Resin composition and molded body

Abstract

To improve compatibility between a polyester resin and a polyolefin resin.SOLUTION: A resin composition contains a polyester resin (A), a polyolefin resin (B) and a compatibilizing agent (C), wherein the compatibilizing agent (C) is a polymer having a first polymer part and a second polymer part, the first polymer part has a constitutional unit different from a constitutional unit constituting the second polymer part, and the second polymer part has a constitutional unit derived from a (meth)acrylate monomer.SELECTED DRAWING: None

Description

[Technical field]

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

[0002] Conventionally, attempts have been made to mix multiple resins to achieve functions or improve performance that cannot be achieved with a single resin. However, since many combinations of resin types are incompatible, the performance or function of the composite is often lower than that of a single resin. Therefore, compatibilizers are added to improve the compatibility of multiple resin types.

[0003] Patent Document 1 discloses a thermoplastic polyester resin composition containing a thermoplastic polyester resin, a polyolefin resin, and a block copolymer of an olefin (co)polymer and an aromatic vinyl (co)polymer. Patent Document 2 discloses a resin composition obtained by blending an aromatic vinyl resin, a thermoplastic resin, and a copolymer of a vinyl resin portion and a polyester resin portion. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 6-107925 [Patent Document 2] Japanese Patent Application Publication No. 10-219074 Summary of the Invention [Problem to be solved by the invention]

[0005] However, the block copolymer described in Patent Document 1 has room for improvement in terms of its function as a compatibilizer between polyester resins and polyolefin resins. Moreover, the effect of the copolymer described in Patent Document 2 on the compatibility between polyester resins and polyolefin resins is unclear.

[0006] An object of one aspect of the present invention is to provide a resin composition or the like that can improve the compatibility between a polyester resin and a polyolefin resin. [Means for solving the problem]

[0007] In order to solve the above problems, a resin composition according to one embodiment of the present invention is a resin composition comprising a polyester resin (A), a polyolefin resin (B) and a compatibilizer (C), wherein the compatibilizer (C) is a polymer having a first polymer portion and a second polymer portion, the first polymer portion has a structural unit different from a structural unit constituting the second polymer portion, and the second polymer portion has a structural unit derived from a (meth)acrylate monomer. Effect of the Invention

[0008] According to one aspect of the present invention, it is possible to provide a resin composition or the like that can improve the compatibility between a polyester resin and a polyolefin resin. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] An embodiment of the present invention will be described in detail below. In this specification, "A to B" indicating a numerical range means "A or more and B or less" unless otherwise specified. Note that the following description is one embodiment of the present invention, and the present invention is not limited to the following configuration.

[0010] A resin composition according to one embodiment of the present invention is a resin composition containing a polyester resin (A), a polyolefin resin (B) and a compatibilizer (C). The compatibilizer (C) has a first polymer portion and a second polymer portion. The first polymer portion has a structural unit different from the structural unit constituting the second polymer portion. The second polymer portion has a structural unit derived from a (meth)acrylate monomer.

[0011] The use of such a compatibilizer (C) can improve the compatibility between the polyester resin (A) and the polyolefin resin (B), thereby reducing phase separation between the polyester resin (A) and the polyolefin resin (B).

[0012] [1. Polyester resin (A)] The polyester resin (A) may be, for example, a polycondensation product of an aromatic or aliphatic dicarboxylic acid and a diol. In producing such a polycondensation product, one kind of dicarboxylic acid and one kind of diol may be selected and produced under normal polycondensation conditions, or two or more kinds may be appropriately combined and produced.

[0013] Examples of dicarboxylic acids include terephthalic acid, isophthalic acid, adipic acid, sebacic acid, succinic acid, naphthalene-1,4-dicarboxylic acid, naphthalene-2,6-dicarboxylic acid, and diphenyl ether-4,4'-dicarboxylic acid.

[0014] Examples of diols include ethylene glycol, propylene glycol, 1,4-butylene glycol, neopentyl glycol, cyclohexanedimethanol, 2,2-bis(4-hydroxyphenyl)propane, etc. In polycondensation, a hydroxycarboxylic acid such as p-hydroxybenzoic acid may be coexisted.

[0015] Examples of the polyester resin (A) produced from the dicarboxylic acid and diol include polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polyethylene naphthalate (PEN), polybutylene naphthalate (PBN), and polybutylene succinate (PBS).

[0016] In addition, the polyester resin (A) may be a polymer having an ester bond, such as polyhydroxyalkanoic acid (PHA) produced by a microorganism and polylactic acid (PLA) obtained by polycondensation of lactic acid, and may be a polymer material of biological origin.

[0017] The polyester resin (A) may be a recycled product obtained by once using such a molded article, or may be a mixture of a virgin product and a recycled product.

