Propylene resin composition and molded body

Abstract

Provided are: a molded body having excellent low-temperature impact strength; and a propylene resin composition as a raw material thereof.　This propylene resin composition contains: a recycled resin having a swell ratio of 1.3 or more; and a virgin propylene polymer.

Description

Propylene resin composition and molded article

[0001] The present invention relates to a propylene resin composition and a molded article.

[0002] Molded articles made of propylene resin compositions are used as materials for automobiles, home appliances, containers and packaging materials, and the like.

[0003] Japanese Patent Application Laid-Open No. 2007-277366

[0004] In recent years, molded articles used in automobile materials and the like are required to have high low-temperature impact strength.

[0005] Therefore, an object of the present invention is to provide a propylene resin composition from which a molded article having excellent low-temperature impact strength can be produced. Another object of the present invention is to provide a molded article having excellent low-temperature impact strength.

[0006] The present invention relates to, but is not limited to, the following: [Invention 1] A propylene resin composition comprising a recycled resin having a swell ratio of 1.3 or more when measured under the following conditions: measurement temperature = 220°C, orifice L / D = 40 mm / 1 mm, shear rate = 2432 sec -1[Invention 2] The propylene resin composition according to Invention 1, wherein the recycled resin comprises at least one selected from the group consisting of a propylene polymer and an ethylene-α-olefin copolymer. [Invention 3] The propylene resin composition according to Invention 2, wherein the propylene polymer comprises at least one selected from the group consisting of a propylene homopolymer and a heterophasic propylene polymer material. [Invention 4] The propylene resin composition according to any one of Inventions 1 to 3, wherein the recycled resin comprises a plurality of recycled resins. [Invention 5] The propylene resin composition according to any one of Inventions 1 to 4, wherein the virgin propylene polymer comprises a propylene polymer. [Invention 6] The propylene resin composition according to Invention 5, wherein the propylene polymer comprises at least one selected from the group consisting of a propylene homopolymer and a heterophasic propylene polymer material. [Invention 7] The propylene resin composition according to any one of Inventions 1 to 6, further comprising an inorganic filler. [Invention 8] The propylene resin composition according to Invention 7, wherein the inorganic filler is a recycled inorganic filler. [Invention 9] The propylene resin composition according to any one of Inventions 1 to 8, which contains an ethylene-α-olefin copolymer as a component other than the recycled resin. [Invention 10] A molded article comprising the propylene resin composition according to any one of Inventions 1 to 9. [Invention 11] A method for producing the propylene resin composition according to any one of Inventions 1 to 9. [Invention B1] A propylene resin composition comprising a recycled resin having a swell ratio of 1.3 or more when measured under the following conditions: Measurement temperature = 220°C, orifice L / D = 40 mm / 1 mm, shear rate = 2432 sec -1[Invention B2] The propylene resin composition according to Invention B1, wherein the recycled resin has a swell ratio of 2.0 or less. [Invention B3] The propylene resin composition according to Invention B1 or B2, wherein the recycled resin is a recycled propylene composition containing a propylene polymer. [Invention B4] The propylene resin composition according to any one of Inventions B1 to B3, wherein the virgin propylene polymer is a heterophasic propylene polymer material. [Invention B5] The propylene resin composition according to any one of Inventions B1 to B4, wherein the recycled resin is contained in an amount of 30 to 90 parts by weight per 100 parts by weight of the propylene resin composition. [Invention B6] The propylene resin composition according to any one of Inventions B1 to B5, wherein the virgin propylene polymer is contained in an amount of 10 to 70 parts by weight per 100 parts by weight of the propylene resin composition. [Invention B7] The propylene resin composition according to any one of Inventions B1 to B6, wherein the total amount of the polymers contained is 70% by weight or more, based on the total weight of the propylene resin composition. [Invention B8] The propylene resin composition according to any one of Inventions B1 to B7, wherein the recycled resin comprises an ethylene-α-olefin copolymer. [Invention B9] The propylene resin composition according to Invention B3, wherein the propylene polymer comprises at least one selected from the group consisting of a propylene homopolymer and a heterophasic propylene polymer material. [Invention B10] The propylene resin composition according to any one of Inventions B1 to B9, wherein a recycled resin different from the recycled resin (hereinafter referred to as a "different recycled resin") is contained, the recycled resin having a swell ratio of 1.3 or more when measured under the conditions described in Invention B1. [Invention B11] The propylene resin composition according to Invention B10, wherein the different recycled resin comprises an ethylene-α-olefin copolymer. [Invention B12] The propylene resin composition according to any one of Inventions B1 to B11, wherein the virgin propylene polymer comprises a propylene homopolymer. [Invention B13] The propylene resin composition according to any one of Inventions B1 to B12, further comprising an inorganic filler. [Invention B14] The propylene resin composition according to Invention B13, wherein the inorganic filler comprises a recycled inorganic filler.[Invention B15] The propylene resin composition according to any one of Inventions B1 to B14, which contains an ethylene-α-olefin copolymer as a component other than the recycled resin. [Invention B16] A molded article comprising the propylene resin composition according to any one of Inventions B1 to B15. [Invention B17] A method for producing the propylene resin composition according to any one of Inventions B1 to B15, which comprises a step of melt-kneading the recycled resin and the virgin propylene polymer. [Invention C1] A propylene resin composition comprising a recycled resin having a swell ratio of 1.3 to 2.0 when measured under the following conditions, and a virgin propylene polymer, wherein the recycled resin is a recycled propylene composition containing a propylene polymer, and the virgin propylene polymer is a heterophasic propylene polymerization material, the propylene resin composition: Measurement temperature=220°C, orifice L / D=40 mm / 1 mm, shear rate=2432 sec. -1[Invention C2] The propylene resin composition according to Invention C1, wherein the content of the recycled resin is 30 to 90 parts by weight per 100 parts by weight of the propylene resin composition. [Invention C3] The propylene resin composition according to Invention C1 or C2, wherein the content of the virgin propylene polymer is 10 to 70 parts by weight per 100 parts by weight of the propylene resin composition. [Invention C4] The propylene resin composition according to any one of Inventions C1 to C3, wherein the total amount of the polymers contained is 70% by weight or more based on the total weight of the propylene resin composition. [Invention C5] The propylene resin composition according to any one of Inventions C1 to C4, wherein the recycled resin comprises an ethylene-α-olefin copolymer. [Invention C6] The propylene resin composition according to any one of Inventions C1 to C5, wherein the propylene polymer comprises at least one selected from the group consisting of a propylene homopolymer and a heterophasic propylene polymer material. [Invention C7] The propylene resin composition according to any one of Inventions C1 to C6, further comprising a recycled resin different from the recycled resin, the recycled resin having a swell ratio of 1.3 or more when measured under the conditions described in Invention C1 (referred to as a "different recycled resin"). [Invention C8] The propylene resin composition according to Invention C7, comprising an ethylene-α-olefin copolymer as the different recycled resin. [Invention C9] The propylene resin composition according to any one of Inventions C1 to C8, wherein the virgin propylene polymer comprises a propylene homopolymer. [Invention C10] The propylene resin composition according to any one of Inventions C1 to C9, comprising a propylene homopolymer as the virgin propylene polymer different from the virgin propylene polymer. [Invention C11] The propylene resin composition according to any one of Inventions C1 to C10, further comprising an inorganic filler. [Invention C12] The propylene resin composition according to Invention C11, comprising a recycled inorganic filler as the inorganic filler. [Invention C13] The propylene resin composition according to any one of Inventions C1 to C12, which contains an ethylene-α-olefin copolymer as a component other than the recycled resin. [Invention C14] A molded article comprising the propylene resin composition according to any one of Inventions C1 to C13.[Invention C15] A method for producing a propylene resin composition according to any one of Inventions C1 to C13, comprising a step of melt-kneading the recycled resin and the virgin propylene polymer.

