Method for producing resin composition and method for producing pellets

Abstract

The present invention aims to provide a method for producing a resin composition, which is capable of producing a molded article having relatively excellent dart impact strength, a method for producing pellets, and a resin composition. [Solution] The method for producing a resin composition according to the present invention includes a melt-kneading process in which raw materials for the resin composition are melt-kneaded, and a filtration process in which the melt-kneaded mixture is filtered using a filtration device, the filtration device having a supply port for supplying the mixture and a filter having a filtration surface, the filtration process including a primary filtration process in which the mixture is initially filtered, and a secondary filtration process in which the mixture that has undergone primary filtration is filtered using a filter with finer mesh than that of the primary filtration process, and at least one of the filtration devices performing the secondary filtration process has a flow path that is expanded from the supply port toward the filtration surface.

Description

[Technical field]

[0001] The present invention relates to a method for producing a resin composition, a method for producing pellets, and a resin composition. [Background technology]

[0002] Molded articles containing resin compositions such as polypropylene are used for industrial parts such as automobile parts and electrical parts, daily necessities, miscellaneous goods, etc. Such molded articles are obtained by using pellets as a raw material, supplying the pellets to an extrusion molding device or the like, melt-kneading the pellets, and then extruding the pellets.

[0003] Conventionally, when producing pellets, raw materials of a resin composition are melt-kneaded, and then the molten raw materials are filtered to remove foreign matter contained in the raw materials (for example, Patent Document 1). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Special Publication No. 2019-527618 Summary of the Invention [Problem to be solved by the invention]

[0005] However, pellets produced by conventional methods have a problem in that the resulting molded articles have low dart impact strength, which is particularly noticeable when the molded articles are used in cold regions, and improvement thereto is desired.

[0006] The present invention has been made in consideration of such problems, and an object of the present invention is to provide a method for producing a resin composition, a method for producing pellets, and a resin composition, which are capable of obtaining molded articles with relatively excellent dart impact strength. [Means for solving the problem]

[0007] The method for producing a resin composition according to the present invention includes a melt-kneading process in which raw materials for the resin composition are melt-kneaded, and a filtration process in which the melt-kneaded mixture is filtered using a filtration device, the filtration device having a supply port for supplying the mixture and a filter having a filtration surface, the filtration process including a primary filtration process in which the mixture is initially filtered, and a secondary filtration process in which the mixture that has undergone primary filtration is filtered using a filter with finer mesh than that of the primary filtration process, and at least one of the filtration devices performing the secondary filtration process has a flow path that is expanded from the supply port toward the filtration surface.

[0008] The method for producing pellets according to the present invention includes a pelletizing step of extruding the resin composition obtained by the above-mentioned method for producing a resin composition with an extruder to obtain pellets.

[0009] The resin composition according to the present invention can be obtained by the above-mentioned method for producing a resin composition. Effect of the Invention

[0010] According to the present invention, it is possible to provide a method for producing a resin composition capable of obtaining a molded article having relatively excellent dart impact strength, a method for producing pellets, and a resin composition. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Hereinafter, an embodiment of the present invention will be described, however, the present invention is not limited to the following embodiment.

[0012] [Method of producing resin composition] The method for producing a resin composition according to this embodiment includes a melt-kneading step of melt-kneading raw materials of the resin composition, and a filtration step of filtering the melt-kneaded mixture using a filtration device.

[0013] <Melting and kneading process> The raw material of the resin composition includes, for example, polyolefin resins such as ethylene-based polymers and propylene-based polymers, polyamide resins, polyester resins, polystyrene resins, polycarbonate resins, etc. From the viewpoint of improving the rigidity and impact resistance of the molded body, the raw material of the resin composition preferably includes a propylene-based polymer.

[0014] The propylene-based polymer is a polymer containing 50% by mass or more of a monomer unit derived from propylene. Examples of the propylene-based polymer include a propylene homopolymer, a random copolymer of propylene and a monomer other than propylene, and a heterophasic propylene polymer material. From the viewpoint of improving the rigidity and impact resistance of a molded article, the raw material of the resin composition preferably contains a heterophasic propylene polymer material as the propylene-based polymer. The raw material of the resin composition may contain only one type of propylene-based polymer, or may contain two or more types of propylene-based polymers.

[0015] The isotactic pentad fraction of the propylene polymer is preferably 0.961 or more, more preferably 0.965 or more, and even more preferably 0.968 or more. The isotactic pentad fraction of the propylene polymer is preferably 1.000 or less, and more preferably 0.995 or less.

[0016] The isotactic pentad fraction means the isotactic fraction in pentad units. That is, the isotactic pentad fraction indicates the content ratio of a structure in which five consecutive monomer units derived from propylene are meso-bonded when viewed in pentad units. When the target component is a copolymer, the isotactic pentad fraction refers to a value measured for the chain of monomer units derived from propylene.

[0017] The isotactic pentad fraction is 13 This is a value measured by C-NMR spectroscopy. 13 The ratio of the area of ​​the mmmm peak to the area of ​​all absorption peaks in the methyl carbon region obtained by C-NMR spectrum is defined as the isotactic pentad fraction.13 The method for measuring the isotactic pentad fraction by C-NMR spectroscopy is described, for example, in Macromolecules, 6, 925 (1973) by A. Zambelli et al. 13 The assignment of absorption peaks obtained by C-spectrum is based on the description in Macromolecules, 8, 687 (1975).