[0018] [2. Polyolefin resin (B)] In the polyolefin resin (B), the proportion of olefin units or cycloolefin units is 80 mol % or more relative to 100 mol % of all the constituent units constituting the polyolefin resin (B). In particular, the total proportion of olefin units and cycloolefin units relative to 100 mol % of all the constituent units constituting the polyolefin resin (B) is preferably 85 mol % or more, and particularly preferably 90 mol % or more.

[0019] Specific examples of polyolefin resin (B) include homopolymers or copolymers of α-olefins, such as α-olefin polymers such as polyethylene, polypropylene, polybutene, poly(3-methyl-1-butene), poly(3-methyl-1-pentene), and poly(4-methyl-1-pentene); α-olefin copolymers such as ethylene-propylene block or random copolymers, α-olefin-propylene block or random copolymers having 4 or more carbon atoms, ethylene-methyl methacrylate copolymer, and ethylene-vinyl acetate copolymer; and cycloolefin polymers such as polycyclohexene and polycyclopentene.

[0020] Examples of polyethylene include low-density polyethylene, linear low-density polyethylene, and high-density polyethylene. Examples of polypropylene include isotactic polypropylene, syndiotactic polypropylene, hemiisotactic polypropylene, and stereoblock polypropylene. In the α-olefin-propylene block or random copolymer having 4 or more carbon atoms, examples of the α-olefin having 4 or more carbon atoms include butene, 3-methyl-1-butene, 3-methyl-1-pentene, and 4-methyl-1-pentene. The resin composition may contain only one type of polyolefin resin (B), or two or more types of polyolefin resin (B). These may be unused polymers or recycled polymers (recycled materials) after once being used.

[0021] Among the above, the polyolefin resin (B) is preferably polyethylene, polypropylene, or polybutene, and more preferably a propylene-based polymer such as polypropylene or block polypropylene.

[0022] The melt flow rate of the polyolefin resin (B) is not particularly limited, but in order to improve mechanical properties, it is preferably 0.1g / 10min or more, more preferably 0.2g / 10min or more, and particularly preferably 0.3g / 10min or more, while in order to improve processability, it is preferably 70g / 10min or less, more preferably 60g / 10min or less, particularly preferably 50g / 10min or less, extremely preferably 30g / 10min or less, particularly preferably 25g / 10min or less, very preferably 15g / 10min or less, most preferably 12.5g / 10min or less, and most preferably 10g / 10min or less. The melt flow rate of the polyolefin resin (B) can be calculated according to JIS K7210.

[0023] Commercially available products of the polyolefin resin (B) include, for example, Novatec (registered trademark) MA3, Novatec MA3H, Novatec MA1B, Novatec EA9, Novatec EA9HD, Novatec EA9FTD, Novatec EA7AD, Novatec FY6H, Novatec EA6A, Novatec FY6, Novatec FY6C, Novatec FY4, and Novatec SA3A manufactured by Japan Polypropylene Corporation; and Prime Polypro (registered trademark) J105G, Prime Polypro J106G, and Prime Polypro J106M manufactured by Prime Polymer Co., Ltd. G, Prime Polypro 107G, Prime Polypro J137G, Prime Polypro J108M, Evolue (registered trademark) SP2320, Evolue SP2520, Evolue SP2510, Evolue SP3010, Evolue SP4020, Evolue SP1071C, Hi-Zex (registered trademark) 1300J, Hi-Zex 2100J, Hi-Zex 2100JH, Hi-Zex 2200J, Hi-Zex 2208J, Hi-Zex 3300F, Hi-Zex 3600F, Hi-Zex 7000F, Hi-Zex 8000F;Novatec LL UF420, Novatec LL UF421, Novatec LL UF621, Novatec LL UF524, Novatec LL UF622, Novatec LL UF230, Novatec LL UF320, Novatec LL UF332, Novatec LL UA421, Novatec LL UF240, Novatec LL UF442, Novatec LL UF641, Novatec LL UF943, Novatec LL UJ960, Novatec LL UJ370, Novatec LL UJ580, Novatec LL UJ480, Novatec LL UJ990, Novatec LL UJ790, Novatec LL UE320, Novatec LL UR951, Novatec C6 SF720, Novatec C6 SF941, Novatec C6 made by Japan Polyethylene Corporation SF8402, Novatec HD HJ360, Novatec HD 362N, Novatec HD HJ560, Novatec HD HJ580N, Novatec HD HJ490, Novatec HD HJ590N, Novatec HD HY420, Novatec HD HY530, Novatec HD HY430, Novatec HD HY331, Novatec HD HY540, Novatec HD HE122R, Novatec HD HF313, Novatec HD HF111K, Novatec HD HF560, Novatec HD HE121, Novatec HD HE212W, Novatec HD HE421, Novatec HD HB420R, Novatec HD HB338RE, Novatec HD HB332E, Novatec HD HB432E, Novatec HD HB530, Novatec HD HB216R, Novatec HDHB111R.

