Meth)Acrylic Acid Ester (a-1)
[0456] In a reaction vessel equipped with a distillator, 32.5 parts
of polytetramethylene glycol (PTMG650; Mn, 650; available from
Mitsubishi Chemical Corporation), 21.52 parts of methyl acrylate,
0.034 parts of hydroquinone, 0.17 parts of tetrabutoxy titanium,
and 250 parts of toluene were placed and heated with stirring at a
bath temperature of 130.degree. C. to 140.degree. C. for 9 hours
under atmospheric pressure under a stream of nitrogen. During this
process, a liquid containing methanol was distilled by
distillation. After the reaction, 3.0 parts of water was added to
the reaction solution, and the resultant was stirred at a bath
temperature of 90.degree. C. for 2 hours. Next, insoluble matter
was removed by suction filtration. Toluene was distilled off at
120.degree. C. under reduced pressure, and low-boiling components
(e.g., methyl acrylate and residual toluene) were distilled off at
50 to 20 mmHg and a bath temperature of 120.degree. C. to
190.degree. C. to obtain a colorless, transparent
polytetramethylene glycol diacrylate (di(meth)acrylic acid ester
(a-1)). The number average molecular weight (Mn) of the
di(meth)acrylic acid ester (a-1) measured by GPC was 670.
Production Example 2-2: Di(Meth)Acrylic Acid Ester (a-2)
[0457] A colorless, transparent polytetramethylene glycol
diacrylate (di(meth)acrylic acid ester (a-2)) was obtained in the
same manner as in Production Example 2-1 except that 42.5 parts of
polytetramethylene glycol (PTMG850; Mn, 850; available from
Mitsubishi Chemical Corporation) were used as polytetramethylene
glycol. The number average molecular weight (Mn) of the
di(meth)acrylic acid ester (a-2) measured by GPC was 860.
Production Example 2-3: Di(Meth)Acrylic Acid Ester (a-3)
[0458] A colorless, transparent polytetramethylene glycol
diacrylate (di(meth)acrylic acid ester (a-3)) was obtained in the
same manner as in Production Example 2-1 except that 50.0 parts of
polytetramethylene glycol (PTMG1000; Mn, 1000; available from
Mitsubishi Chemical Corporation) were used as polytetramethylene
glycol. The number average molecular weight (Mn) of the
di(meth)acrylic acid ester (a-3) measured by GPC was 1010.
Production Example 2-4: Di(Meth)Acrylic Acid Ester (a-4)
[0459] A colorless, transparent polytetramethylene glycol
diacrylate (di(meth)acrylic acid ester (a-4)) was obtained in the
same manner as in Production Example 2-1 except that 75.0 parts of
polytetramethylene glycol (PTMG1500; Mn, 1500; available from
Mitsubishi Chemical Corporation) were used as polytetramethylene
glycol. The number average molecular weight (Mn) of the
di(meth)acrylic acid ester (a-4) measured by GPC was 1560.
Production Example 2-5: Di(Meth)Acrylic Acid Ester (a-5)
[0460] A colorless, transparent polytetramethylene glycol
diacrylate (di(meth)acrylic acid ester (a-5)) was obtained in the
same manner as in Production Example 2-1 except that 100.0 parts of
polytetramethylene glycol (PTMG2000; Mn, 2000; available from
Mitsubishi Chemical Corporation) were used as polytetramethylene
glycol. The number average molecular weight (Mn) of the
di(meth)acrylic acid ester (a-5) measured by GPC was 2070.
Production Example 2-6: Di(Meth)Acrylic Acid Ester (a-6)
[0461] A colorless, transparent polytetramethylene glycol
diacrylate (di(meth)acrylic acid ester (a-6)) was obtained in the
same manner as in Production Example 2-1 except that 150.0 parts of
polytetramethylene glycol (PTMG3000; Mn, 3000; available from
Mitsubishi Chemical Corporation) were used as polytetramethylene
glycol. The number average molecular weight (Mn) of the
di(meth)acrylic acid ester (a-6) measured by GPC was 3020.
Production Example 2-7: Di(Meth)Acrylic Acid Ester (a-7)
[0462] A white polyethylene glycol diacrylate (di(meth)acrylic acid
ester (a-7)) was obtained in the same manner as in Production
Example 2-1 except that 300.0 parts of polyethylene glycol
(PEG6000; Mn, 6000; available from TOHO Chemical Industry Co.,
Ltd.) were used in place of polytetramethylene glycol. The number
average molecular weight (Mn) of the di(meth)acrylic acid ester
(a-7) measured by GPC was 6040.
Production Example 2-8: Di(Meth)Acrylic Acid Ester (a-8)
[0463] A white polyethylene glycol diacrylate (di(meth)acrylic acid
ester (a-8)) was obtained in the same manner as in Production
Example 2-1 except that 400.0 parts of polyethylene glycol
(PEG8000; Mn, 8000; available from MP Biomedicals) were used in
place of polytetramethylene glycol. The number average molecular
weight (Mn) of the di(meth)acrylic acid ester (a-8) measured by GPC
was 8010.
Production Example 2-9: Di(Meth)Acrylic Acid Ester (a-9)
[0464] A white polyethylene glycol diacrylate (di(meth)acrylic acid
ester (a-9)) was obtained in the same manner as in Production
Example 2-1 except that 500.0 parts of polyethylene glycol
(PEG10000; Mn, 10000; available from TOHO Chemical Industry Co.,
Ltd.) were used in place of polytetramethylene glycol. The number
average molecular weight (Mn) of the di(meth)acrylic acid ester
(a-9) measured by GPC was 10040.
Production Example 2-10: Di(Meth)Acrylic Acid Ester (a-10)
[0465] A colorless, transparent polycaprolactone diol diacrylate
(di(meth)acrylic acid ester (a-10)) was obtained in the same manner
as in Production Example 2-1 except that 100.0 parts of
polycaprolactone diol (PRAXEL 220N; Mn, 2000; available from Daicel
Corporation) were used in place of polytetramethylene glycol. The
number average molecular weight (Mn) of the di(meth)acrylic acid
ester (a-10) measured by GPC was 2040.
Production Example 2-11: Di(Meth)Acrylic Acid Ester (a-11)
[0466] A colorless, transparent polycarbonate diol diacrylate
(di(meth)acrylic acid ester (a-11)) was obtained in the same manner
as in Production Example 2-1 except that 100.0 parts of
polycarbonate diol (UH-200; Mn, 2000; available from Ube
Industries, Ltd.) were used in place of polytetramethylene glycol.
The number average molecular weight (Mn) of the di(meth)acrylic
acid ester (a-11) measured by GPC was 2020.
Production Example 2-12: Di(Meth)Acrylic Acid Ester (a-12)
[0467] A colorless, transparent polytetramethylene glycol
dimethacrylate (di(meth)acrylic acid ester (a-12)) was obtained in
the same manner as in Production Example 2-1 except that 150.0
parts of polytetramethylene glycol (PTMG3000; Mn, 3000; available
from Mitsubishi Chemical Corporation) were used as
polytetramethylene glycol and 25.02 parts of methyl methacrylate
were used in place of methyl acrylate. The number average molecular
weight (Mn) of the di(meth)acrylic acid ester (a-12) measured by
GPC was 3020.
[0468] The component composition and number average molecular
weight (Mn) of the di(meth)acrylic acid esters (a-1) to (a-12)
obtained in Production Examples 2-1 to 2-12 are summarized in Table
5 below.
TABLE-US-00005 TABLE 5 Di(meth)acrylic X source (Meth)acrylic acid
ester Diol Mn acid ester Mn Remark a-1 Polytetramethylene 650
Methyl acrylate 670 For glycol comparison a-2 Polytetramethylene
850 Methyl acrylate 860 Present glycol invention example a-3
Polytetramethylene 1000 Methyl acrylate 1010 Present glycol
invention example a-4 Polytetramethylene 1500 Methyl acrylate 1560
Present glycol invention example a-5 Polytetramethylene 2000 Methyl
acrylate 2070 Present glycol invention example a-6
Polytetramethylene 3000 Methyl acrylate 3020 Present glycol
invention example a-7 Polyethylene glycol 6000 Methyl acrylate 6040
Present invention example a-8 Polyethylene glycol 8000 Methyl
acrylate 8010 Present invention example a-9 Polyethylene glycol
10000 Methyl acrylate 10040 For comparison a-10 Polycaprolactone
2000 Methyl acrylate 2040 Present diol invention example a-11
Polycarbonate diol 2000 Methyl acrylate 2020 Present invention
example a-12 Polytetramethylene 3000 Methyl 3020 Present glycol
methacrylates invention example
[0469] [Production of Crosslinked Particles (A-I) or Graft
Crosslinked Particles (B-I)]
Production Example 2-13: Crosslinked Particles (A-I-1)
[0470] Forty parts of styrene, 20 parts of acrylonitrile, 310 parts
of deionized water, 1 part of dipotassium alkenyl succinate, 0.2
parts of t-butyl hydroperoxide, and 2.5 parts of hexadecane were
added to 40 parts of the di(meth)acrylic acid ester (a-1). While
stirring the mixture, ultrasonic irradiation was performed using an
ULTRASONIC HOMOGENIZER available from Nihonseiki Kaisha Ltd. at an
amplitude output of 80% for 20 minutes to obtain a miniemulsion of
a styrene-acrylonitrile solution in which the di(meth)acrylic acid
ester (a-1) was dissolved.