[0007] According to the present invention, it is possible to provide a molded article having excellent low-temperature impact strength and a propylene resin composition which is a raw material thereof.

[0008] Definitions As used herein, the term "propylene polymer" refers to a polymer having 50% by weight or more of monomer units derived from propylene. This will be explained in detail later. As used herein, the term "propylene resin composition" refers to a composition containing a propylene polymer. This will be explained in detail later. As used herein, the term "α-olefin" refers to an aliphatic unsaturated hydrocarbon having a carbon-carbon unsaturated double bond at the α-position. As used herein, the term "C4-10 hydrocarbon group" refers to a hydrocarbon group having 4 to 10 carbon atoms. The same applies to other similar expressions. As used herein, the term "ethylene-α-olefin copolymer" refers to a copolymer containing monomer units derived from ethylene and monomer units derived from a C4 or higher (meaning 4 or more carbon atoms; the same applies to other similar expressions), and is substantially free of monomer units derived from propylene. This will be explained in detail later. As used herein, the term "heterophagic propylene polymer material" refers to a mixture containing a polymer I containing 80% by weight or more of monomer units derived from propylene (where the total weight of polymer I is taken as 100% by weight), and a polymer II containing monomer units derived from at least one α-olefin selected from the group consisting of ethylene and C4-12 α-olefins and monomer units derived from propylene. As used herein, the term "xylene-insoluble component (also referred to as "CXIS component")" refers to a component contained in a polymer that is insoluble in p-xylene and is a solid obtained by the following method: a method in which approximately 2 g of a polymer is dissolved in boiling p-xylene for 2 hours to obtain a solution, and then the solution is cooled to 20°C to precipitate a solid. As used herein, the term "xylene-soluble component (also referred to as "CXS component")" refers to components in a polymer other than the "CXIS component".

[0009] All numbers disclosed herein are approximations, whether or not the word "about" or "approximately" is used in connection therewith. They may vary by 1 percent, 2 percent, 5 percent, or sometimes 10 to 20 percent. Whenever a numerical range with a lower limit, RL, and an upper limit, RU, is disclosed, any number falling within the range is specifically disclosed. Specifically, the following numbers within the range are specifically disclosed: R = RL + k * (RU - RL), where k is a variable ranging from 1 percent to 100 percent in 1 percent increments, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, ..., 50 percent, 51 percent, 52 percent, ..., 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Additionally, any numerical range defined by two R numbers as set forth above is also specifically disclosed.

[0010] The expression "lower limit to upper limit" expressing a numerical range means "greater than or equal to the lower limit, and less than or equal to the upper limit," and the expression "upper limit to lower limit" means "less than or equal to the upper limit, greater than or equal to the lower limit." In other words, these expressions express a numerical range including the lower limit and the upper limit, but in one aspect, one or both of the upper limit and the lower limit may be excluded, that is, "lower limit to upper limit" may express "more than the lower limit and less than the upper limit," "greater than or equal to the lower limit and less than the upper limit," or "more than the lower limit and less than the upper limit." Similarly, "xx or more" may express "more than xx," and "xx or less" may express "less than xx."

[0011] Hereinafter, several embodiments of the present invention will be described in detail, but the present invention is not limited to the following embodiments.

[0012] Propylene Resin Composition The "propylene resin composition" of the present invention comprises a recycled resin having a swell ratio of 1.3 or more and a virgin propylene polymer. The swell ratio is measured under the following conditions: measurement temperature = 220°C, orifice L / D = 40 mm / 1 mm, shear rate = 2432 sec -1 .

[0013] In this specification, the term "recycled resin" means a resin that has been processed, such as molded, or used for some final purpose, and then goes through a recovery process before being reused. The same applies to other "recycled xxx" types.

[0014] Examples of raw materials that can be subjected to the recovery process include used automobile interior parts (instrument panels, door trims, etc.), automobile exterior parts (bumpers, etc.), other automobile parts (battery cases, etc.), packaging containers (food retort pouches, refill pouches, detergent bottles, etc.), housings for household electrical appliances, office supplies (trays, etc.), and household commodities (contact lens cases, etc.). Depending on the application, these recovered raw materials may contain elastomer components that enhance impact resistance, such as ethylene-α-olefin copolymers, and / or additives such as fillers (e.g., inorganic fillers), neutralizing agents, antioxidants, UV absorbers, nucleating agents, lubricants, antistatic agents, antiblocking agents, colorants (e.g., inorganic pigments, organic pigments, pigment dispersants), and flame retardants. The recovery process is not particularly limited, and known methods may be used.

[0015] In one embodiment, the process for preparing recycled resin may include optional steps other than the recovery step, such as crushing, refining, melting, kneading with other substances, and molding into pellets. Examples of refining steps include washing with water, aqueous and / or oil-based chemicals, microbial treatment, magnetic separation, and gravity separation. Examples of molded products include, but are not limited to, injection molded products.

[0016] In this specification, the term "virgin propylene polymer" means a propylene polymer that, unlike the above-mentioned "recycled propylene polymer," has not been molded into a product such as an automobile or a part thereof, and has not been used for any final application after being produced by a process including a polymerization step. The same applies to other "virgin xxx" products.

[0017] Swell ratio The swell ratio is the degree of expansion of the strand diameter of the thermoplastic elastomer composition relative to the orifice diameter when the molten thermoplastic elastomer composition is extruded from an orifice using a capillary rheometer. The swell ratio was measured at a temperature of 220°C and a shear rate of 2432 sec. －１ The thermoplastic elastomer composition is extruded through an orifice having a diameter of 1 mm and a length of 40 mm under the conditions of (a) above, and the diameter of the resulting strand is divided by the diameter of the orifice, and can be determined, for example, according to the method described in the Examples.

[0018] A resin composition having a desired swell ratio can be produced by appropriately selecting the types and content ratio of monomers constituting the polymer, polymerization conditions such as the type of catalyst, the type and content of filler, etc. After the virgin resin composition produced in this way is used for some purpose, a recycled resin obtained through recycling can be used to produce the propylene resin composition of the present invention.

[0019] When the propylene resin composition of the present invention contains a recycled resin having a swell ratio of 1.3 or more, a molded article containing (produced from) the propylene resin composition of the present invention has excellent low-temperature impact strength.