[0024] [3. Compatibilizer (C)] The compatibilizer (C) according to one embodiment of the present invention is a polymer having a first polymer portion and a second polymer portion, the first polymer portion having a structural unit different from the structural unit constituting the second polymer portion, and the second polymer portion having a structural unit derived from a (meth)acrylate monomer.

[0025] In one embodiment of the present invention, the polymer having a first polymer portion and a second polymer portion may be a polymer in which the first polymer portion and the second polymer portion are covalently bonded to each other. In another embodiment of the present invention, the polymer also includes a complex in which the first polymer portion and the second polymer portion are not covalently bonded to each other and the first polymer portion is encapsulated or enclosed by the second polymer portion.

[0026] An example of a polymer in which a first polymer portion and a second polymer portion are covalently bonded is a block copolymer having a first polymer portion and a second polymer portion. Also, an example of a polymer in which a first polymer portion is encapsulated or enveloped by a second polymer portion is a polymer having a core-shell structure composed of a core portion and a shell portion. A core-shell structure is a structure in which a portion called a core is encapsulated in a portion called a shell. A polymer having a core-shell structure may be one in which the core portion contains one of the first polymer portion and the second polymer portion, and the shell portion contains the other of the first polymer portion and the second polymer portion.

[0027] Among them, the compatibilizer (C) is preferably a polymer having a core-shell structure, in which the first polymer portion constitutes the shell portion of the core-shell structure. That is, the compatibilizer (C) is preferably a polymer having a core-shell structure, in which the first polymer portion constitutes the shell portion, and the second polymer portion constituted by a polymer different from the first polymer portion constitutes the core portion. Below, a preferred embodiment of the compatibilizer (C) having the core-shell structure will be described in detail as a representative example.

[0028] <3-1. First polymer portion> As described above, the first polymer portion is not particularly limited as long as it has a structural unit different from the structural unit constituting the second polymer portion, but is preferably composed of, for example, a polyester polymer. In one aspect of the present invention, the polyester polymer means a polymer composed of a structural unit containing an ester bond as a repeating unit. The polyester polymer may be synthesized, for example, by a polycondensation reaction between a dicarboxylic acid component and a diol component.

[0029] Although the function of the first polymer portion is not particularly limited, when the first polymer portion is composed of a polyester polymer, it is considered that the affinity with the polyester resin (A) is improved, and as a result, it is considered that the compatibility between the polyester resin (A) and the polyolefin resin (B) is improved by the compatibilizer (C).

[0030] The dicarboxylic acid is not particularly limited, and examples thereof include aromatic dicarboxylic acids, aliphatic dicarboxylic acids, and alicyclic dicarboxylic acids. Examples of such aromatic dicarboxylic acids include terephthalic acid, isophthalic acid, phthalic acid, 2,5-norbonanedicarboxylic acid, 1,4-naphthalic acid, 1,5-naphthalic acid, 4,4-oxybenzoic acid, fumaric acid, maleic anhydride, succinic acid, glutaric acid, adipic acid, sebacic acid, dodecanedicarboxylic acid, tetrahydrophthalic anhydride, tetrahydroterephthalic acid, 5-sodium sulfoisophthalic acid, 5-lithium sulfoisophthalic acid, trimellitic anhydride, and pimellitic anhydride.

[0031] The diol component is not particularly limited, and examples thereof include ethylene glycol, propylene glycol, 1,3-butylene glycol, 1,4-butanediol, 1,6-hexanediol, neopentyl glycol, triethylene glycol, dipropylene glycol, 2,2,4-trimethyl-1,3-pentanediol, cyclohexanedimethanol, an ethylene oxide adduct of bisphenol A, a propylene oxide adduct of bisphenol A, an ethylene oxide and propylene oxide adduct of bisphenyl A, an ethylene oxide adduct and propylene oxide adduct of hydrogenated bisphenol A, polytetramethylene glycol, polyethylene glycol, polypropylene glycol and modified products thereof, and sodium sulfobutanediol.

[0032] Two or more kinds of dicarboxylic acid components may be used, and similarly, two or more kinds of diol components may be used.

[0033] The first polymer portion may be composed of a plurality of polymers each having a plurality of different structural units. In this case, the structural units may be any of those exemplified as the structural units of the first polymer portion.

[0034] The mass average molecular weight of the first polymer portion is not particularly limited, but is preferably 3000 or more, more preferably 5000 or more, and particularly preferably 7000 or more, in terms of powder handling properties. On the other hand, in order to reduce the increase in viscosity when a matrix resin is added, the mass average molecular weight is preferably 200,000 or less, more preferably 100,000 or less, and particularly preferably 50,000 or less. The mass average molecular weight can be measured by gel permeation chromatography (GPC).