[0471] The miniemulsion of the styrene-acrylonitrile solution in
which the di(meth)acrylic acid ester (a-1) was dissolved was loaded
into a reaction vessel equipped with a reagent injector, a
condenser, a jacket heater, and a stirring device. The reaction
vessel was purged with nitrogen, and the temperature was then
raised to 55.degree. C. Next, 0.3 parts of sodium formaldehyde
sulfoxylate, 0.0001 parts of ferrous sulfate heptahydrate, 0.0003
parts of disodium ethylenediaminetetraacetate, and 10 parts of
deionized water were added to initiate polymerization. After
polymerization exotherm was observed, the jacket temperature was
set at 80.degree. C., and the polymerization was continued until
polymerization exotherm was not observed anymore. The resultant was
further maintained for 1 hour to obtain a water dispersion of
crosslinked particles (A-I-1). The volume average particle size of
the crosslinked particles (A-I-1) measured using the water
dispersion of the crosslinked particles (A-I-1) was 0.15 .mu.m.
Next, the water dispersion of the crosslinked particles (A-I-1) was
coagulated using 5% sulfuric acid, washed with water, and dried to
obtain the crosslinked particles (A-I-1).
Production Example 2-14: Crosslinked Particles (A-I-2) to
(A-I-13)
[0472] Crosslinked particles (A-I-2) to (A-I-13) were obtained in
the same manner as in Production Example 2-13 except that the
di(meth)acrylic acid esters (a-2) to (a-12) were used in place of
the di(meth)acrylic acid ester (a-1) and the monomer compositions
shown in Table 6 were used.
[0473] The volume average particle size of the crosslinked
particles (A-I-1) to (A-I-13) is shown in Table 6.
TABLE-US-00006 TABLE 6 Crosslinked particles A-I- A-I- A-I- A-I-
A-I-1 A-I-2 A-I-3 A-I-4 A-I-5 A-I-6 A-I-7 A-I-8 A-I-9 10 11 12 13
Monomer Type and (a-1) Mn = 670 40 com- Mn of (a-2) Mn = 860 40
position di(meth)acrylic (a-3) Mn = 1010 40 (parts) acid ester
(a-4) Mn = 1560 40 (a-5) Mn = 2070 40 (a-6) Mn = 3020 40 40 (a-7)
Mn = 6040 40 (a-8) Mn = 8010 40 (a-9) Mn = 10040 40 (a-10) Mn =
2040 40 (a-11) Mn = 2020 40 (a-12) Mn = 3020 40 Styrene 40 40 40 40
40 40 40 40 40 40 40 40 45 Acrylonitrile 20 20 20 20 20 20 20 20 20
20 20 20 15 Volume average particle size (.mu.m) 0.15 0.15 0.15
0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 Remarks For
Present invention example For Present invention example com-
comparison parison
Production Example 2-15: Graft Crosslinked Particles (B-I-1)
[0474] A water dispersion (70 parts on a solids basis) of the
crosslinked particles (A-I-6) was placed in a stainless steel
polymerization tank equipped with a stirrer, and 0.4 parts of
potassium alkenyl succinate, 0.002 parts of ferrous sulfate
heptahydrate, 0.64 parts of sodium aldehyde sulfoxide, and 0.006
parts of disodium ethylenediamine-N,N,N',N'-tetracarboxylate were
added. To the resulting mixture, a mixed solution of 20 parts of
styrene, 10 parts of acrylonitrile, and 0.45 parts of t-butyl
hydroperoxide was added over 100 minutes and maintained for 30
minutes to complete the reaction. A latex of the reaction product
was coagulated with an aqueous sulfuric acid solution, washed with
water, and then dried to obtain graft crosslinked particles
(B-I-1). The volume average particle size of the water dispersion
was 0.15 .mu.m, and the graft rate was 43%.
[0475] [Production of Thermoplastic Resins]
Production Example 2-16: Thermoplastic Resin (D-I-1)
[0476] Into a stainless steel polymerization tank equipped with a
stirrer, 150 parts of ion-exchanged water, 67 parts of styrene, 33
parts of acrylonitrile, 0.2 parts of 2,2'-azobis(isobutyronitrile),
0.25 parts of n-octyl mercaptan, 0.47 parts of calcium
hydroxyapatite, and 0.003 parts of potassium alkenyl succinate were
loaded. The inner temperature of the polymerization tank was set at
75.degree. C., and the reaction was allowed to proceed for 3 hours.
The temperature was raised to 90.degree. C., and the reaction was
allowed to proceed for 1 hour. The contents were extracted, washed
with a centrifugal dehydrator, and dried to obtain a powdery
thermoplastic resin (D-I-1).
Production Example 2-17: Thermoplastic Resin (D-I-2)
[0477] A powdery thermoplastic resin (D-I-2) was obtained in the
same manner as in Production Example 2-16 except that 75 parts of
styrene and 25 parts of acrylonitrile were used.
Production Example 2-18: Thermoplastic Resin (D-I-3)
[0478] A powdery thermoplastic resin (D-I-3) was obtained in the
same manner as in Production Example 2-16 except that 54 parts of
styrene, 26 parts of acrylonitrile, and, furthermore, 20 parts of
N-phenylmaleimide were used.
[0479] [Other Thermoplastic Resins]
[0480] The following other thermoplastic resins were used.
[0481] Thermoplastic resin (D-I-4): AAS (ASA) resin
(acrylic-rubber-dispersed AS resin) available from UMG ABS, Ltd;
5310
[0482] Thermoplastic resin (D-I-5): ABS resin
(butadiene-rubber-dispersed AS resin) available from UMG ABS, Ltd;
EX18A
[0483] Thermoplastic resin (D-I-6): AES resin (ethylene
.alpha.-olefin-rubber-dispersed AS resin) available from UMG ABS,
Ltd; ESA30
[0484] Thermoplastic resin (D-I-7): polycarbonate available from
Mitsubishi Engineering-Plastics Corporation; Novarex 7025R
[0485] The monomer composition of the thermoplastic resins (D-I-1)
to (D-I-7) is summarized in Table 7 below.
TABLE-US-00007 TABLE 7 Thermoplastic resin D-1-1 D-1-2 D-1-3 D-1-4
D-1-5 D-1-6 D-1-7 Monomer Styrene 67 75 54 ASA ABS AES PC
composition Acrylonitrile 33 25 26 (parts) N-Phenylmaleimide 20
Examples 2-1 to 2-17, Comparative Examples 2-1 to 2-7
[0486] The crosslinked particles (A-I) or the graft crosslinked
particles (B-I) and the thermoplastic resin (D-I) were used in
amounts shown in Tables 8 to 10 and pelletized by the method of
Melt Kneading 2-1 or 2-2 described above, and molded articles were
obtained by Injection Molding 2-1 or 2-2. The MVR of the
thermoplastic resin composition obtained in Melt Kneading 2-1 was
measured. The molded articles obtained were evaluated for impact
resistance, color developability, abrasion resistance, and mold
shrinkage rate. The results are shown in Tables 8 to 10.
TABLE-US-00008 TABLE 8 Example 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9
2-10 2-11 Thermoplastic resin Crosslinked A-I-2 30 composition
particles (A-I) A-I-3 30 formulation (parts) A-I-4 30 A-I-5 30
A-I-6 30 A-I-7 30 A-I-8 30 A-I-10 30 A-I-11 30 A-I-12 30 A-I-13 30
Thermoplastic resin D-I-1 70 70 70 70 70 70 70 70 70 70 (D-I) D-I-2
70 Evaluation MVR cm.sup.3/10 min 10 10 12 12 15 9 8 15 15 15 17
results Impact resistance kJ/m.sup.2 5 7 10 12 15 15 15 10 10 15 12
Color developability L* (ma) 4.2 4.2 4.2 4.2 4.2 6.4 6.5 7.1 5.1
7.1 4.2 Abrasion Resistance .DELTA. L* (mc-ma) B B A A A A A B B A
A Mold shrinkage rate 23.degree. C. (%) 0.4 0.4 0.4 0.4 0.4 0.4 0.4
0.4 0.4 0.4 0.4
TABLE-US-00009 TABLE 9 Example 2-12 2-13 2-14 2-15 2-16 2-17
Thermoplastic resin Crosslinked particles A-I-6 30 10 10 10
composition (A-I) A-I-13 10 formulation Graft crosslinked B-I-1 43
(parts) particles (B-I) Thermoplastic resin D-I-1 57 (D-I) D-I-3 70
D-I-4 90 D-I-5 90 D-I-6 90 D-I-7 90 Evaluation MVR cm.sup.3/10 min
8 21 20 21 15 16 results Impact resistance kJ/m.sup.2 12 22 13 17
80 17 Color developability L* (ma) 5.5 5.4 4.5 5.5 3 4.2 Abrasion
Resistance .DELTA.L* (mc-ma) A A A A A A Mold shrinkage rate
23.degree. C. (%) 0.4 0.5 0.6 0.7 0.7 0.3
TABLE-US-00010 TABLE 10 Comparative example 2-1 2-2 2-3 2-4 2-5 2-6
2-7 Thermoplastic resin Crosslinked particles A-I-1 30 composition
(A-I) A-I-9 30 formulation Thermoplastic resin D-I-1 70 70 100
(parts) (D-I) D-I-4 100 D-I-5 100 D-I-6 100 D-I-7 100 Evaluation
results MVR cm.sup.3/10 min 14 2 10 20 18 19 1 Impact resistance
kJ/m.sup.2 2 15 1 18 13 15 65 Color developability L* (ma) 5 11 4.2
5.4 4.5 5.5 3 Abrasion Resistance .DELTA.L* (mc-ma) C A C C C A C
Mold shrinkage rate 23.degree. C. (%) 0.4 0.5 0.4 0.5 0.6 0.8
0.7
[0487] As is clear from Tables 8 to 10, the thermoplastic resin
compositions of Examples 2-1 to 2-17 were excellent in flowability.