[0020] In one embodiment, the recycled resin is preferably in the form of crushed molded articles or pellets granulated from the crushed molded articles. More preferably, the recycled resin has a swell ratio of 1.3 or more measured in the crushed molded article state, so that the molded article containing (produced from) the propylene resin composition of the present invention has excellent low-temperature impact strength.

[0021] The "recycled resin having a swell ratio of 1.3 or more" (also referred to as component A) preferably contains at least one selected from the group consisting of propylene polymer P and ethylene-α-olefin copolymer E, and more preferably contains propylene polymer P. Component A may contain a plurality of recycled resins.

[0022] Each component indicated as "propylene polymer P" or the like will also be simply referred to as "component P" or the like.

[0023] Each component will be described below.

[0024] Propylene Polymer P (Component P) The propylene resin composition of the present invention may contain a propylene polymer P (component P) as component A. Component P is a polymer having 50% by weight or more of monomer units derived from propylene, where the total weight of component P is 100% by weight. Examples of component P include a propylene homopolymer, a random copolymer of propylene and a monomer other than propylene, and a heterophasic propylene polymer material. The propylene resin composition of the present invention may contain only one type of component P as component A, or may contain two or more types. From the viewpoint of rigidity and impact resistance of a molded product, it is preferable that component P contains at least one selected from the group consisting of a propylene homopolymer and a heterophasic propylene polymer material.

[0025] Propylene Homopolymer When a propylene homopolymer is contained as component P, the intrinsic viscosity number ([η]) of the propylene homopolymer is preferably 0.10 to 4.00 dL / g, more preferably 0.50 to 3.00 dL / g, and even more preferably 0.70 to 2.00 dL / g, from the viewpoints of the fluidity of the resin composition when melted and the toughness of the molded body.

[0026] In this specification, the intrinsic viscosity (unit: dL / g) means a value measured at a temperature of 135°C using tetralin as a solvent by the following method.

[0027] Using an Ubbelohde viscometer, the reduced viscosity is measured at three concentrations: 0.1 g / dL, 0.2 g / dL, and 0.5 g / dL. The reduced viscosity is plotted against the concentration, and the intrinsic viscosity is calculated by extrapolation, where the concentration is extrapolated to zero. The method for calculating the intrinsic viscosity by extrapolation is described, for example, on page 491 of "Polymer Solutions, Polymer Experiments 11" (published by Kyoritsu Shuppan Co., Ltd. in 1982).

[0028] The molecular weight distribution (Mw / Mn) of the propylene homopolymer is preferably 3.0 or more, more preferably 4.0 or more. The molecular weight distribution may be 15.0 or less, or may be 10.0 or less. The molecular weight distribution is preferably 3.0 to 15.0, more preferably 4.0 to 10.0.

[0029] In this specification, the molecular weight distribution refers to the ratio (Mw / Mn) of the weight average molecular weight (Mw) to the number average molecular weight (Mn), calculated using the weight average molecular weight (Mw) and number average molecular weight (Mn) measured by gel permeation chromatography (GPC) under the following conditions: Apparatus: HLC-8121 GPC / HT manufactured by Tosoh Corporation Separation column: Three GMHHR-H(S)HT manufactured by Tosoh Corporation Measurement temperature: 140°C Carrier: orthodichlorobenzene Flow rate: 1.0 mL / min Sample concentration: Approximately 1 mg / mL Sample injection amount: 400 μL Detector: Differential refractometry Calibration curve creation method: Standard polystyrene was used

[0030] The propylene homopolymer may be, for example, a recycled product produced by polymerizing propylene using a polymerization catalyst.

[0031] Examples of the polymerization catalyst include Ziegler catalysts; Ziegler-Natta catalysts; catalysts containing a compound of a transition metal of Group 4 of the periodic table having a cyclopentadienyl ring and an alkylaluminoxane; catalysts containing a compound of a transition metal of Group 4 of the periodic table having a cyclopentadienyl ring, a compound that reacts with the transition metal compound to form an ionic complex, and an organoaluminum compound; and modified catalysts obtained by supporting a catalyst component (a compound of a transition metal of Group 4 of the periodic table having a cyclopentadienyl ring, a compound that forms an ionic complex, an organoaluminum compound, etc.) on inorganic particles (silica, clay mineral, etc.).

[0032] Examples of the polymerization catalyst include catalysts described in JP-A-61-218606, JP-A-5-194685, JP-A-7-216017, JP-A-9-316147, JP-A-10-212319, JP-A-2004-182981, JP-A-2010-168545, JP-A-2011-246699, and the like.

[0033] Furthermore, a polymer obtained by prepolymerizing propylene in the presence of the above polymerization catalyst may be used as the polymerization catalyst.

[0034] Examples of polymerization methods include bulk polymerization, solution polymerization, and gas-phase polymerization. Here, bulk polymerization refers to a method in which polymerization is carried out using an olefin that is liquid at the polymerization temperature as a medium, and solution polymerization refers to a method in which polymerization is carried out in an inert hydrocarbon solvent such as propane, butane, isobutane, pentane, hexane, heptane, or octane. Gas-phase polymerization refers to a method in which gaseous monomers are used as a medium and the gaseous monomers are polymerized in that medium.

[0035] Examples of the polymerization method include a batch method, a continuous method, and a combination thereof. The polymerization method may be a multi-stage method in which a plurality of polymerization reactors are connected in series.

[0036] From the viewpoint of industrial and economical excellence, a continuous gas phase polymerization method or a bulk-gas phase polymerization method in which a bulk polymerization method and a gas phase polymerization method are carried out continuously is preferred.

[0037] Various conditions in the polymerization step (polymerization conditions such as polymerization temperature, polymerization pressure, monomer concentration, catalyst input amount, and polymerization time) can be appropriately determined depending on the molecular structure of the target polymer.

[0038] Other steps may be carried out before or after the polymerization step. For example, after the polymerization step, the polymer may be dried at a temperature equal to or lower than the melting point of the polymer, if necessary, to remove residual solvent contained in the polymer, ultralow molecular weight oligomers produced as by-products during production, etc. Examples of drying methods include those described in JP-A-55-75410 and Japanese Patent No. 2,565,753.

[0039] Random copolymer of propylene and a monomer other than propylene The random copolymer of propylene and a monomer other than propylene contains monomer units derived from propylene and monomer units derived from a monomer other than propylene. When the random copolymer is contained as component P, the random copolymer preferably contains 0.01 to 20 wt % of monomer units derived from a monomer other than propylene, based on the weight of the random copolymer.

[0040] Examples of the monomer other than propylene include ethylene and C4 to 12 α-olefins. Among them, at least one selected from the group consisting of ethylene and C4 to 10 α-olefins is preferred, at least one selected from the group consisting of ethylene, 1-butene, 1-hexene, and 1-octene is more preferred, and at least one selected from the group consisting of ethylene and 1-butene is even more preferred.

[0041] Examples of the random copolymer include propylene-ethylene random copolymer, propylene-1-butene random copolymer, propylene-1-hexene random copolymer, propylene-1-octene random copolymer, propylene-ethylene-1-butene random copolymer, propylene-ethylene-1-hexene random copolymer, and propylene-ethylene-1-octene random copolymer.