[0035] The glass transition temperature of the first polymer portion is not particularly limited, but in order to ensure powder recoverability, it is preferably 40° C. or higher, more preferably 45° C. or higher, and even more preferably 50° C. or higher. On the other hand, in order to avoid pulverization of the powder, the glass transition temperature is preferably 150° C. or lower, more preferably 130° C. or lower, and even more preferably 100° C. or lower.

[0036] <3-2. Second polymer portion> The second polymer portion has a structural unit derived from a (meth)acrylate monomer. When the second polymer portion has a structural unit derived from a (meth)acrylate monomer, the tensile elongation of an article molded from the resin composition is improved.

[0037] In addition, the second polymer portion preferably has a structural unit other than the structural unit derived from the (meth)acrylate monomer, and such a structural unit is preferably a component that has excellent affinity with the polyolefin resin (B).

[0038] Regarding the (meth)acrylate monomer-derived constituent unit constituting the second polymer portion, examples of the (meth)acrylate monomer include methyl methacrylate, ethyl methacrylate, methyl acrylate, ethyl acrylate, butyl acrylate, butyl methacrylate, propyl acrylate, 2-ethylhexyl acrylate, glycidyl acrylate, propyl methacrylate, 2-ethylhexyl methacrylate, glycidyl methacrylate, phenyl acrylate, phenyl methacrylate, hydroxyethyl acrylate, 4-hydroxybutyl acrylate, benzyl acrylate, benzyl methacrylate, polyalkylene glycol monoacrylate, and polyalkylene glycol monomethacrylate. Among these, methyl methacrylate, butyl acrylate, glycidyl methacrylate, and polyalkylene glycol monomethacrylate are preferred from the viewpoint of tensile elongation of the molded article.

[0039] The content of the structural unit derived from the (meth)acrylate monomer relative to 100 parts by mass of the second polymer portion is preferably 5 parts by mass or more, more preferably 10 parts by mass or more, even more preferably 20 parts by mass or more, and even more preferably 25 parts by mass or more. On the other hand, the upper limit is not particularly limited, and is, for example, 100 parts by mass or less. According to such a configuration, the compatibility between the polyester resin (A) and the polyolefin resin (B) can be improved by the compatibilizer (C), and the tensile elongation of the molded article can also be improved.

[0040] Examples of the structural units constituting the second polymer portion other than the structural units derived from the (meth)acrylate monomer include structural units derived from aromatic vinyl monomers. When the structural units constituting the second polymer portion contain structural units derived from aromatic vinyl monomers, the affinity between the second polymer portion and the polyolefin resin (B) is improved. As a result, it is expected that the compatibility between the polyester resin (A) and the polyolefin resin (B) will be improved.

[0041] The structural unit constituting the second polymer portion is more preferably a structural unit derived from an aromatic vinyl monomer having a six-membered monocyclic structure, and even more preferably a structural unit derived from styrene which may have a substituent. The structural unit derived from styrene which may have a substituent includes a structural unit derived from styrene or a structural unit derived from α-methylstyrene, and among these, a structural unit derived from styrene is particularly preferred.

[0042] The content of the aromatic vinyl monomer-derived structural unit relative to 100 parts by mass of the second polymer portion is not particularly limited, but is preferably 30 parts by mass or more, more preferably 50 parts by mass or more, more preferably 60 parts by mass or more, and even more preferably 70 parts by mass or more, while it is preferably 95 parts by mass or less and less than 100 parts by mass. According to such a configuration, the compatibility between the polyester resin (A) and the polyolefin resin (B) can be effectively improved by the compatibilizer (C).

[0043] The second polymer portion may further have other structural units. The content of the other structural units relative to 100 parts by mass of the second polymer portion is not particularly limited, but is preferably 50 parts by mass or less in order to further improve the compatibility between the polyester resin (A) and the polyolefin resin (B). It is more preferably 30 parts by mass or less, more preferably 20 parts by mass or less, and is 0 parts by mass or more.

[0044] The second polymer portion may be composed of a plurality of polymers composed of a plurality of different structural units. In this case, the structural units may be any of those exemplified as the structural units of the second polymer portion.

[0045] The content of the first polymer portion is preferably 20 parts by mass or more and 70 parts by mass or less relative to 100 parts by mass of the total of the first polymer portion and the second polymer portion. The upper limit of the content is preferably 60 parts by mass or less, more preferably 50 parts by mass or less. With this configuration, the compatibility between the polyester resin (A) and the polyolefin resin (B) can be effectively improved by the compatibilizer (C).