The molded articles obtained in Examples 2-1 to 2-17 were excellent
in impact resistance, color developability, abrasion resistance,
and mold shrinkage rate. By contrast, Comparative Examples 2-1 to
2-7, which did not meet the requirements of the second invention,
were poor in any of flowability, and impact resistance, color
developability, abrasion resistance, and mold shrinkage rate of the
molded articles. Specifically, in Comparative Example 2-1, in which
crosslinked particles obtained using a di(meth)acrylic acid ester
(a) having an Mn of less than 800 are used, impact resistance and
abrasion resistance are poor. In Comparative Example 2-2, in which
crosslinked particles obtained using a di(meth)acrylic acid ester
(a) having an Mn of more than 9,000 are used, flowability and color
developability are poor. In Comparative Examples 2-3 to 2-7, in
each of which a thermoplastic resin alone is used and the
crosslinked particles (A-I) or the graft crosslinked particles
(B-I) of the second invention is not used, there is a defect due to
each thermoplastic resin, and flowability, impact resistance,
abrasion resistance, and mold shrinkage rate cannot be satisfied at
the same time.
[0488] These results show that the crosslinked particles (A-I) and
the graft crosslinked particles (B-I) of the second invention can
improve the flowability, impact resistance, and abrasion resistance
of a thermoplastic resin without impairing its color developability
and mold shrinkage rate and are suitable for use in applications
such as automotive interior and exterior parts, office machines,
household electrical appliances, and building materials.
Examples and Comparative Examples of Third Invention
[Methods of Measurements and Evaluations]
[0489] Methods of various measurements, evaluations, and operations
therefor in the following Examples and Comparative Examples are as
described below.
[0490] <Measurement of Number Average Molecular Weight
(Mn)>
[0491] The number average molecular weight (Mn) in terms of
polystyrene was measured by GPC (GPC: "GPC/V2000" available from
Waters, column: "Shodex AT-G+AT-806MS" available from Showa Denko
K.K.) using o-dichlorobenzene (145.degree. C.) as a solvent.
[0492] <Measurement of Average Particle Size>
[0493] The volume average particle size (MV) measured using a
Microtrac ("Nanotrac 150" available from Nikkiso Co., Ltd.) and
pure water as a measurement solvent was used as an average particle
size.
[0494] It was confirmed by electron microscopic image analysis that
the average particle size of the crosslinked particles (A-II)
dispersed in the graft crosslinked particles (B-II) equated with
the average particle size of the crosslinked particles (A-II) and
the graft crosslinked particles (B-II) in a thermoplastic resin
composition.
[0495] <Mass Proportion of Agglomerates>
[0496] An aqueous dispersion was filtered through a 100-mesh
stainless-steel wire net, and the residue on the mesh was washed
with water and dried, after which the mass of the filtered solid
residue was measured. The mass proportion of agglomerates in the
aqueous dispersion was determined by the following formula (6).
This proportion is preferably as low as possible for better process
passability, and is preferably 0.3% or less.
Mass proportion of agglomerates (% by mass)=[mass (g) of filtered
solid residue/mass (g) of total solid content].times.100 (6)
[0497] <Melt Kneading 3-1>
[0498] The crosslinked particles (A-II) or the graft crosslinked
particles (B-II) and the thermoplastic resin (D-II) were mixed
together, and using a twin-screw extruder ("PCM30" available from
Ikegai Corp.) having a diameter of 30 mm and equipped with a vacuum
vent, melt kneading was performed at a cylinder temperature of
200.degree. C. to 260.degree. C. and a reduced pressure of 93.325
kPa to obtain a transparent thermoplastic resin composition.
Furthermore, after the melt kneading, pelletization was performed
using a pelletizer ("Model SH pelletizer" available from
Soukensya).
[0499] <Melt Kneading 3-2>
[0500] The crosslinked particles (A-II) or the graft crosslinked
particles (B-II), the thermoplastic resin (D-II), and, furthermore,
carbon black ("#966B" available from Mitsui Chemicals, Inc.) in an
amount of 0.8 parts relative to 100 parts of the total of the
crosslinked particles (A-II) or the graft crosslinked particles
(B-II) and the thermoplastic resin (D-II) were mixed together, and
using a twin-screw extruder ("PCM30" available from Ikegai Corp.)
having a diameter of 30 mm and equipped with a vacuum vent, melt
kneading was performed at a cylinder temperature of 200.degree. C.
to 260.degree. C. and a reduced pressure of 93.325 kPa to obtain a
black-colored thermoplastic resin composition. Furthermore, after
the melt kneading, pelletization was performed using a pelletizer
("Model SH pelletizer" available from Soukensya).
[0501] <Measurement of Melt Volume Rate (MVR)>
[0502] The MVR of the thermoplastic resin composition obtained in
Melt Kneading 3-1 was measured in accordance with ISO 1133
standard. The MVR indicates the flowability of the thermoplastic
resin composition.
[0503] <Injection Molding 3-1>
[0504] Using the pellets of the thermoplastic resin composition
obtained in Melt Kneading 3-1, a molded article 80 mm long, 10 mm
wide, and 4 mm thick was molded with an injection molding machine
("IS55FP-1.5A" available from Toshiba Machine Co., Ltd.) under the
conditions of a cylinder temperature of 200.degree. C. to
270.degree. C. and a mold temperature of 60.degree. C. and used as
a molded article for Charpy impact testing.
[0505] <Injection Molding 3-2>
[0506] Using the pellets of the thermoplastic resin composition
obtained in Melt Kneading 3-1, molded articles 100 mm long, 100 mm
wide, and 2 mm thick were molded with an injection molding machine
("IS55FP-1.5A" available from Toshiba Machine Co., Ltd.) under the
conditions of a cylinder temperature of 200.degree. C. to
270.degree. C. and a mold temperature of 60.degree. C. and used as
a molded article for transparency evaluation and a molded article
for weather resistance evaluation.
[0507] Using the pellets of the thermoplastic resin composition
obtained in Melt Kneading 3-2, molded articles 100 mm long, 100 mm
wide, and 2 mm thick were molded with an injection molding machine
("IS55FP-1.5A" available from Toshiba Machine Co., Ltd.) under the
conditions of a cylinder temperature of 200.degree. C. to
270.degree. C. and a mold temperature of 60.degree. C. and used as
a molded article for color developability evaluation and a molded
article for abrasion resistance evaluation.
[0508] <Evaluation of Impact Resistance>
[0509] The Charpy impact strength of the molded article for Charpy
impact testing was measured in the same manner as in the second
invention.
[0510] <Evaluation of Color Developability>
[0511] The molded article for color developability evaluation was
evaluated for color developability in the same manner as in the
second invention.
[0512] <Evaluation of Abrasion Resistance>
[0513] By the method shown in FIG. 1, evaluation and assessment of
abrasion resistance were made in the same manner as in the second
invention.
[0514] <Evaluation of Weather Resistance>
[0515] Using a Sunshine Weather Meter (available from Suga Test
Instruments Co., Ltd.), the molded article for weather resistance
evaluation was treated for 1000 hours under the conditions of a
black panel temperature of 63.degree. C. and a cycle of 60 minutes
(rainfall: 12 minutes). The degree of change in color (.DELTA.E)
before and after the treatment was measured with a color difference
meter and evaluated.
[0516] The smaller the .DELTA.E, the better the weather resistance,
and A and B were assessed as having weather resistance.
[0517] A: 0 or more and less than 1. No change in color is
observed, and the design of a molded article is not impaired.
[0518] B: 1 or more and less than 3. Practically no change in color
is observed, and the design of a molded article is not
impaired.
[0519] C: 5 or more and less than 10. A slight change in color is
observed, and the design of a molded article is impaired.
[0520] D: 10 or more. A great change in color is observed, and the
design of a molded article is impaired.
[0521] <Evaluation of Transparency>
[0522] The cloudiness (Haze) of the molded article for transparency
evaluation was measured using a Haze meter (available from Murakami
Color Research Laboratory Co., Ltd). Lower cloudiness means higher
transparency.
[0523] The transparency was evaluated according to the following
criteria, and A and B were assessed as having transparency.
[0524] A: 0% or more and less than 5%
[0525] B: 5% or more and less than 10%
[0526] C: 10% or more and less than 30%
[0527] D: 30% or more
[0528] [Production of Di(Meth)Acrylic Acid Ester (a)]
[0529] Di(meth)acrylic acid esters (a-1) to (a-12) were produced in
the same manner as in Production Examples 2-1 to 2-12 of the second
invention. The component composition and number average molecular
weight (Mn) of the di(meth)acrylic acid esters (a-1) to (a-12) are
as shown in Table 5 in the second invention.