[0042] When component P contains a random copolymer of propylene and a monomer other than propylene, the intrinsic viscosity ([η]) of the random copolymer is preferably 0.10 to 4.00 dL / g, more preferably 0.50 to 3.00 dL / g, and even more preferably 0.70 to 2.00 dL / g, from the viewpoint of fluidity of the resin composition when melted.

[0043] The molecular weight distribution (Mw / Mn) of the random polymer is preferably 3.0 or more, and more preferably 4.0 or more. The molecular weight distribution of the random polymer may be 10.0 or less, or may be 7.0 or less. The molecular weight distribution of the random polymer is preferably 3.0 to 10.0, and more preferably 4.0 to 7.0.

[0044] The random copolymer may be prepared by polymerizing propylene and a monomer other than propylene according to the polymerization catalyst, polymerization method, polymerization scheme, and polymerization conditions that can be used in preparing the propylene homopolymer.

[0045] Heterophagic Propylene Polymerization Material When a heterophasic propylene polymerization material is included as component P, the heterophasic propylene polymerization material can be produced, for example, by carrying out a first polymerization step to form polymer I and a second polymerization step to form polymer II. These polymerization steps can be carried out in accordance with the polymerization catalyst, polymerization method, polymerization system, and polymerization conditions that can be used in the production of the propylene homopolymer. In the heterophasic propylene polymerization material, the total weight of polymer I and polymer II contained in the heterophasic propylene polymerization material may be 98 to 100% by weight, with the total weight of the heterophasic propylene polymerization material being 100% by weight.

[0046] As described above, polymer I contains 80% by weight or more of monomer units derived from propylene (where the total weight of polymer I is 100% by weight). Polymer I may be, for example, a propylene homopolymer, or may contain monomer units derived from a monomer other than propylene. When polymer I contains monomer units derived from a monomer other than propylene, the content of such units may be, for example, 0.01% by weight or more and less than 20% by weight based on the total weight of polymer I.

[0047] Examples of the monomer other than propylene include ethylene and C4 or higher α-olefins. Among them, at least one selected from the group consisting of ethylene and C4 to C10 α-olefins is preferred, at least one selected from the group consisting of ethylene, 1-butene, 1-hexene, and 1-octene is more preferred, and at least one selected from the group consisting of ethylene and 1-butene is even more preferred.

[0048] Examples of copolymers containing monomer units derived from a monomer other than propylene include propylene-ethylene copolymer, propylene-1-butene copolymer, propylene-1-hexene copolymer, propylene-1-octene copolymer, propylene-ethylene-1-butene copolymer, propylene-ethylene-1-hexene copolymer, and propylene-ethylene-1-octene copolymer.

[0049] From the viewpoint of dimensional stability of the molded article, polymer I is preferably a propylene homopolymer, a propylene-ethylene copolymer, a propylene-1-butene copolymer, or a propylene-ethylene-1-butene copolymer, and more preferably a propylene homopolymer.

[0050] Provided that the heterophasic propylene polymer material has a swell ratio of 1.3 or more, the swell ratio of Polymer I is not particularly limited, but is preferably 1.1 or more, for example, 1.2 or more, or even 1.3. The upper limit is not particularly limited, but may be, for example, 2.0 or less.

[0051] The content of Polymer I is preferably 50 to 99% by weight, more preferably 60 to 95% by weight, based on the total weight of the heterophasic propylene polymer material.

[0052] As described above, Polymer II contains monomer units derived from at least one α-olefin selected from the group consisting of ethylene and C4-12 α-olefins and monomer units derived from propylene. Preferably, Polymer II contains 30% by weight or more of monomer units derived from at least one α-olefin selected from the group consisting of ethylene and C4-12 α-olefins, and also contains monomer units derived from propylene (where the total weight of Polymer II is taken as 100% by weight).

[0053] In Polymer II, the content of monomer units derived from at least one α-olefin selected from the group consisting of ethylene and C4-12 α-olefins may be 30 to 70% by weight, or may be 35 to 60% by weight (where the total weight of Polymer II is 100% by weight).

[0054] In Polymer II, the at least one α-olefin selected from the group consisting of ethylene and C4-12 α-olefins is preferably at least one selected from the group consisting of ethylene and C4-10 α-olefins, more preferably at least one selected from the group consisting of ethylene, 1-butene, 1-hexene, 1-octene, and 1-decene, and even more preferably at least one selected from the group consisting of ethylene and 1-butene.

[0055] Examples of polymer II include propylene-ethylene copolymer, propylene-ethylene-1-butene copolymer, propylene-ethylene-1-hexene copolymer, propylene-ethylene-1-octene copolymer, propylene-ethylene-1-decene copolymer, propylene-1-butene copolymer, propylene-1-hexene copolymer, propylene-1-octene copolymer, and propylene-1-decene copolymer. Among these, propylene-ethylene copolymer, propylene-1-butene copolymer, and propylene-ethylene-1-butene copolymer are preferred, and propylene-ethylene copolymer is more preferred.

[0056] The content of polymer II is preferably 1 to 50% by weight, more preferably 5 to 40% by weight, based on the total weight of the heterophasic propylene polymer material.

[0057] In the heterophasic propylene polymerization material, the content of monomer units derived from at least one α-olefin selected from the group consisting of ethylene and C4-12 α-olefins may be 0.3 to 35% by weight, or may be 0.7 to 24% by weight (where the total weight of the heterophasic propylene polymerization material is 100% by weight).

[0058] The content of xylene insoluble components (CXIS components) in the heterophasic propylene polymer material is preferably 50 to 99 wt %, more preferably 60 to 95 wt %, based on the total weight of the heterophasic propylene polymer material.

[0059] The content of xylene soluble components (CXS components) in the heterophasic propylene polymer material is preferably 1 to 50 wt %, more preferably 5 to 40 wt %, based on the total weight of the heterophasic propylene polymer material.

[0060] Provided that the heterophasic propylene polymer material has a swell ratio of 1.3 or more, the swell ratio of the CXIS of the heterophasic propylene polymer material is not particularly limited, but is preferably 1.1 or more, for example, 1.2 or more, or even 1.3. The upper limit is not particularly limited, but may be, for example, 2.0 or less.

[0061] In the present invention, it is believed that the CXIS component in the heterophasic propylene polymer material is mainly composed of polymer I, and the CXS component in the heterophasic propylene polymer material is mainly composed of polymer II.