[0046] <3-3. Manufacturing method of compatibilizer (C)> The method of producing the compatibilizer (C) when it has a core-shell structure is not particularly limited, and it can be produced by a known method such as suspension polymerization, solution polymerization, or emulsion polymerization. Among them, from the viewpoint of ease of production, it is preferable to produce it by emulsion polymerization. That is, it is preferable that the compatibilizer (C) is a polymer obtained by emulsion polymerization of the monomer component constituting the second polymer portion in the presence of the polymer constituting the first polymer portion finally obtained. In addition, when carrying out emulsion polymerization, the monomer component may be added and polymerized at once by batch polymerization, or may be added stepwise by dropwise polymerization.

[0047] More specifically, a monomer component constituting the second polymer portion can be added to a solution in which the polymer constituting the first polymer portion is dispersed in an arbitrary solvent, emulsified using various mixers, and a polymerization initiator can be added to polymerize.

[0048] A solution in which the polymer constituting the first polymer portion is dispersed in an arbitrary solvent can be obtained, for example, by adding the polymer to one or more solvents such as water, various alcohols such as isopropyl alcohol, ethanol, and methanol, acetone, methyl ethyl ketone, and diethyl ether, and stirring while applying shear. The proportion of the polymer constituting the first polymer portion in the dispersion solution is preferably 10% by mass or more in view of excellent dispersibility, and is preferably 50% by mass or less in view of handleability taking into account the viscosity of the dispersion solution.

[0049] When the monomer component constituting the second polymer portion is added to a solution in which the polymer constituting the first polymer portion is dispersed in an arbitrary solvent, a surfactant may be further added. Examples of the surfactant include anionic surfactants, cationic surfactants, and neutral surfactants. One type of surfactant may be used alone, or two or more types may be used in combination.

[0050] As the polymerization initiator, those generally used for radical polymerization can be used. Specific examples thereof include persulfates such as potassium persulfate, sodium persulfate, and ammonium persulfate; oil-soluble azo compounds such as azobisisobutyronitrile, 2,2'-azobis(2-methylbutyronitrile), 2,2'-azobis(2,4-dimethylvaleronitrile), 2,2'-azobis(4-methoxy-2,4-dimethylvaleronitrile), and 2-phenylazo-4-methoxy-2,4-dimethylvaleronitrile; 2,2'-azobis{2-methyl-N-[1,1-bis(hydroxymethyl)-2-hydroxyethyl]propionamide}, 2,2'-azobis{2-methyl-N-[2-(1-hydroxyethyl)]propionamide}, 2,2'-azobis{2-methyl-N-[2-(1 water-soluble azo compounds such as 2,2'-azobis[2-(5-methyl-2-imidazolin-2-yl)propane] and its salts, 2,2'-azobis[2-(2-imidazolin-2-yl)propane] and its salts, 2,2'-azobis{2-[1-(2-hydroxyethyl)-2-imidazolin-2-yl]propane} and its salts, 2,2'-azobis(2-methylpropynamidine) and its salts, and 2,2'-azobis[N-(2-carboxyethyl)-2-methylpropionamidine]; and organic peroxides such as benzoyl peroxide, cumene hydroperoxide, t-butyl hydroperoxide, t-butyl peroxy-2-ethylhexanoate, and t-butyl peroxyisobutyrate. The polymerization initiator may be used alone or in combination of two or more kinds.

[0051] Preferred radical polymerization methods in one embodiment of the present invention include, for example, a method in which polymerization is carried out using a water-soluble polymerization initiator, and a method in which polymerization is carried out by a redox reaction using an organic peroxide and a reducing agent such as ferrous sulfate or isoascorbic acid.

[0052] The amount of the polymerization initiator used is preferably 0.05 to 1.0 parts by mass relative to 100 parts by mass of the total of the monomer components constituting the second polymer portion, and more preferably the lower limit is 0.1 parts by mass or more and the upper limit is 0.3 parts by mass or less. When a peroxide-based polymerization initiator is used, it can be used as a redox-based polymerization initiator in combination with a reducing agent. The amount of the reducing agent used is preferably 0.0001 to 1 part by mass relative to 100 parts by mass of the total of the monomer components constituting the second polymer portion.

[0053] Furthermore, the polymerization of the monomer components constituting the second polymer portion may be carried out using a known chain transfer agent as a molecular weight regulator, such as n-octyl mercaptan, n-dodecyl mercaptan, t-dodecyl mercaptan, or α-methylstyrene dimer.

[0054] The reaction temperature is not particularly limited, but is usually from 45° C. to 80° C. The reaction time is not particularly limited, but is usually from 30 minutes to 300 minutes.

[0055] The latex of the compatibilizer (C) obtained by emulsion polymerization can be dried by spray drying or freeze drying, or coagulated, to recover it as a polymer powder. Among these, drying or coagulation by spray drying is preferred.