Production Example 3-1: Crosslinked Particles (A-II-1)
[0530] Fifty parts of methyl methacrylate, 10 parts of styrene, 310
parts of deionized water, 1 part of dipotassium alkenyl succinate,
0.2 parts of t-butyl hydroperoxide, and 2.5 parts of hexadecane
were added to 40 parts of the di(meth)acrylic acid ester (a-1).
While stirring the mixture, ultrasonic irradiation was performed
using an ULTRASONIC HOMOGENIZER available from Nihonseiki Kaisha
Ltd. at an amplitude output of 80% for 20 minutes to obtain a
miniemulsion of a methyl methacrylate solution in which the
di(meth)acrylic acid ester (a-1) was dissolved.
[0531] The miniemulsion of the methyl methacrylate solution in
which the di(meth)acrylic acid ester (a-1) was dissolved was loaded
into a reaction vessel equipped with a reagent injector, a
condenser, a jacket heater, and a stirring device. The reaction
vessel was purged with nitrogen, and the temperature was then
raised to 55.degree. C. Next, 0.3 parts of sodium formaldehyde
sulfoxylate, 0.0001 parts of ferrous sulfate heptahydrate, 0.0003
parts of disodium ethylenediaminetetraacetate, and 10 parts of
deionized water were added to initiate polymerization. After
polymerization exotherm was observed, the jacket temperature was
set at 80.degree. C., and the polymerization was continued until
polymerization exotherm was not observed anymore. The resultant was
further maintained for 1 hour to obtain a water dispersion of
crosslinked particles (A-II-1). The volume average particle size of
the crosslinked particles (A-II-1) measured using the water
dispersion of the crosslinked particles (A-II-1) was 0.15 .mu.m,
and the mass proportion of agglomerates was 0.001%. Next, the water
dispersion of the crosslinked particles (A-II-1) was coagulated
using 5% sulfuric acid, washed with water, and dried to obtain the
crosslinked particles (A-II-1).
Production Example 3-2: Crosslinked Particles (A-II-2) to
(A-II-12)
[0532] Crosslinked particles (A-II-2) to (A-II-12) were obtained in
the same manner as in Production Example 3-1 except that the
di(meth)acrylic acid esters (a-2) to (a-12) were used in place of
the di(meth)acrylic acid ester (a-1) and the monomer compositions
shown in Table 11 were used.
[0533] The mass proportion of agglomerates during production and
volume average particle size of the crosslinked particles (A-II-1)
to (A-II-12) are shown in Table 11.
TABLE-US-00011 TABLE 11 Crosslinked particles A-II-1 A-II-2 A-II-3
A-II-4 A-II-5 A-II-6 Monomer Type and Mn of (a-1) Mn = 670 40
composition di(meth)acrylic acid (a-2) Mn = 860 40 (parts) ester
(a-3) Mn = 1010 40 (a-4) Mn = 1560 40 (a-5) Mn = 2070 40 (a-6) Mn =
3020 40 (a-7) Mn = 6040 (a-8) Mn = 8010 (a-9) Mn = 10040 (a-10) Mn
= 2040 (a-11) Mn = 2020 (a-12) Mn = 3020 Methyl methacrylate 50 50
50 50 50 50 Styrene 10 10 10 10 10 10 Volume average particle
size(.mu.m) 0.15 0.15 0.15 0.15 0.15 0.15 Mass proportion of
agglomerates(%) 0.001 0.001 0.001 0.001 0.001 0.001 Remarks For
Present invention example comparison A-II- A-II- A-II- A-II-7
A-II-8 A-II-9 10 11 12 Monomer Type and Mn of (a-1) Mn = 670
composition di(meth)acrylic acid (a-2) Mn = 860 (parts) ester (a-3)
Mn = 1010 (a-4) Mn = 1560 (a-5) Mn = 2070 (a-6) Mn = 3020 (a-7) Mn
= 6040 40 (a-8) Mn = 8010 40 (a-9) Mn = 10040 40 (a-10) Mn = 2040
40 (a-11) Mn = 2020 40 (a-12) Mn = 3020 40 Methyl methacrylate 50
50 50 40 60 50 Styrene 10 10 10 20 10 Volume average particle size
(.mu.m) 0.15 0.15 0.15 0.15 0.15 0.15 Mass proportion of
agglomerates (%) 0.005 0.001 0.03 0.001 0.001 0.001 Remarks Present
For Present invention comparison invention example example
Production Example 3-3: Crosslinked Particles (A-II-13) to
(A-II-24)
[0534] Crosslinked particles (A-II-13) to (A-II-24) were obtained
in the same manner as in Production Example 3-1 except that the
di(meth)acrylic acid ester (a-6) was used in place of the
di(meth)acrylic acid ester (a-1) and the monomer compositions shown
in Table 12 were used.
[0535] The mass proportion of agglomerates during production and
volume average particle size of the crosslinked particles (A-II-13)
to (A-II-24) are shown in Table 12.
TABLE-US-00012 TABLE 12 Crosslinked particles A-II- A-II- A-II-
A-II- A-II- A-II- A-II- A-II- A-II- A-II- A-II- A-II- 13 14 15 16
17 18 19 20 21 22 23 24 Monomer Di(meth)acrylic 19 21 24 26 29 31
49 51 69 71 79 81 composition acid ester(a-6) (parts) Mn = 3020
Methyl 76 74 70 67 63 61 38 35 13 10 1 19 methacrylate Styrene 5 5
6 7 8 8 13 14 18 19 20 Volume average particle 0.15 0.15 0.15 0.15
0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 size (.mu.m) Mass
proportion of 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001
0.001 0.001 0.001 agglomerates (%) Remarks For Present invention
example For com- comparison parison
Production Example 3-4: Crosslinked Particles (A-II-25)
[0536] A water dispersion of crosslinked particles (A-II-25) was
obtained in the same manner as in Production Example 3-1 except
that 40 parts of the di(meth)acrylic acid ester (a-6), 50 parts of
methyl methacrylate, and 3 parts of dipotassium alkenyl succinate
were used and the amplitude output of the ULTRASONIC HOMOGENIZER
available from Nihonseiki Kaisha Ltd. was 90%. The volume average
particle size of the crosslinked particles (A-II-25) was 0.06
.mu.m, and the mass proportion of agglomerates was 0.001%.
Production Example 3-5: Crosslinked Particles (A-II-26)
[0537] A water dispersion of crosslinked particles (A-II-26) was
obtained in the same manner as in Production Example 3-4 except
that 2 parts of dipotassium alkenyl succinate was used. The volume
average particle size of the crosslinked particles (A-II-26) was
0.09 .mu.m, and the mass proportion of agglomerates 0.001%.
Production Example 3-6: Crosslinked Particles (A-II-27)
[0538] A water dispersion of crosslinked particles (A-II-27) was
obtained in the same manner as in Production Example 3-4 except
that 0.4 parts of dipotassium alkenyl succinate was used and the
amplitude output of the ULTRASONIC HOMOGENIZER available from
Nihonseiki Kaisha Ltd. was 30%. The volume average particle size of
the crosslinked particles (A-II-27) was 0.45 .mu.m, and the mass
proportion of agglomerates was 0.003%.
Production Example 3-7: Crosslinked Particles (A-II-28)
[0539] Into a reaction vessel equipped with a reagent injector, a
condenser, a jacket heater, and a stirring device, 200 parts of
deionized water, 2.1 parts of potassium oleate, 4.2 parts of
dioctyl sodium sulfosuccinate, 0.003 parts of ferrous sulfate
heptahydrate, 0.009 parts of sodium ethylenediaminetetraacetate,
and 0.3 parts of sodium formaldehyde sulfoxylate were loaded. The
reaction vessel was purged with nitrogen, and the temperature was
then raised to 60.degree. C. Next, after 81.4 parts of butyl
acrylate, 18.6 parts of acrylic acid, and 0.5 parts of cumene
hydroperoxide were added dropwise over 2 hours, the reaction was
further allowed to proceed for 2 hours to obtain a water dispersion
of an acid-radical-containing copolymer.
[0540] A 5% aqueous solution of 2.4 parts of sodium pyrophosphate
in 100 parts (on a solids basis) of a water dispersion of the
crosslinked particles (A-II-6) was added into the reactor and
thoroughly stirred, after which 1.8 parts (on a solids basis) of
the water dispersion of the acid-radical-containing copolymer was
added. The mixture was stirred for 30 minutes while maintaining the
inner temperature at 30.degree. C. to obtain crosslinked particles
(A-II-28) and a water dispersion thereof. The volume average
particle size of the crosslinked particles (A-II-28) was 0.57
.mu.m, and the mass proportion of agglomerates was 0.01%.
Production Example 3-8: Crosslinked Particles (A-II-29)
[0541] After 0.15 parts of sodium dodecylbenzene sulfonate was
added to 100 parts (on a solids basis) of a water dispersion of the
crosslinked particles (A-II-6), 30 parts of a 5% aqueous acetic
acid solution was added dropwise over 30 minutes. After completion
of the dropwise addition, a 10% aqueous sodium hydroxide solution
was added dropwise over 10 minutes to obtain a water dispersion of
crosslinked particles (A-II-29). The volume average particle size
of the crosslinked particles (A-II-29) was 0.88 .mu.m, and the mass
proportion of agglomerates was 0.01%.