[0062] Examples of heterophasic propylene polymeric materials include (propylene)-(propylene-ethylene) polymeric materials, (propylene)-(propylene-ethylene-1-butene) polymeric materials, (propylene)-(propylene-ethylene-1-hexene) polymeric materials, (propylene)-(propylene-ethylene-1-octene) polymeric materials, (propylene)-(propylene-1-butene) polymeric materials, (propylene)-(propylene-1-hexene) polymeric materials, (propylene)-(propylene-1-octene) polymeric materials, and (propylene)-(propylene-1-decene) polymeric materials. (Propylene-ethylene)-(propylene-ethylene) polymerization material, (propylene-ethylene)-(propylene-ethylene-1-butene) polymerization material, (propylene-ethylene)-(propylene-ethylene-1-hexene) polymerization material, (propylene-ethylene)-(propylene-ethylene-1-octene) polymerization material, (propylene-ethylene)-(propylene-ethylene-1-decene) polymerization material, (propylene-ethylene)-(propylene-1-butene) polymerization material, (propylene-ethylene)-(propylene-1-hexene) polymerization material, (propylene-ethylene (propylene-1-octene) polymerization material, (propylene-ethylene)-(propylene-1-decene) polymerization material, (propylene-1-butene)-(propylene-ethylene) polymerization material, (propylene-1-butene)-(propylene-ethylene-1-butene) polymerization material, (propylene-1-butene)-(propylene-ethylene-1-hexene) polymerization material, (propylene-1-butene)-(propylene-ethylene-1-octene) polymerization material, (propylene-1-butene)-(propylene-ethylene-1-decene) polymerization material, (propylene-1-butene)-(propylene-ethylene-1-decene) polymerization material, (propylene-1-butene)-( (propylene-1-butene) polymerization material, (propylene-1-butene)-(propylene-1-hexene) polymerization material, (propylene-1-butene)-(propylene-1-octene) polymerization material, (propylene-1-butene)-(propylene-1-decene) polymerization material, (propylene-1-hexene)-(propylene-1-hexene) polymerization material, (propylene-1-hexene)-(propylene-1-octene) polymerization material, (propylene-1-hexene)-(propylene-1-decene) polymerization material, (propylene-1-octene)-(propylene-1-octene) polymerization material,and (propylene-1-octene)-(propylene-1-decene) polymeric materials.

[0063] Here, the expression "(propylene)-(propylene-ethylene) polymer material" means "a heterophasic propylene polymer material in which polymer I is a propylene homopolymer and polymer II is a propylene-ethylene copolymer." The same applies to other similar expressions.

[0064] As the heterophasic propylene polymer material, a (propylene)-(propylene-ethylene) polymer material, a (propylene)-(propylene-ethylene-1-butene) polymer material, a (propylene-ethylene)-(propylene-ethylene) polymer material, a (propylene-ethylene)-(propylene-ethylene-1-butene) polymer material, or a (propylene-1-butene)-(propylene-1-butene) polymer material is preferred, and a (propylene)-(propylene-ethylene) polymer material is more preferred.

[0065] The intrinsic viscosity number ([η]I) of Polymer I is preferably 0.10 to 4.00 dL / g, more preferably 0.50 to 3.00 dL / g, and even more preferably 0.70 to 2.00 dL / g.

[0066] The intrinsic viscosity number ([η]II) of Polymer II is preferably from 1.00 to 10.00 dL / g, more preferably from 2.00 to 10.00 dL / g, and even more preferably from 2.00 to 9.00 dL / g.

[0067] The ratio ([η]II / [η]I) of the intrinsic viscosity number ([η]II) of Polymer II to the intrinsic viscosity number ([η]I) of Polymer I is preferably 1 to 20, and more preferably 1 to 10.

[0068] An example of a method for measuring the intrinsic viscosity number ([η]I) of polymer I is a method in which polymer I formed is extracted from a reactor in which polymer I is formed, and the intrinsic viscosity number of the polymer is measured.

[0069] The intrinsic viscosity number ([η]II) of polymer II can be calculated, for example, by the following formula using the intrinsic viscosity number ([η]Total) of the heterophasic propylene polymerization material, the intrinsic viscosity number ([η]I) of polymer I, and the contents of polymer II and polymer I.

[0070] [η]II = ([η]Total - [η]I × XI) / XII [η]Total: intrinsic viscosity number (dL / g) of the heterophasic propylene polymer material [η]I: intrinsic viscosity number (dL / g) of polymer I XI: ratio of the weight of polymer I to the total weight of the heterophasic propylene polymer material (weight of polymer I / weight of heterophasic propylene polymer material) XII: ratio of the weight of polymer II to the total weight of the heterophasic propylene polymer material (weight of polymer II / weight of heterophasic propylene polymer material)

[0071] Here, XI and XII can be determined from the material balance during polymerization.

[0072] XII may be calculated by measuring the heat of fusion of polymer I and the heat of fusion of the heterophasic propylene polymer material and using the following formula: XII=1-(ΔHf)T / (ΔHf)P, where (ΔHf)T is the heat of fusion of the heterophasic propylene polymer material (J / g) and (ΔHf)P is the heat of fusion of polymer I (J / g).

[0073] The intrinsic viscosity number ([η]CXIS) of the CXIS component is preferably 0.10 to 4.00 dL / g, more preferably 0.50 to 3.00 dL / g, and even more preferably 0.70 to 2.00 dL / g.

[0074] The intrinsic viscosity number ([η]CXS) of the CXS component is preferably 1.00 to 10.00 dL / g, more preferably 2.00 to 10.00 dL / g, and even more preferably 2.00 to 9.00 dL / g.

[0075] The ratio ([η]CXS / [η]CXIS) of the intrinsic viscosity number of the CXS component ([η]CXS) to the intrinsic viscosity number of the CXIS component ([η]CXIS) is preferably 1 to 20, and more preferably 1 to 10.

[0076] The molecular weight distribution (Mw(I) / Mn(I)) of Polymer I is preferably 3.0 or more, and more preferably 4.0 or more.

[0077] The molecular weight distribution of the CXIS component (Mw(CXIS) / Mn(CXIS)) is preferably 3.0 or more, and more preferably 4.0 or more.

[0078] In this specification, the melt flow rate refers to a value measured in accordance with JIS K7210.

[0079] Ethylene-α-olefin copolymer E (component E) The propylene resin composition of the present invention may contain ethylene-α-olefin copolymer E (component E) as component A. Component E is a polymer in which the total content of monomer units derived from ethylene contained in component E and the content of monomer units derived from C4 or higher α-olefins is 50% by weight or more, where the total weight of component E is 100% by weight, and preferably, the total content is 98 to 100% by weight. Component E may be an ethylene-α-olefin random polymer Er.

[0080] Examples of C4 or higher α-olefins include C4 to C12 α-olefins. Examples of C4 to C12 α-olefins include 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene, 1-octene, and 1-decene. Of these, 1-butene, 1-hexene, and 1-octene are preferred. The α-olefins may be α-olefins having a cyclic structure, such as vinylcyclopropane and vinylcyclobutane.

[0081] Examples of component E include ethylene-1-butene copolymers, ethylene-1-hexene copolymers, ethylene-1-octene copolymers, ethylene-1-decene copolymers, ethylene-(3-methyl-1-butene) copolymers, and copolymers of ethylene and an α-olefin having a cyclic structure.

[0082] In Component E, the content of monomer units derived from C4 or higher α-olefins is preferably 1 to 49 wt %, more preferably 5 to 49 wt %, and even more preferably 24 to 49 wt %, based on the total weight of Component E.