[0056] When drying is performed by the spray drying method, it is preferable to spray the latex of the compatibilizer (C) onto fine droplets and then dry them by applying hot air to them. Any device such as a rotating disk type, a pressure nozzle type, or a two-fluid nozzle type may be used as a device for generating droplets.

[0057] When the latex of the compatibilizer (C) is dried by applying hot air, the hot air temperature is preferably 100° C. or higher and 200° C. or lower. When the hot air temperature is 100° C. or higher, the latex can be sufficiently dried, and when the hot air temperature is 200° C. or lower, thermal decomposition of the obtained powder can be reduced.

[0058] When coagulation is performed, the latex of the compatibilizer (C) is put into hot water in which a coagulant is dissolved, and the compatibilizer (C) is salted out and separated, purified, coagulated, and made wet, which is then dehydrated and dried. Examples of the coagulant include inorganic salts such as aluminum chloride, aluminum sulfate, sodium sulfate, magnesium sulfate, sodium nitrate, and calcium acetate, and acids such as sulfuric acid, with calcium acetate being particularly preferred. These coagulants may be used alone or in combination of two or more, but when used in combination, it is preferable to select a combination that does not form a water-insoluble salt. For example, the combination of calcium acetate with sulfuric acid or its sodium salt is not preferable because it forms a water-insoluble calcium salt.

[0059] It is common technical knowledge that the polymerization mode of the first polymer portion and the second polymer portion of the compatibilizer (C) changes depending on the manufacturing method thereof, but it is difficult to specify what the polymerization mode is. For example, the polymerization mode of the compatibilizer (C) obtained by emulsion polymerization of the monomer component constituting the second polymer portion in the presence of the polymer constituting the first polymer portion is different from that of the compatibilizer (C) obtained by other methods, and it is considered that the structure or characteristics are different. However, it is technically impossible or almost impractical to specify the structure or characteristics so that such differences are clear.

[0060] [4. Resin composition] The resin composition according to one embodiment of the present invention includes a polyester resin (A), a polyolefin resin (B), and a compatibilizer (C). The content of the compatibilizer (C) is not particularly limited relative to 100 parts by mass of the total of the polyester resin (A) and the polyolefin resin (B), but is preferably 0.1 parts by mass or more and 20 parts by mass or less, and more preferably 5 parts by mass or more and 20 parts by mass or less. If the content of the compatibilizer (C) is 0.1 parts by mass or more, the compatibility between the polyester resin (A) and the polyolefin resin (B) is further improved, and if it is 20 parts by mass or less, the processability during production of the resin composition is excellent.

[0061] The resin composition according to one embodiment of the present invention may further contain other components. For example, known auxiliary agents may be blended as necessary to impart functionality or improve properties. Examples of such auxiliary agents include flame retardants, anti-dripping agents, antioxidants, UV absorbers, light stabilizers, release agents, lubricants, sliding agents, colorants, fluorescent brighteners, phosphorescent pigments, fluorescent dyes, and antistatic agents.

[0062] The method for producing the resin composition according to one embodiment of the present invention is not particularly limited, but the resin composition can be produced by mixing or melt-kneading the polyester resin (A), the polyolefin resin (B) and the compatibilizer (C) in the form of powder. For mixing or melt-kneading, for example, a Henschel mixer, a Banbury mixer, a single-screw extruder, a twin-screw extruder, a two-roll machine, a kneader, a Brabender, or the like is used.

[0063] 5. Molded body The resin composition according to one embodiment of the present invention can be molded into a molded article. The resin composition according to one embodiment of the present invention may be mixed with other materials and then molded into a molded article. That is, the molded article may contain the resin composition according to one embodiment of the present invention.

[0064] The shape of the molded product is not particularly limited, and may be various shapes such as a resin plate, a sheet, a film, a cable, a fiber, an irregular shape, etc. As a molding method for the molded product, a known method can be used, and examples thereof include compression molding, transfer molding, injection molding, blow molding, vacuum molding, extrusion molding, lamination molding, and calendar molding.

[0065] [6. Summary] As described above, the present invention has the following aspects.

[0066] The resin composition according to aspect 1 of the present invention is a resin composition comprising a polyester resin (A), a polyolefin resin (B) and a compatibilizer (C), wherein the compatibilizer (C) is a polymer having a first polymer portion and a second polymer portion, the first polymer portion having a structural unit different from the structural unit constituting the second polymer portion, and the second polymer portion having a structural unit derived from a (meth)acrylate monomer.

[0067] In the resin composition according to aspect 2 of the present invention, in the above-mentioned aspect 1, the first polymer portion may be constituted by a polyester-based polymer.