Production Example 3-9: Crosslinked Particles (A-II-30)
[0542] A water dispersion of crosslinked particles (A-II-30) was
obtained in the same manner as in Production Example 3-8 except
that the amount of 5% aqueous acetic acid solution used was 50
parts. The volume average particle size of the crosslinked
particles (A-II-30) was 1.2 .mu.m, and the mass proportion of
agglomerates was 0.04%.
Production Example 3-10: Crosslinked Particles (A-II-31)
[0543] After 0.15 parts of sodium dodecylbenzene sulfonate was
added to 100 parts (on a solids basis) of a water dispersion of the
crosslinked particles (A-II-6), 30 parts of a 20% aqueous acetic
acid solution was added dropwise over 40 minutes. After completion
of the dropwise addition, a 10% aqueous sodium hydroxide solution
was added dropwise over 10 minutes to obtain a water dispersion of
crosslinked particles (A-II-31). The volume average particle size
of the crosslinked particles (A-II-31) was 2.1 .mu.m, and the mass
proportion of agglomerates was 0.05%.
Production Example 3-11: Crosslinked Particles (A-II-32)
[0544] A water dispersion of crosslinked particles (A-II-32) was
obtained in the same manner as in Production Example 3-1 except
that 40 parts of the di(meth)acrylic acid ester (a-12), 40 parts of
n-butyl acrylate, and 20 parts of styrene were used. The volume
average particle size of the crosslinked particles (A-II-32) was
0.15 .mu.m, and the mass proportion of agglomerates was 0.001%.
Production Example 3-12: Crosslinked Particles (A-II-33)
[0545] Into a reaction vessel equipped with a reagent injector, a
condenser, a jacket heater, and a stirring device, 40 parts of the
di(meth)acrylic acid ester (a-6), 50 parts of methyl methacrylate,
10 parts of styrene, 310 parts of deionized water, 1 part of
dipotassium alkenyl succinate, and 0.2 parts of t-butyl
hydroperoxide were added. The reaction vessel was purged with
nitrogen, and the temperature was then raised to 55.degree. C.
Next, 0.3 parts of sodium formaldehyde sulfoxylate, 0.0001 parts of
ferrous sulfate heptahydrate, 0.0003 parts of disodium
ethylenediaminetetraacetate, and 10 parts of deionized water were
added to initiate polymerization. After polymerization exotherm was
observed, the jacket temperature was set at 80.degree. C., and the
polymerization was continued until polymerization exotherm was not
observed anymore. The resultant was further maintained for 1 hour
to obtain a water dispersion of crosslinked particles (A-II-33).
The volume average particle size of the crosslinked particles
(A-II-33) was 0.47 .mu.m, and the mass proportion of agglomerates
was 2.5%.
[0546] The mass proportion of agglomerates during production and
volume average particle size of the crosslinked particles (A-II-25)
to (A-II-33) are shown in Tables 13 and 14.
TABLE-US-00013 TABLE 13 Crosslinked particles A-II- A-II- A-II-
A-II- A-II- A-II- A-II- 25 26 27 28 29 30 31 Monomer
Di(meth)acrylic acid ester 40 40 40 composition (a-6) (parts) Mn =
3020 Methyl methacrylate 50 50 50 Styrene 10 10 10 Enlarged
crosslinked particles 100 100 100 100 (A-II-6) Volume average
particle size 0.06 0.09 0.45 0.57 0.88 1.2 2.1 (.mu.m) Mass
proportion of 0.001 0.001 0.001 0.01 0.01 0.04 0.05 agglomerates
(%) Remarks For Present invention example For comparison
comparison
TABLE-US-00014 TABLE 14 Crosslinked particles A-II-32 A-II-33
Monomer Di(meth)acrylic acid (a-6) 40 composition ester (a-12) 40
(parts) Methyl methacrylate 50 n-Butyl acrylate 40 Styrene 20 10
Volume average particle size(.mu.m) 0.15 0.47 Mass proportion of
agglomerates(%) 0.001 2.5 Remarks Present invention example
Production Example 3-13: Graft Crosslinked Particles (B-II-1)
[0547] A water dispersion (70 parts on a solids basis) of the
crosslinked particles (A-II-1) was placed in a stainless steel
polymerization tank equipped with a stirrer, and 0.56 parts of
potassium alkenyl succinate, 0.003 parts of ferrous sulfate
heptahydrate, 0.89 parts of sodium aldehyde sulfoxide, and 0.008
parts of disodium ethylenediamine-N,N,N',N'-tetracarboxylate were
added. To the resulting mixture, a mixed solution of 29 parts of
methyl methacrylate, 1 part of methyl acrylate, and 0.45 parts of
t-butyl hydroperoxide was added over 100 minutes and maintained for
30 minutes to complete the reaction. A latex of the reaction
product was coagulated with an aqueous sulfuric acid solution,
washed with water, and then dried to obtain graft crosslinked
particles (B-II-1). The volume average particle size of the water
dispersion was 0.15 .mu.m, the graft rate was 43%, and the mass
proportion of agglomerates was 0.02%.
Production Example 3-14: Graft Crosslinked Particles (B-II-2) to
(B-II-33)
[0548] Graft crosslinked particles (B-II-2) to (B-II-33) were
obtained in the same manner as in Production Example 3-13 except
that the type of the crosslinked particles (A-II) was changed to
the crosslinked particles (A-II-2) to (A-II-33) and the raw
material compositions shown in Tables 15 to 17 were used.
[0549] The graft rate, volume average particle size, and mass
proportion of agglomerates during production of the graft
crosslinked particles (B-II-1) to (B-II-33) are shown in Tables 15
to 17.
TABLE-US-00015 TABLE 15 Graft crosslinked particles B-II- B-II-
B-II- B-II- B-II- B-II- B-II- B-II- B-II- 1 2 3 4 5 6 B-II-7 B-II-8
B-II-9 10 11 12 Raw material Crosslinked particles (A-II-1) 70
composition Crosslinked particles (A-II-2) 70 (parts) Crosslinked
particles (A-II-3) 70 Crosslinked particles (A-II-4) 70 Crosslinked
particles (A-II-5) 70 Crosslinked particles (A-II-6) 70 Crosslinked
particles (A-II-7) 70 Crosslinked particles (A-II-8) 70 Crosslinked
particles (A-II-9) 70 Crosslinked particles 70 (A-II-10)
Crosslinked particles 70 (A-II-11) Crosslinked particles 70
(A-II-12) Methyl methacrylate 29 29 29 29 29 29 29 29 29 29 29 29
Methyl acrylate 1 1 1 1 1 1 1 1 1 1 1 1 Graft rate (%) 43 43 43 43
43 43 43 43 43 43 43 43 Volume average particle size (.mu.m) 0.15
0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 Proportion
of agglomerates (%) 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02
0.02 0.02 0.02 Remarks For Present invention example For Present
comparison comparison invention example
TABLE-US-00016 TABLE 16 Graft crosslinked particles B-II- B-II-
B-II- B-II- B-II- B-II- B-II- B-II- B-II- B-II- B-II- B-II- 13 14
15 16 17 18 19 20 21 22 23 24 Raw material Crosslinked particles
(A-II-13) 70 composition Crosslinked particles (A-II-14) 70 (parts)
Crosslinked particles (A-II-15) 70 Crosslinked particles (A-II-16)
70 Crosslinked particles (A-II-17) 70 Crosslinked particles
(A-II-18) 70 Crosslinked particles (A-II-19) 70 Crosslinked
particles (A-II-20) 70 Crosslinked particles (A-II-21) 70
Crosslinked particles (A-II-22) 70 Crosslinked particles (A-II-23)
70 Crosslinked particles (A-II-24) 70 Methyl methacrylate 29 29 29
29 29 29 29 29 29 29 29 29 Methyl acrylate 1 1 1 1 1 1 1 1 1 1 1 1
Graft rate (%) 43 43 43 43 43 43 43 43 43 43 43 43 Volume average
particle size (.mu.m) 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15
0.15 0.15 0.15 Proportion of agglomerates (%) 0.02 0.02 0.02 0.02
0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 Remarks For Present
invention example For comparison comparison
TABLE-US-00017 TABLE 17 Graft crosslinked particles B-II- B-II-
B-II- B-II- B-II- B-II- B-II- B-II- B-II- 25 26 27 28 29 30 31 32
33 Raw material Crosslinked particles(A-II-25) 70 composition
Crosslinked particles(A-II-26) 70 (parts) Crosslinked
particles(A-II-27) 70 Crosslinked particles(A-II-28) 70 Crosslinked
particles(A-II-29) 70 Crosslinked particles(A-II-30) 70 Crosslinked
particles(A-II-31) 70 Crosslinked particles(A-II-32) 70 Crosslinked
particles(A-II-33) 70 Methyl methacrylate 29 29 29 29 29 29 29 29
29 Methyl acrylate 1 1 1 1 1 1 1 1 1 Graft rate (%) 43 43 43 43 43
43 43 43 43 Volume average particle size (.mu.m) 0.06 0.09 0.45
0.57 0.88 1.2 2.1 0.15 0.47 Proportion of agglomerates (%) 0.02
0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 Remarks For Present
invention example For Present comparison comparison invention
example
[0550] [Production of Thermoplastic Resins]
Production Example 3-15: Thermoplastic Resin (D-II-1)
[0551] Into a stainless steel polymerization tank equipped with a
stirrer, 150 parts of ion-exchanged water, 98 parts of methyl
methacrylate, 2 parts of methyl acrylate, 0.2 parts of
2,2'-azobis(isobutyronitrile), 0.25 parts of n-octyl mercaptan,
0.47 parts of calcium hydroxyapatite, and 0.003 parts of potassium
alkenyl succinate were loaded. The inner temperature of the
polymerization tank was set at 75.degree. C., and the reaction was
allowed to proceed for 3 hours. The temperature was raised to
90.degree. C., and the reaction was allowed to proceed for 1 hour.