[0083] The density of component E is 0.85 to 0.89 g / cm from the viewpoint of impact resistance of the molded product. ３ It is preferable that the density is 0.85 to 0.88 g / cm ３ More preferably, it is 0.85 to 0.87 g / cm ３ It is more preferable that:

[0084] In one embodiment, the melt flow rate (MFR) (temperature 230°C, load 2.16 kgf) of component A is preferably 0.1 to 300 g / 10 min or more from the viewpoint of the molding processability of the resin composition and / or the low-temperature impact strength of the molded article. The lower limit of the MFR is more preferably 1 g / 10 min, and may be 5 g / 10 min, 10 g / 10 min, 15 g / 10 min, 20 g / 10 min, 25 g / 10 min, or 30 g / 10 min. The upper limit of the MFR is more preferably 200 g / 10 min, and may be 100 g / 10 min, 80 g / 10 min, 70 g / 10 min, 60 g / 10 min, 50 g / 10 min, or 40 g / 10 min. From the viewpoint of the molding processability of the resin composition, the MFR of the recycled resin A is preferably 20 g / 10 min or more.

[0085] Method for Producing Component E Component E may be produced by polymerizing ethylene and an α-olefin of 4 or more carbon atoms using a polymerization catalyst.

[0086] Examples of the polymerization catalyst include homogeneous catalysts such as metallocene catalysts, and Ziegler-Natta catalysts.

[0087] Examples of homogeneous catalysts include a catalyst containing a compound of a transition metal of Group 4 of the periodic table having a cyclopentadienyl ring and an alkylaluminoxane; a catalyst containing a compound of a transition metal of Group 4 of the periodic table having a cyclopentadienyl ring, a compound that reacts with the transition metal compound to form an ionic complex, and an organoaluminum compound; and a modified catalyst obtained by supporting a catalyst component (a compound of a transition metal of Group 4 of the periodic table having a cyclopentadienyl ring, a compound that forms an ionic complex, an organoaluminum compound, etc.) on inorganic particles (silica, clay mineral, etc.).

[0088] Examples of Ziegler-Natta type catalysts include catalysts that combine a titanium-containing solid transition metal component with an organometallic component.

[0089] A recycled used commercially available product may be used as component E. Examples of commercially available component E include Engage (registered trademark) manufactured by Dow Chemical Japan, Tafmer (registered trademark) manufactured by Mitsui Chemicals, Inc., Neozex (registered trademark) and Ultozex (registered trademark) manufactured by Prime Polymer Co., Ltd., Excellen FX (registered trademark), Sumikathene (registered trademark), and Esprene SPO (registered trademark) manufactured by Sumitomo Chemical Co., Ltd.

[0090] The propylene resin composition of the present invention may contain, as component A, a component other than components P and E. Examples of such components include thermoplastic resins (polystyrenes (e.g., polystyrene, poly(p-methylstyrene), poly(α-methylstyrene), AS (acrylonitrile / styrene copolymer) resin), ABS (acrylonitrile / butadiene / styrene copolymer) resin, AAS (special acrylic rubber / acrylonitrile / styrene copolymer) resin, ACS (acrylonitrile / chlorinated polyethylene / styrene copolymer) resin, polychloroprene, chlorinated rubber, polyvinyl chloride, polyvinylidene chloride, acrylic resin, ethylene / vinyl alcohol copolymer resin, fluororesin, polyacetal, grafted polyphenylene ether resin, and polyphenylene sulfide resin). Examples of suitable polymers include polyesters, polyurethanes, polyamides, polyester resins (e.g., polyethylene terephthalate, polybutylene terephthalate), polycarbonates, polysulfones, polyether ether ketones, polyethersulfones, aromatic polyester resins, polybutadiene, 1,2-polybutadiene, polyisoprene, styrene / butadiene copolymers, butadiene / acrylonitrile copolymers, natural rubber, etc.), epoxy resins, diallyl phthalate prepolymers, silicone resins, silicone rubbers, epichlorohydrin rubbers, acrylic rubbers, and PLA resins (polylactic acid) produced by polymerizing plant-derived monomers extracted from biomaterials.

[0091] In one embodiment, the recycled resin A (component A) contained in the propylene resin composition of the present invention may contain a filler F.

[0092] Filler F (Component F) Examples of component F include inorganic fillers FI and organic fillers FO. Component A may contain only one type of component F, or may contain two or more types of component F.

[0093] Examples of the inorganic filler FI include glass, silicate minerals, alumina, silica, silicon dioxide, titanium oxide, iron oxide, aluminum oxide, magnesium oxide, antimony oxide, barium ferrite, strontium ferrite, beryllium oxide, magnesium hydroxide, aluminum hydroxide, basic magnesium carbonate, calcium carbonate, magnesium carbonate, carbonate minerals, calcium sulfate, magnesium sulfate, basic magnesium sulfate, calcium sulfite, carbon black, and cadmium sulfide.

[0094] The organic filler FO includes polyester, aromatic polyamide, cellulose and vinylon.

[0095] The shape of the filler may be plate-like, needle-like, or fibrous.

[0096] From the viewpoint of the rigidity, impact resistance and dimensional stability of the molded article, component F is preferably an inorganic filler, and more preferably talc, which is a plate-like silicate mineral.

[0097] From the viewpoints of the rigidity, impact resistance, and dimensional stability of the molded article, the average particle diameter D50[L] of component F is preferably 20.0 μm or less, and more preferably 15.0 μm or less. The average particle diameter D50[L] of component F may be 2.0 μm or more, or may be 4.0 μm or more. The average particle diameter D50[L] of component F is preferably 2.0 to 20.0 μm, and more preferably 4.0 to 15.0 μm. From the viewpoints of the rigidity, impact resistance, and dimensional stability of the molded article, the average particle diameter D50[S] of component F is preferably 5.0 μm or less, and more preferably 3.0 μm or less. The average particle diameter D50[S] of component F may be 0.5 μm or more, or may be 1.0 μm or more. The average particle diameter D50[S] of component F is preferably 0.5 to 5.0 μm, and more preferably 1.0 to 3.0 μm. The ratio of the average particle diameter D50[L] to the average particle diameter D50[S] of component F (D50[L] / D50[S]) may be 1.5 or more, or 2.5 or more, from the viewpoint of rigidity and dimensional stability of the molded article. D50[L] / D50[S] may be 10 or less, or 8 or less. D50[L] / D50[S] may be 1.5 to 10, 1.5 to 8, 2.5 to 10, or 2.5 to 8.

[0098] In this specification, "average particle diameter D50[L]" is determined based on volume-based particle diameter distribution measurement data measured by laser diffraction according to the method specified in JIS R1629, and refers to the particle diameter (50% equivalent particle diameter) when the cumulative number of particles from the smaller particle diameter side reaches 50% in the particle diameter distribution measurement data. Particle diameters defined in this manner are generally referred to as "50% equivalent particle diameter" and are represented by "D50". In this specification, "average particle diameter D50[S]" is determined based on volume-based particle diameter distribution measurement data measured by centrifugal sedimentation according to the method specified in JIS R1619, and refers to the particle diameter (50% equivalent particle diameter) when the cumulative number of particles from the smaller particle diameter side reaches 50% in the particle diameter distribution measurement data. The larger the ratio of the average particle diameter D50[L] to the average particle diameter D50[S] of component F (D50[L] / D50[S]), the more excellent the rigidity and dimensional stability of the molded article.