[0068] In the resin composition according to aspect 3 of the present invention, in aspect 1 or 2, the content of the structural unit derived from the (meth)acrylate monomer per 100 parts by mass of the second polymer portion may be 5 parts by mass or more.

[0069] The resin composition according to aspect 4 of the present invention may be any of aspects 1 to 3, wherein the compatibilizer (C) has a core-shell structure, the first polymer portion constitutes a shell portion of the core-shell structure, and the second polymer portion constitutes a core portion of the core-shell structure.

[0070] The resin composition according to aspect 5 of the present invention, in any one of aspects 1 to 4, may have a content of the first polymer portion in the compatibilizer (C) of 20 parts by mass or more and 70 parts by mass or less, relative to 100 parts by mass of the total of the first polymer portion and the second polymer portion.

[0071] The resin composition according to aspect 6 of the present invention may be the resin composition according to any one of aspects 1 to 5, wherein the compatibilizer (C) is obtained by emulsion polymerization of a monomer component constituting the second polymer portion in the presence of a polymer constituting the first polymer portion.

[0072] The resin composition according to aspect 7 of the present invention, in any one of aspects 1 to 6, may have a content of the compatibilizer (C) of 0.1 parts by mass or more and 20 parts by mass or less per 100 parts by mass of the polyester resin (A) and the polyolefin resin (B) combined.

[0073] A molded article according to an eighth aspect of the present invention comprises the resin composition according to any one of the first to seventh aspects. EXAMPLES

[0074] An embodiment of the present invention will now be described with reference to the following examples. In the examples, "parts" refers to "parts by mass."

[0075] <Impact properties> The impact properties were evaluated by measuring the Charpy strength of a 4 mm thick molded product at 23°C in accordance with JIS K7111.

[0076] <Tensile modulus, tensile stress, tensile elongation> A tensile test was carried out using a Tensilon universal testing machine (model name "RTC-1250A-PL", manufactured by Orientec Co., Ltd.) in accordance with JIS K7139 to measure the tensile modulus and tensile elongation of the molded body.

[0077] <Optical properties> The optical properties were evaluated by measuring the total light transmittance of a molded product with a thickness of 2 mm in accordance with JIS K7375.

[0078] (Production Example 1) As an aqueous dispersion solution of the polymer (hereinafter also referred to as "first polymer") constituting the first polymer portion, 300 parts of Nichigo Polyester (registered trademark) WR-905 (manufactured by Mitsubishi Chemical Corporation: solid content 20%), 90 parts of methyl methacrylate (MMA) and 10 parts of butyl acrylate (BA) as radical polymerizable monomers, and 3 parts of normal octyl mercaptan (manufactured by Tokyo Chemical Industry Co., Ltd.) as a chain transfer agent were mixed and emulsified with a homomixer to obtain a pre-emulsion liquid of the radical polymerizable monomer. The radical polymerizable monomer constitutes the second polymer portion.

[0079] A flask equipped with a stirrer, a reflux condenser, and a temperature controller was charged with 180 parts of the pre-emulsion liquid and deionized water, and the temperature was raised to 50°C while nitrogen bubbling was performed at a flow rate of 200 mL per minute, and the temperature was maintained for 1 hour. 0.7 parts of Percumyl (registered trademark) P (manufactured by NOF Corp.) as a polymerization initiator, 0.002 parts of ferrous sulfate as a reducing agent, 0.006 parts of sodium ethylenediaminetetraacetate (EDTA), 0.3 parts of sodium formaldehyde sulfoxylate, and 10 parts of deionized water were added, and the nitrogen flow was switched to initiate polymerization. After 1 hour, the temperature was raised to 60°C, and the mixture was cooled after being maintained for 2 hours, to obtain a latex of the compatibilizer C1 according to one embodiment of the present invention. The obtained latex of the compatibilizer C1 was added to 460 parts of deionized water containing 5 parts by mass of calcium acetate, coagulated, washed with water, dehydrated, and dried to obtain the compatibilizer C1 in the form of a powder.

[0080] (Production Examples 2 to 7) Compatibilizers C2 to C5 according to an embodiment of the present invention and compatibilizers C6 and C7 according to comparative examples were obtained by the same production method as in Production Example 1, except that the amount of the first polymer used, the type of radical polymerizable monomer, and the copolymerization amount were changed as shown in the following Table 1. In Production Examples 2 to 7, at least one of styrene (St), butyl acrylate (BA), methyl methacrylate (MMA), and polypropylene glycol monomethacrylate (Blenmer (registered trademark) PP-800 manufactured by NOF Corporation) was used as the radical polymerizable monomer.