The contents were extracted, washed with a centrifugal dehydrator,
and dried to obtain a powdery thermoplastic resin (D-II-1).
Production Example 3-16: Thermoplastic Resin (D-II-2)
[0552] A powdery thermoplastic resin (D-II-2) was obtained in the
same manner as in Production Example 3-15 except that 70 parts of
methyl methacrylate, 10 parts of styrene, and 20 parts of
N-phenylmaleimide were used.
[0553] [Other Thermoplastic Resins]
[0554] The following other thermoplastic resins were used.
[0555] Thermoplastic resin (D-II-3): polycarbonate available from
Mitsubishi Engineering-Plastics Corporation; Novarex 7025R
[0556] Thermoplastic resin (D-II-4): AAS(ASA) resin
(acrylic-rubber-dispersed AS resin) available from UMG ABS, Ltd;
S310
[0557] The monomer composition of the thermoplastic resins (D-II-1)
to (D-II-4) is summarized in Table 18 below.
TABLE-US-00018 TABLE 18 Thermoplastic resin D-II-1 D-II-2 D-II-3
D-II-4 Monomer Methyl methacrylate 98 70 PC ASA composition Methyl
acrylate 2 (parts) Styrene 10 N-Phenylmaleimide 20
Examples 3-1 to 3-38, Comparative Examples 3-1 to 3-7
[0558] The crosslinked particles (A-II) or the graft crosslinked
particles (B-II) and the thermoplastic resin (D-II) were used in
amounts shown in Tables 19 to 24 and pelletized by the method of
Melt Kneading 3-1 or 3-2 described above, and molded articles were
obtained by Injection Molding 3-1 or 3-2. The MVR of the
thermoplastic resin composition obtained in Melt Kneading 3-1 was
measured. The molded articles obtained were evaluated for impact
resistance, color developability, abrasion resistance, and weather
resistance. The results are shown in Tables 19 to 24.
[0559] The thermoplastic resin compositions of Example 3-6 and
Comparative Example 3-2 were evaluated for transparency, and the
results are shown in Table 25.
TABLE-US-00019 TABLE 19 Example 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9
3-10 Thermoplastic resin Graft B-II-2 30 composition Crosslinked
particles B-II-3 30 formulation (parts) (B-II) B-II-4 30 B-II-5 30
B-II-6 30 B-II-7 30 B-II-8 30 B-II-10 30 B-II-11 30 B-II-12 30
Thermoplastic resin D-II-1 70 70 70 70 70 70 70 70 70 70 (D-II)
Evaluation MVR cm.sup.3/10 min 9 9 9 9 9 9 7 9 9 9 results Impact
resistance kJ/m.sup.2 5 7 8 9 10 10 10 8 8 10 Color developability
L* (ma) 2.1 2.1 2.1 2.1 2.1 3.3 3.8 2.5 2.1 2.2 Abrasion Resistance
.DELTA.L* (mc-ma) B B A A A A A B B A Weather resistance .DELTA.E A
A A A A A A A A A
TABLE-US-00020 TABLE 20 Example 3-11 3-12 3-13 3-14 3-15 3-16 3-17
3-18 3-19 3-20 Thermoplastic resin Graft B-II-14 30 composition
Crosslinked particles B-II-15 30 formulation (parts) (B-II) B-II-16
30 B-II-17 30 B-II-18 30 B-II-19 30 B-II-20 30 B-II-21 30 B-II-22
30 B-II-23 30 Thermoplastic resin D-II-1 70 70 70 70 70 70 70 70 70
70 (D-II) Evaluation MVR cm.sup.3/10 min 10 9 9 9 9 9 8 8 7 7
results Impact resistance kJ/m.sup.2 7 8 9 9 10 10 10 10 11 11
Color developability L* (ma) 2.1 2.1 2.1 2.1 2.1 2.1 2.3 2.5 2.6
2.8 Abrasion Resistance .DELTA.L* (mc-ma) B B A A A A A A A A
Weather resistance .DELTA.E A A A A A A A A A A
TABLE-US-00021 TABLE 21 Example 3-21 3-22 3-23 3-24 3-25
Thermoplastic resin Graft crosslinked B-II-26 30 composition
particles B-II-27 30 formulation (parts) (B-II) B-II-28 30 B-II-29
30 B-II-30 30 Thermoplastic resin D-II-1 70 70 70 70 70 (D-II)
Evaluation results MVR cm.sup.3/10 min 8 9 9 9 10 Impact resistance
kJ/m.sup.2 6 10 11 11 12 Color developability L* (ma) 2.1 2.6 2.8
2.9 3.5 Abrasion Resistance .DELTA.L* (mc-ma) A A A A B Weather
resistance .DELTA.E A A A A A
TABLE-US-00022 TABLE 22 Example 3-26 3-27 3-28 3-29 3-30 3-31
Thermoplastic resin Crosslinked particles A-II-6 21 composition
(A-II) formulation (parts) Graft crosslinked B-II-6 30 30 10
particles B-II-32 30 (B-II) B-II-33 30 Thermoplastic resin D-II-1
70 70 79 (D-II) D-II-2 70 D-II-3 70 D-II-4 90 Evaluation results
MVR cm.sup.3/10 min 8 9 8 8 15 9 Impact resistance kJ/m.sup.2 20 8
9 50 20 9 Color developability L* (ma) 2.5 2.6 3.1 3.5 3.8 2.5
Abrasion Resistance .DELTA.L* (mc-ma) A B A A A A Weather
resistance .DELTA.E A A A B A A
TABLE-US-00023 TABLE 23 Example 3-32 3-33 3-34 3-35 3-36 3-37 3-38
Thermoplastic Graft crosslinked B-II-6 10 17 25 29 55 80 95 resin
particles(B-II) composition Thermoplastic resin D-II-1 90 83 75 71
45 20 5 formulation (D-II) (parts) Evaluation MVR cm.sup.3/10 min
10 10 9 9 8 8 7 results Impact resistance kJ/m.sup.2 5 7 8 8 10 10
11 Color developability L* (ma) 2.1 2.1 2.1 2.1 2.3 2.5 2.7
Abrasion Resistance .DELTA.L* (mc-ma) B B A A A A A Weather
resistance .DELTA.E A A A A A A A
TABLE-US-00024 TABLE 24 Comparative example 3-1 3-2 3-3 3-4 3-5 3-6
3-7 Thermoplastic resin Graft crosslinked B-II-1 30 composition
particles B-II-9 30 formulation (parts) (B-II) B-II-13 30 B-II-24
30 B-II-25 30 B-II-31 30 Thermoplastic resin D-II-1 70 70 70 70 70
70 (D-II) D-II-4 100 Evaluation results MVR cm.sup.3/10 min 10 5 9
5 5 10 12 Impact resistance kJ/m.sup.2 2 10 4 12 2 15 15 Color
developability L* (ma) 2.1 4.2 2.1 4.5 2.1 4.2 3.8 Abrasion
Resistance .DELTA.L* (mc-ma) D A C A A C D Weather resistance
.DELTA.E A A A A A A A
TABLE-US-00025 TABLE 25 Comparative Example example 3-6 3-2
Thermoplastic Graft crosslinked B-II-6 30 resin particles B-II-9 30
composition (B-II) formulation Thermoplastic resin C-II-1 70 70
(parts) (D-II) Evaluation Transparency Haze A C results
[0560] As is clear from Tables 19 to 24, the thermoplastic resin
compositions of Examples 3-1 to 3-38 were excellent in flowability.
The molded articles obtained in Examples 3-1 to 3-38 were excellent
in impact resistance, color developability, abrasion resistance,
and weather resistance. By contrast, Comparative Examples 3-1 to
3-7, which did not meet the requirements of the third invention,
were poor in any of flowability, and impact resistance, color
developability, abrasion resistance, and weather resistance of the
molded articles.
[0561] As shown in Table 25, the molded article of Example 3-6 was
excellent in transparency, whereas the molded article of the
Comparative Example 3-2 was poor in transparency.
[0562] These results show that the crosslinked particles (A-II) and
the graft crosslinked particles (B-II) can improve the flowability,
impact resistance, and abrasion resistance of a thermoplastic resin
without impairing its color developability and weather resistance
and are suitable for use in applications such as automotive
interior and exterior parts, office machines, household electrical
appliances, and building materials.