[0099] In one embodiment, component (A) and / or component (B) contain ash. Ash refers to the components remaining as ash after heating the crushed material at 600°C for 60 minutes. The ash content can be determined by the following method.

[0100] (Method for measuring ash content) The crucible is heated at 600°C for 60 minutes using an electric furnace, removed and cooled in a desiccator for 1 hour, and then weighed on a precision balance. 10 g of crushed material is weighed into the crucible and heated at 600°C for 60 minutes using an electric furnace to completely incinerate it. Next, the crucible is cooled in a desiccator for 1 hour, and the mass of the ash is measured to the nearest 0.1 mg using a precision balance, and the ash content (mass%) relative to component (A) or component (B) is calculated.

[0101] When component (A) or component (B) contains a filler, the majority of the filler is contained in the ash content of component (A) or component (B).When component (A) or component (B) contains a filler, the content of the filler is considered to roughly correspond to the ash content of component (A) or component (B).

[0102] Virgin Propylene Polymer The propylene resin composition of the present invention contains a virgin propylene polymer. The definition and preferred embodiments of this propylene polymer are the same as those of component P described above.

[0103] The propylene resin composition of the present invention may contain components other than "recycled resin having a swell ratio of 1.3 or more" and "virgin propylene polymer." An example of such a component is a recycled resin having a swell ratio of less than 1.3. The definition and preferred embodiments of the component are the same as those of component A (component P, component E, etc.) except for the description of the swell ratio. Another example is a virgin resin other than virgin propylene polymer. The definition and preferred embodiments of the component are the same as those of component A (component E, etc.) except for the descriptions of the swell ratio, the recycling, and the component P. Another example is a filler. The definition and preferred embodiments of the filler are the same as those of component F. Other examples include neutralizing agents, antioxidants, ultraviolet absorbers, nucleating agents, lubricants, antistatic agents, antiblocking agents, processing aids, organic peroxides, colorants (inorganic pigments, organic pigments, pigment dispersants, etc.), foaming agents, foam nucleating agents, plasticizers, flame retardants, crosslinking agents, crosslinking aids, brightness enhancers, antibacterial agents, and light diffusing agents.

[0104] Content of each component In the propylene resin composition of the present invention, the content of each component is not particularly limited. From the viewpoint of low-temperature impact strength of a molded product, the content of component A is preferably 40 to 99 parts by weight, 50 to 95 parts by weight, or 60 to 90 parts by weight, relative to 100 parts by weight of the total content of components A and E. Preferably, the content of component A is 40 to 99 parts by weight, 50 to 95 parts by weight, or 60 to 90 parts by weight, relative to 100 parts by weight of the propylene resin composition.

[0105] In the propylene resin composition of the present invention, from the viewpoint of low-temperature impact strength of a molded product, the content of Component E is preferably 1 to 60 parts by weight, 5 to 50 parts by weight, or 10 to 40 parts by weight, relative to 100 parts by weight of the total content of Components A and E. Preferably, the content of Component E is 1 to 60 parts by weight, 5 to 50 parts by weight, or 10 to 40 parts by weight, relative to 100 parts by weight of the propylene resin composition.

[0106] When the propylene resin composition of the present invention contains component F as a component other than components A and E, the content of component F may be, for example, 0.1 to 50 parts by weight, 1 to 40 parts by weight, or 5 to 30 parts by weight, relative to 100 parts by weight of the total content of components A, E, and F. In another embodiment, the content of component F may be 0.1 to 50 parts by weight, 1 to 40 parts by weight, or 5 to 30 parts by weight, relative to 100 parts by weight of the propylene resin composition.

[0107] From the viewpoint of low-temperature impact strength of the molded product, the total amount of the polymers contained is preferably 70% by weight or more, 80% by weight or more, or 90% by weight or more, based on the total weight of the propylene resin composition of the present invention.

[0108] From the viewpoint of low-temperature impact strength of the molded product, it is preferable that the total content of components A and E is 50% by weight or more, 60% by weight or more, 70% by weight or more, 80% by weight or more, or 90% by weight or more, based on the total weight of the propylene resin composition of the present invention.

[0109] The propylene resin composition of the present invention can be obtained by melt-kneading the raw material components. The temperature during melt-kneading may be 180°C or higher, 180 to 300°C, or 180 to 250°C.

[0110] For melt kneading, a Banbury mixer, a single-screw extruder, a twin-screw co-rotating extruder, or the like can be used.

[0111] The order in which the raw material components are kneaded is not particularly limited. For example, the raw material components may be kneaded all at once, or some of the raw material components may be kneaded and then the resulting kneaded mixture may be kneaded with the other components.

[0112] The shape of the propylene resin composition is not particularly limited, and the propylene resin composition may be in the form of, for example, a strand, a sheet, a plate, or a pellet. The pellet-shaped resin composition can be produced, for example, by forming a strand-shaped resin composition and then cutting it to an appropriate length.

[0113] From the viewpoint of the moldability of the resin composition and the production stability when producing a molded article, the shape of the resin composition before being molded into a molded article is preferably in the form of pellets having a length of about 1 to 50 mm.

[0114] Properties of Propylene Resin Composition In one aspect, the melt flow rate (MFR) (temperature 230°C, load 2.16 kgf) of the propylene resin composition of the present invention is preferably 1 to 300 g / 10 min from the viewpoint of the molding processability of the resin composition and / or the low-temperature impact strength of the molded product. The lower limit of the MFR may be 110 g / 10 min, 12 g / 10 min, or 15 g / 10 min. The upper limit of the MFR may be 100 g / 10 min, 70 g / 10 min, or 40 g / 10 min.

[0115] The propylene resin composition of the present invention can be used as a material for molding to form a molded article. The propylene resin composition of the present invention is preferably used as an injection molding material. Hereinafter, an example of an injection molded article produced using the propylene resin composition of the present invention as an injection molding material will be described.

[0116] Molded Article The molded article of the present invention contains (is made from) the propylene resin composition of the present invention. The molded article of the present invention has excellent low-temperature impact strength.

[0117] The injection-molded article can be produced by injection molding. Examples of injection molding methods include general injection molding, injection foam molding, supercritical injection foam molding, ultra-high speed injection molding, injection compression molding, gas-assisted injection molding, sandwich molding, sandwich foam molding, and insert-outsert molding. There are no particular restrictions on the shape of the injection-molded article.

[0118] The injection-molded article of the present invention can be preferably used for, for example, automotive materials, home appliance materials, and containers, and is particularly suitable for automotive interior and exterior applications. Examples of automotive interior and exterior parts include door trims, pillars, instrument panels, and bumpers.

[0119] The present invention will be described in more detail below using examples, although the present invention is not limited to these examples.

[0120] Recycled Resins A1 to A4 Recycled resins A1 to A4, each having a swell ratio of 1.3 or more, were prepared. All of these were recycled propylene compositions.