[0081] Example 1 70 parts of polybutylene terephthalate (PBT, manufactured by Mitsubishi Chemical Corporation: Novaduran (registered trademark) 5010R5) as polyester resin (A), 30 parts of polypropylene (PP, manufactured by Japan Polypropylene Corporation: MA1B) as polyolefin resin (B), and 5 parts of the compatibilizer C1 manufactured in Manufacturing Example 1 were placed in a polyethylene bag. The polyethylene bag was shaken well by hand to hand blend, and then melt-kneaded at 250°C using a twin-screw extruder (manufactured by Toshiba Machine Co., Ltd., product name: TEM35B), and the extruded strand was cut to obtain pellets.

[0082] The obtained pellets were molded using an injection molding machine (Toshiba Machine Co., Ltd., product name: IS100EN) at a molding temperature of 250°C and a mold temperature of 60°C to produce molded bodies conforming to the respective tests, thereby obtaining the molded body according to Example 1. The result of the impact test on the molded body was 2.1 kJ / m at 23°C. 2 The molded body was subjected to a tensile test and an impact test. The tensile modulus of the molded body in the tensile test was 1.7 GPa, and the tensile elongation was 8.9%. In terms of optical properties, the total light transmittance was 14.2%.

[0083] (Examples 2 to 5) Molded articles were obtained and evaluated in the same manner as in Example 1, except that the type of compatibilizer (C) used was changed as shown in Table 2 below.

[0084] Comparative Example 1 A resin composition and a molded article were produced in the same manner as in Example 1, except that the compatibilizer C1 obtained in Production Example 1 was not added, and a molded article according to Comparative Example 1 was obtained. A tensile test and an impact test were carried out on the molded article. The result of the impact test on the molded article was 2.0 kJ / m at 23°C. 2 The molded body was subjected to a tensile test and an impact test. The tensile modulus of the molded body in the tensile test was 2.0 GPa, and the tensile elongation was 3.8%. In terms of optical properties, the total light transmittance was 11.3%.

[0085] (Comparative Examples 2 and 3) Molded articles were obtained and evaluated in the same manner as in Example 1, except that the type of compatibilizer (C) used was changed as shown in Table 2 below.

[0086] [Table 1]

[0087] [Table 2]

[0088] In Examples 1 to 5, in which compatibilizers C1 to C5, each of which had a (meth)acrylate monomer in the second polymer portion, were added to an alloy of PBT and PP, the tensile elongation and total light transmittance of the molded body were improved compared to Comparative Example 1, in which no compatibilizer was used.

[0089] On the other hand, in Comparative Example 2, which used the compatibilizer C6 not using a (meth)acrylate monomer in the second polymer portion, the tensile elongation was lower than that of Comparative Example 1, which used no compatibilizer. Also, in Comparative Example 3, which used the compatibilizer C7 not containing the first polymer portion, the tensile elongation was lower than that of Comparative Example 1, which used no compatibilizer. [Industrial Applicability]

[0090] In the resin composition according to one embodiment of the present invention, the polyester resin (A) and the polyolefin resin (B) are well compatible with each other, and therefore the resin composition has excellent tensile elongation when molded into a molded product. Such molded products can be suitably used as molded products obtained by recycling automobile, motorcycle, and ship parts, electrical and electronic parts, office appliance parts, miscellaneous goods, fibers, films, and molded products, and molded products useful in other fields.

Claims

1. A resin composition comprising a polyester resin (A), a polyolefin resin (B) and a compatibilizer (C), The compatibilizer (C) is a polymer having a first polymer portion and a second polymer portion, the first polymer portion has a structural unit different from a structural unit constituting the second polymer portion, The resin composition, wherein the second polymer portion has a structural unit derived from a (meth)acrylate monomer.

2. The resin composition according to claim 1 , wherein the first polymer portion is composed of a polyester-based polymer.

3. The resin composition according to claim 1 , wherein the content of the structural unit derived from the (meth)acrylate monomer is 5 parts by mass or more per 100 parts by mass of the second polymer portion.

4. 2. The resin composition according to claim 1, wherein the compatibilizer (C) has a core-shell structure, the first polymer portion constitutes a shell portion of the core-shell structure, and the second polymer portion constitutes a core portion of the core-shell structure.

5. 2. The resin composition according to claim 1, wherein a content of the first polymer portion in the compatibilizer (C) is 20 parts by mass or more and 70 parts by mass or less with respect to a total of 100 parts by mass of the first polymer portion and the second polymer portion.

6. The resin composition according to claim 1, wherein the compatibilizer (C) is obtained by emulsion polymerization of a monomer component constituting the second polymer portion in the presence of a polymer constituting the first polymer portion.

7. The resin composition according to claim 1, wherein the compatibilizer (C) is 0.1 parts by mass or more and 20 parts by mass or less per 100 parts by mass of the total of the polyester resin (A) and the polyolefin resin (B).

8. A molded article comprising the resin composition according to any one of claims 1 to 7.

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