Examples and Comparative Examples of Fourth Invention
[Production of Rubbery Polymer]
Synthesis Example 4-1: Production of Rubbery Polymer (A-III-1)
[0563] A rubbery polymer (A-III-1) was produced according to the
following formulation.
TABLE-US-00026 [Formulation] n-Butyl acrylate 100 parts Hexadecane
2.4 parts Dipotassium alkenyl succinate 0.4 parts Allyl
methacrylate 0.2 parts 1,3-Butylene dimethacrylate 1.0 part t-Butyl
hydroperoxide 0.25 parts Ferrous sulfate 0.0002 parts Sodium
formaldehyde sulfoxylate 0.33 parts Disodium
ethylenediaminetetraacetate 0.0004 parts Distilled water 203
parts
[0564] Distilled water, n-butyl acrylate, hexadecane, dipotassium
alkenyl succinate, allyl methacrylate, 1,3-butylene dimethacrylate,
and t-butyl hydroperoxide were loaded into a reactor equipped with
a reagent injector, a condenser, a jacket heater, and a stirring
device, and ultrasonication was performed at an amplitude of 35
.mu.m for 20 minutes using an ULTRASONIC HOMOGENIZER US-600
available from Nihonseiki Kaisha Ltd. at normal temperature to
obtain a pre-emulsion (a-III-1). The average particle size of the
latex obtained was 180 nm.
[0565] After the pre-emulsion (a-III-1) was heated to 60.degree.
C., ferrous sulfate, sodium formaldehyde sulfoxylate, and disodium
ethylenediaminetetraacetate were added to initiate radical
polymerization. The polymerization of the acrylate components
caused the liquid temperature to rise to 78.degree. C. The
temperature was maintained at 70.degree. C. for 30 minutes, and the
polymerization of the acrylate components was completed to obtain a
rubbery polymer (A-III-1). The solid content of the rubbery polymer
(A-III-1) in the latex obtained was 18.7%, and the volume average
particle size (X) was 180 nm. The volume average particle size,
largest 10% frequency particle size (Y), and smallest 10% frequency
particle size (Z) of the rubbery polymer (A-III-1) are shown in
Table 26.
[0566] The average particle size and particle size distribution of
the rubbery polymer (A-III-1) and rubbery polymers (A-III-2) to
(A-III-12) described below and the average particle size of graft
copolymers (B-III-1) to (B-111-12) described below were measured by
the following method.
[0567] <Measurement of Particle Size>
[0568] The volume average particle size was determined by a dynamic
light scattering method using a Nanotrac UPA-EX150 available from
Nikkiso Co., Ltd.
[0569] The particle size distribution was determined in the same
manner as described above. The ratio of the largest 10% frequency
particle size (Y), which is a particle size at a largest 10%
frequency, to the volume average particle size (X) and the ratio of
the smallest 10% frequency particle size (Z), which is a particle
size at a smallest 10% frequency, to the volume average particle
size (X) were calculated.
Synthesis Examples 4-2 to 4-9: Production of Rubbery Polymers
(A-III-2) to (A-III-9)
[0570] Using materials shown in Table 26 in proportions shown in
Table 26, synthesis was performed in the same manner as in
Synthesis Example 4-1 to obtain rubbery polymers (A-III-2) to
(A-III-9). The volume average particle size (X), largest 10%
frequency particle size (Y), and smallest 10% frequency particle
size (Z) of the rubbery polymers (A-III-2) to (A-III-9) are shown
in Table 26.
Synthesis Example 4-10: Production of Rubbery Polymer
(A-III-10)
[0571] A rubbery polymer (A-III-10) was produced according to the
following formulation.
TABLE-US-00027 [Formulation] n-Butyl acrylate 100 parts Hexadecane
2.4 parts Dipotassium alkenyl succinate 1.0 part Allyl methacrylate
0.2 parts 1,3-Butylene dimethacrylate 1.0 part t-Butyl
hydroperoxide 0.25 parts Ferrous sulfate 0.0002 parts Sodium
formaldehyde sulfoxylate 0.33 parts Disodium
ethylenediaminetetraacetate 0.0004 parts Distilled water 203
parts
[0572] Distilled water was loaded into a reactor equipped with a
reagent injector, a condenser, a jacket heater, and a stirring
device. After heating to 60.degree. C., ferrous sulfate, sodium
formaldehyde sulfoxylate, and disodium ethylenediaminetetraacetate
were added. A mixed solution of n-butyl acrylate, hexadecane,
dipotassium alkenyl succinate, allyl methacrylate, 1,3-butylene
dimethacrylate, and t-butyl hydroperoxide was added dropwise with a
pump over 120 minutes to raise the temperature to 80.degree. C.
After completion of the dropwise addition, the temperature was
maintained at 70.degree. C. for 30 minutes, and the polymerization
of the acrylate components was completed to obtain a rubbery
polymer (A-III-10). The solid content of the rubbery polymer
(A-III-10) in the latex obtained was 18.4%, and the volume average
particle size (X) was 180 nm. The largest 10% frequency particle
size (Y) and smallest 10% frequency particle size (Z) were as shown
in Table 27.
Synthesis Example 4-11: Production of Rubbery Polymer
(A-III-11)
[0573] A rubbery polymer (A-III-11) was produced according to the
following formulation.
TABLE-US-00028 [Formulation] n-Butyl acrylate 100 parts Hexadecane
2.4 parts Dipotassium alkenyl succinate 1.0 part Allyl methacrylate
0.2 parts 1,3-Butylene dimethacrylate 1.0 part t-Butyl
hydroperoxide 0.25 parts Ferrous sulfate 0.0002 parts Sodium
formaldehyde sulfoxylate 0.33 parts Disodium
ethylenediaminetetraacetate 0.0004 parts Distilled water 203
parts
[0574] Distilled water, n-butyl acrylate, hexadecane, dipotassium
alkenyl succinate, allyl methacrylate, 1,3-butylene dimethacrylate,
and t-butyl hydroperoxide were loaded into a reactor equipped with
a reagent injector, a condenser, a jacket heater, and a stirring
device. After heating to 60.degree. C., ferrous sulfate, sodium
formaldehyde sulfoxylate, and disodium ethylenediaminetetraacetate
were added to initiate radical polymerization. The polymerization
of the acrylate components caused the liquid temperature to rise to
78.degree. C. The temperature was maintained at 70.degree. C. for
30 minutes, and the polymerization of the acrylate components was
completed to obtain a rubbery polymer. The solid content of the
rubbery polymer in the latex obtained was 18.4%, and the volume
average particle size was 100 nm.
[0575] After the liquid temperature inside the reactor decreased to
70.degree. C., 1.0 part, on a solids basis, of a 5% aqueous sodium
pyrophosphate solution was added. After the inner temperature was
controlled to be 70.degree. C., 0.3 parts, on a solid basis, of an
acid-radical-containing copolymer latex containing 15 parts of
methacrylic acid was added, and stirring and enlargement were
performed for 30 minutes to obtain a rubbery polymer (A-III-11).
The volume average particle size (X) of the rubbery polymer
(A-III-11) was 560 nm. The largest 10% frequency particle size (Y)
and smallest 10% frequency particle size (Z) were as shown in Table
27.
Synthesis Example 4-12: Production of Rubbery Polymer
(A-III-12)
[0576] A rubbery polymer (A-III-12) was obtained in the same manner
as in Synthesis Example 4-11 except that 3.0 parts, on a solid
basis, of an aqueous sodium pyrophosphate solution was added. The
volume average particle size (X) thereof was 950 nm. The largest
10% frequency particle size (Y) and smallest 10% frequency particle
size (Z) were as shown in Table 27.
[0577] [Production and Evaluation of Graft Copolymers]
Example 4-1: Production of Graft Copolymer (B-III-1)
[0578] Raw materials of the following formulation were loaded into
a reactor equipped with a reagent injector, a condenser, a jacket
heater, and a stirring device, and the reactor was thoroughly
purged with nitrogen, after which the inner temperature was raised
to 70.degree. C. with stirring.
TABLE-US-00029 [Formulation] Water (including water in rubbery 230
parts polymer latex) Rubbery polymer (A-III-1) latex 50 parts (on a
solids basis) Dipotassium alkenyl succinate 0.2 parts Sodium
formaldehyde sulfoxylate 0.3 parts Ferrous sulfate 0.001 parts
Disodium ethylenediaminetetraacetate 0.003 parts
[0579] Next, a mixed solution containing acrylonitrile (AN),
styrene (ST), and t-butyl hydroperoxide according to the following
formulation was added dropwise over 100 minutes, while the
temperature was raised to 80.degree. C.
TABLE-US-00030 [Formulation] Acrylonitrile 12.5 parts Styrene 37.5
parts t-Butyl hydroperoxide 0.2 parts
[0580] After completion of the dropwise addition, the temperature
at 80.degree. C. was maintained for 30 minutes and then cooled to
obtain a graft copolymer (B-III-1) latex. The solid content of the
graft copolymer (B-III-1) in the latex obtained was 29.7%, and the
volume average particle size was 210 nm.
[0581] Next, 100 parts of a 1.5% aqueous sulfuric acid solution
were heated to 80.degree. C., and while stirring the aqueous
solution, 100 parts of the graft copolymer (B-III-1) latex was
gradually added dropwise to the aqueous solution to solidify the
graft copolymer (B-III-1). Furthermore, the temperature was raised
to 95.degree. C. and maintained for 10 minutes.