[0121] Recycled resin A1 Swell ratio: 1.30 MFR (230°C, 2.16 kg load): 53.9 g / 10 min Ash content: 22.4 wt%

[0122] Recycled resin A2 Swell ratio: 1.34 MFR (230°C, 2.16 kg load): 45.1 g / 10 min Ash content: 7.0 wt%

[0123] Recycled resin A3 Swell ratio: 1.35 MFR (230°C, 2.16 kg load): 40.7 g / 10 min Ash content: 16.4 wt%

[0124] Recycled resin A4 Swell ratio: 1.37 MFR (230°C, 2.16 kg load): 32.4 g / 10 min Ash content: 8.6 wt%

[0125] Recycled Resins B1 to B3 Recycled resins B1 to B3, each of which is a recycled propylene composition, were prepared, each having a swell ratio of less than 1.3.

[0126] Recycled resin B1 Swell ratio: 1.10 MFR (230°C, 2.16 kg load): 43.2 g / 10 min Ash content: 19.9 wt%

[0127] Recycled resin B2 Swell ratio: 1.24 MFR (230°C, 2.16 kg load): 34.1 g / 10 min Ash content: 13.3 wt%

[0128] Recycled resin B3 Swell ratio: 1.27 MFR (230°C, 2.16 kg load): 24.8 g / 10 min Ash content: 29.3 wt%

[0129] Measurement method of swell ratio (unit: -) A capillary rheometer (Capilograph 1D manufactured by Toyo Seiki Seisakusho Co., Ltd.) equipped with a capillary diameter (D) of 1 mm and a capillary length (L) of 40 mm, i.e., L / D = 40, was used, and the test temperature was 220°C and the shear rate was 2432 sec －１ The molten composition was extruded from the outlet of the capillary at a piston downward speed of 200 mm / min to produce a strand. The diameter of the strand was measured using a laser at a point 12 mm vertically downward from the outlet of the capillary. The swell ratio at each shear rate is expressed by the following formula: Swell ratio = Strand diameter (mm) / Capillary diameter (mm)

[0130] Virgin Propylene Polymer As a virgin propylene polymer, the following virgin heterophasic propylene polymer material was prepared.

[0131] Virgin propylene polymer C1 Propylene polymer (heterophagic propylene polymerization material) C1 was produced by gas phase polymerization in the presence of a polymerization catalyst obtained by the method described in Example 1 of JP-A 2004-182981. The physical properties of the obtained component C1 are as follows: MFR (230°C, 2.16 kg load): 27.5 g / 10 min Amount of CXIS component: 84.1 wt% Amount of CXS component: 15.9 wt%

[0132] Production of Propylene Resin Composition The raw materials having the composition shown in Table 1 and additives, such as 0.03 parts by mass of "calcium stearate," 0.03 parts by mass of "Sumilizer GA80," and 0.03 parts by mass of "SONGNOX 6260," were weighed, and all components were mixed and melt-kneaded under the following conditions to obtain a pellet-shaped propylene resin composition. Kneader: Twin-screw kneader KZW-15 / 45MG (cylinder inner diameter 15.5 mm, screw outer diameter 15.0 mm, L / D = 45) manufactured by Technovel Co., Ltd. Cylinder temperature: 200°C; Screw rotation speed: 500 rpm; Screen mesh: two overlapping sheets of 100 mesh and 50 mesh; Extrusion rate: 6 kg / hr

[0133] Production of injection-molded articles for evaluation of low-temperature impact strength and Rockwell hardness The crushed material of each molded article was injection-molded under the following conditions within the range specified in JIS K7152 to produce injection-molded articles for evaluation of low-temperature impact strength and Rockwell hardness. The resin composition melted in the injection molding machine was supplied from the gate into the mold cavity by the injection molding machine. Injection molding machine: Toyo Machinery & Metal Si30III (clamping force 30 tons, cylinder diameter 18 mm) Cylinder temperature: 220°C Mold temperature: 50°C Injection speed: 20 mm / sec Cooling time: 30 sec

[0134] Measurement of low-temperature impact strength A test piece having a thickness of 4 mm was cut out from the above-mentioned injection molded article and measured at −30° C. using an IZOD impact tester (manufactured by Toyo Seiki Seisakusho Co., Ltd.) in accordance with ASTM D256. The results are shown in Table 1.

[0135] Measurement of Rockwell hardness A test piece having a thickness of 4 mm was cut out from the above-mentioned injection molded article, and the Rockwell hardness was measured on the R scale using a Rockwell hardness tester (ARK-F1000, manufactured by Akashi Seisakusho Co., Ltd.) in accordance with ASTM D785. The results are shown in Table 1.

[0136] Examples 1 to 7 are examples of the present invention, and Examples 8 to 10 are comparative examples.

[0137] It can be seen from Table 1 that the molded articles according to the examples are excellent in low-temperature impact strength. That is, it was confirmed that the propylene resin composition of the present invention can produce a molded article having excellent low-temperature impact strength, and that the molded article of the present invention is excellent in low-temperature impact strength.

Claims

1. A propylene resin composition containing a recycled resin and a virgin propylene polymer, the swell ratio of which is 1.3 or more when measured under the following conditions: Measurement temperature = 220°C, orifice L / D = 40 mm / 1 mm, shear rate = 2432 sec -1 .

2. The propylene resin composition according to claim 1, wherein the recycled resin has a swell ratio of 2.0 or less.

3. The propylene resin composition according to claim 1 or 2, wherein the recycled resin is a recycled propylene composition containing a propylene polymer.

4. The propylene resin composition according to any one of claims 1 to 3, wherein the virgin propylene polymer is a heterophasic propylene polymer material.

5. The propylene resin composition according to any one of claims 1 to 4, wherein the content of the recycled resin is 30 to 90 parts by weight per 100 parts by weight of the propylene resin composition.

6. The propylene resin composition according to any one of claims 1 to 5, wherein the content of the virgin propylene polymer is 10 to 70 parts by weight based on 100 parts by weight of the propylene resin composition.

7. The propylene resin composition according to any one of claims 1 to 6, wherein the total amount of the polymers contained is 70% by weight or more based on the total weight of the propylene resin composition.

8. The propylene resin composition according to any one of claims 1 to 7, wherein the recycled resin comprises an ethylene-α-olefin copolymer.

9. The propylene resin composition according to claim 3, wherein the propylene polymer comprises at least one selected from the group consisting of propylene homopolymers and heterophasic propylene polymer materials.

10. A propylene resin composition according to any one of claims 1 to 9, comprising a recycled resin (referred to as a "different recycled resin") different from the recycled resin, the recycled resin having a swell ratio of 1.3 or more when measured under the conditions described in claim 1.

11. The propylene resin composition according to claim 10, comprising an ethylene-α-olefin copolymer as the different recycled resin.

12. The propylene resin composition according to any one of claims 1 to 11, wherein the virgin propylene polymer comprises a propylene homopolymer.

13. The propylene resin composition according to any one of claims 1 to 12, further comprising an inorganic filler.

14. The propylene resin composition according to claim 13, comprising recycled inorganic filler as said inorganic filler.

15. The propylene resin composition according to any one of claims 1 to 14, which contains an ethylene-α-olefin copolymer as a component other than the recycled resin.

16. A molded article comprising the propylene resin composition according to any one of claims 1 to 15.

17. A method for producing the propylene resin composition according to any one of claims 1 to 15, comprising a step of melt-kneading the recycled resin and the virgin propylene polymer.

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