[0582] Next, the solidified product was dehydrated, washed, and
dried to obtain the graft copolymer (B-III-1) in powder form.
Examples 4-2 to 4-5, Comparative Examples 4-1 to 4-3: Production of
Graft Copolymers (B-III-2) to (B-III-12)
[0583] Graft copolymers (B-III-2) to (B-III-12) were obtained in
the same manner as in Example 4-1 except that rubbery polymer
(A-III-2) to (A-III-12) latexes were each used in place of the
rubbery polymer (A-III-1) latex. The volume average particle size
of the graft copolymers (B-III-2) to (B-III-12) were as shown in
Tables 26 and 27.
[0584] <Production of Thermoplastic Resin Composition>
[0585] Forty parts of each of the graft copolymers (B-III-1) to
(B-III-12) and 60 parts of an acrylonitrile-styrene copolymer ("UMG
AXS resin S102N" available from UMG ABS, Ltd.) produced by
suspension polymerization were mixed together using a Henschel
mixer, and the mixture was fed to an extruder heated to 240.degree.
C. and kneaded to obtain pellets.
[0586] <Preparation of Test Piece>
[0587] Each of the above-described pellets was molded with a 4
ounce injection molding machine (available from Japan Steel Works,
LTD.) under the conditions of a cylinder temperature of 240.degree.
C. and a mold temperature of 60.degree. C. to obtain a test piece 1
having a length of 80 mm, a width of 10 mm, and a thickness of 4
mm.
[0588] In a similar manner, a plate-like molded body 2 having a
length of 100 mm, a width of 100 mm, and a thickness of 2 mm was
obtained under the conditions of a cylinder temperature of
240.degree. C., a mold temperature of 60.degree. C., and an
injection rate of 20 g/s.
[0589] <Evaluation>
<<Measurement of Charpy Impact Strength>>
[0590] Using the test piece 1, Charpy impact strength was measured
in a 23.degree. C. atmosphere in accordance with ISO 179.
[0591] <<Measurement of Melt Volume Rate (MVR)>>
[0592] The MVR of the thermoplastic resin composition pellets was
measured under the conditions of 220.degree. C. and 98 N in
accordance with ISO 1133 standard. The MVR indicates the
flowability of the thermoplastic resin compositions.
[0593] <<Measurement of Color Developability>>
[0594] The L* of a surface of the molded body 2 was measured using
a colorimeter CM-508D available from Minolta. Smaller L* values
indicate better color developability.
[0595] <<Measurement of Image Clarity>>
[0596] The image clarity (%) at a reflectance of 60.degree. of the
surface of the molded body 2 was measured with an image clarity
meter (ICM-IDP available from Suga Test Instruments Co., Ltd).
Higher image clarity values indicate higher brightness of a molded
article surface and better molded appearance.
[0597] The evaluation results of the above-described measurements
are shown in Tables 26 and 27.
TABLE-US-00031 TABLE 26 Example 4-1 Example 4-2 Example 4-3 Example
4-4 Example 4-5 Graft Type of graft copolymer B-III-1 B-III-2
B-III-3 B-III-4 B-III-5 copolymer Rubbery polymer/AN/ST (parts)
50/12.5/37.5 50/12.5/37.5 50/12.5/37.5 50/12.5/37.5 50/12.5/37.5
(B-III) Volume average nm 210 310 590 770 1150 particle size
Rubbery Type A-III-1 A-III-2 A-III-3 A-III-4 A-III-5 polymer
Preparation method Miniemulsion Miniemulsion Miniemulsion
Miniemulsion Miniemulsion (A-III) Hydrophobe Parts 2.4 2.4 2.4 2.4
2.4 Emulsifier Parts 0.40 0.20 0.10 0.06 0.04 Volume average
particle nm 180 280 560 760 960 size (X) Largest 10% frequency nm
290 390 950 1140 1730 particle size (Y) (1.6X) (1.4X) (1.7X) (1.5X)
(1.8X) Smallest 10% frequency nm 130 220 340 460 480 particle size
(Z) (0.72X) (0.79X) (0.60X) (0.60X) (0.50X) Evaluation Charpy
impact strength kJ/m.sup.2 7 10 12 13 10 results MVR cm.sup.3/10
min 11 11 10 9 10 Color developability L value 8.9 9.4 10.5 11.5
11.8 Image clarity % 85 82 80 78 75 Example 4-6 Example 4-7 Example
4-8 Example 4-9 Graft Type of graft copolymer B-III-6 B-III-7
B-III-8 B-III-9 copolymer Rubbery polymer/AN/ST (parts)
50/12.5/37.5 50/12.5/37.5 50/12.5/37.5 50/12.5/37.5 (B-III) Volume
average nm 310 130 880 440 particle size Rubbery Type A-III-6
A-III-7 A-III-8 A-III-9 polymer Preparation method Miniemulsion
Miniemulsion Miniemulsion Miniemulsion (A-III) Hydrophobe Parts 2.4
2.4 2.4 2.4 Emulsifier Parts 0.22 0.70 0.05 0.15 Volume average
particle nm 290 120 790 350 size (X) Largest 10% frequency nm 520
190 1420 600 particle size (Y) (1.8X) (1.6X) (1.8X) (1.7X) Smallest
10% frequency nm 200 80 510 190 particle size (Z) (0.70X) (0.66X)
(0.64X) (0.53X) Evaluation Charpy impact strength kJ/m.sup.2 11 5
13 10 results MVR cm.sup.3/10 min 10 11 9 11 Color developability L
value 11.3 8.9 12.2 11.2 Image clarity % 72 86 75 77
TABLE-US-00032 TABLE 27 Comparative Comparative Comparative
example4-1 example4-2 example4-3 Graft Type of graft copolymer
B-III-10 B-III-11 B-III-12 copolymer Rubbery polymer/AN/ST (parts)
50/12.5/37.5 50/12.5/37.5 50/12.5/37.5 (B-III) Volume average nm
200 600 1330 particle size Rubbery Type A-III-10 A-III-11 A-III-12
polymer Preparation method Seeding Enlargement Enlargement (A-III)
Hydrophobe Parts 2.4 2.4 2.4 Emulsifier Parts 1.00 1.00 1.00 Volume
average particle nm 180 560 950 size (X) Largest 10% frequency nm
320 (1.8X) 1060 (1.9X) 1810 (1.9X) particle size (Y) Smallest 10%
frequency nm 110 (0.61X) 280 (0.50X) 380 (0.40X) particle size (Z)
Evaluation Charpy impact strength kJ/m.sup.2 4 9 12 results MVR
cm.sup.3/10 min 10 10 10 Color developability L value 9.6 13.4 17.8
Image clarity % 82 70 65
[0598] The results of Examples and Comparative Examples revealed
the following.
[0599] The thermoplastic resin compositions of Examples 4-1 to 4-9
are excellent in impact resistance, color developability, and
molded appearance.
[0600] By contrast, the thermoplastic resin compositions of
Comparative Examples 4-1 to 4-3 were poor in any of impact
resistance, color developability, and molded appearance.
Specifically, in Comparative Example 4-1, impact resistance is poor
because the rubbery polymer (A-III-10) is a seeded polymerization
product. In Comparative Example 4-2, color developability and
molded appearance are poor because the rubbery polymer (A-III-11)
is an enlargement polymerization product and has a wide particle
size distribution. In Comparative Example 4-3, color developability
and molded appearance are poor because the rubbery polymer
(A-III-12) is an enlargement polymerization product and has a wide
particle size distribution and low polymerization stability.
INDUSTRIAL APPLICABILITY
[0601] The thermoplastic resin composition of the first invention
and molded articles thereof are excellent in weather resistance,
color developability, and also impact resistance and thus is
suitable for long-term outdoor use such as vehicles and building
materials.
[0602] Thermoplastic resin molded articles including the
crosslinked particles (A-I) and/or the graft crosslinked particles
(B-I) of the second invention are useful as vehicle interior and
exterior parts, office machines, household electrical appliances,
building materials, etc.
[0603] Thermoplastic resin molded articles including the
crosslinked particles (A-II) and/or the graft crosslinked particles
(B-II) of the third invention are useful as vehicle interior and
exterior parts, office machines, household electrical appliances,
building materials, etc.
[0604] Molded articles made of the thermoplastic resin composition
of the fourth invention including the graft copolymer (B-III) of
the third invention obtained using the rubbery polymer (A-III) of
the fourth invention are good in impact resistance, color
developability, and molded appearance. This balance of impact
resistance, color developability, and molded appearance is very
excellent as compared to molded articles made of conventional
thermoplastic resin compositions, and thus the thermoplastic resin
composition of the fourth invention and molded articles thereof are
extremely useful as various industrial materials.
[0605] Although the present invention has been described in detail
by using a specific embodiment, it should be apparent to those
skilled in the art that various modifications can be made without
departing from the spirit and the scope of the present
invention.
[0606] This application is based on Japanese Patent Application No.
2015-212024 filed on Oct. 28, 2015, Japanese Patent Application No.
2015-212025 filed on the same date, Japanese Patent Application No.
2015-212026 filed on the same date, and Japanese Patent Application
No. 2015-212027 filed on the same date, which are incorporated by
reference herein in their entirety.
* * * * *