[0018] The isotactic pentad fraction of the propylene-based polymer can be adjusted to the above range by appropriately selecting a catalyst, a donor, polymerization conditions, etc. Also, a propylene-based polymer having a desired isotactic pentad fraction can be obtained from a commercial product.

[0019] The content of the propylene-based polymer may be from 40% by mass to 99% by mass, or from 50% by mass to 95% by mass, relative to 100% by mass of the total mass of the raw materials of the resin composition.

[0020] (Propylene homopolymer) The propylene homopolymer has an intrinsic viscosity ([η]) of preferably 0.10 dL / g or more and 4.00 dL / g or less, more preferably 0.50 dL / g or more and 3.00 dL / g or less, and even more preferably 0.70 dL / g or more and 2.00 dL / g or less, from the viewpoint of improving the fluidity of the resin composition when melted and the toughness of the molded body.

[0021] In this specification, the intrinsic viscosity (unit: dL / g) is a value measured at a temperature of 135° C. using tetralin as a solvent by the following method.

[0022] 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 the extrapolation method in which the concentration is extrapolated to zero. The method for calculating the intrinsic viscosity by the extrapolation method is described, for example, in page 491 of "Polymer Solutions, Polymer Experiments 11" (published by Kyoritsu Publishing Co., Ltd. in 1982).

[0023] 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 of the propylene homopolymer is preferably 15.0 or less, more preferably 10.0 or less. The molecular weight distribution of the propylene homopolymer is preferably 3.0 or more and 15.0 or less, more preferably 4.0 or more and 10.0 or less.

[0024] In this specification, the molecular weight distribution means 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. Equipment: Tosoh Corporation HLC-8121 GPC / HT Separation column: 3 GMHHR-H(S)HT, manufactured by Tosoh Corporation Measurement temperature: 140℃ Carrier: Orthodichlorobenzene Flow rate: 1.0mL / min Sample concentration: Approximately 1 mg / mL Sample injection volume: 400 μL Detector: Differential Refraction Calibration curve creation method: Use standard polystyrene

[0025] The propylene homopolymer can be produced, for example, by carrying out a polymerization step of polymerizing propylene using a polymerization catalyst.

[0026] Examples of the polymerization catalyst include Ziegler type catalysts; Ziegler-Natta type 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 catalysts modified 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 minerals, etc.).

[0027] 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, and JP-A-2011-246699.

[0028] Furthermore, a polymer obtained by prepolymerizing propylene in the presence of the above polymerization catalyst can also be used as the polymerization catalyst.

[0029] Examples of the polymerization method 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. 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 a gaseous monomer is used as a medium and the gaseous monomer is polymerized in the medium.

[0030] The polymerization method may be, for example, a batch method, a continuous method, or a combination thereof. The polymerization method may be a multi-stage method in which a plurality of polymerization reaction vessels are connected in series.

[0031] From the viewpoint of industrial and economical superiority, the polymerization method is preferably 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.

[0032] Various conditions in the polymerization step (polymerization conditions such as polymerization temperature, polymerization pressure, monomer concentration, catalyst input amount, and polymerization time) may be appropriately determined depending on the molecular structure of the desired polymer.

[0033] In the method for producing a propylene homopolymer, 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 temperature of the polymer, if necessary, in order to remove residual solvent contained in the polymer and ultralow molecular weight oligomers produced as by-products during production. Examples of the drying method include the methods described in JP-A-55-75410 and JP-A-2565753.

[0034] (Random copolymer of propylene and monomers 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, and preferably contains monomer units derived from a monomer other than propylene in an amount of 0.01% by mass or more and 20% by mass or less, based on the total mass of the copolymer (100% by mass).

[0035] Examples of monomers other than propylene include ethylene and α-olefins having 4 to 12 carbon atoms. In this specification, α-olefins are aliphatic unsaturated hydrocarbons having a carbon-carbon unsaturated double bond at the α-position. Examples of α-olefins having 4 to 12 carbon atoms include 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1-dodecene, 4-methyl-1-pentene, and 4-methyl-1-hexene.

[0036] The monomer other than propylene is preferably at least one selected from the group consisting of ethylene and α-olefins having 4 to 10 carbon atoms, more preferably at least one selected from the group consisting of ethylene, 1-butene, 1-hexene, and 1-octene, and even more preferably at least one selected from the group consisting of ethylene and 1-butene.

[0037] Examples of random copolymers of propylene and monomers other than propylene include propylene-ethylene random copolymers, propylene-1-butene random copolymers, propylene-1-hexene random copolymers, propylene-1-octene random copolymers, propylene-ethylene-1-butene random copolymers, propylene-ethylene-1-hexene random copolymers, and propylene-ethylene-1-octene random copolymers.

[0038] The random copolymer of propylene and a monomer other than propylene has an intrinsic viscosity ([η]) of preferably 0.10 dL / g or more and 4.00 dL / g or less, more preferably 0.50 dL / g or more and 3.00 dL / g or less, and even more preferably 0.70 dL / g or more and 2.00 dL / g or less, from the viewpoint of improving the fluidity of the propylene resin composition when melted.

[0039] The molecular weight distribution (Mw / Mn) of the random polymer of propylene and a monomer other than propylene is preferably 3.0 or more, more preferably 4.0 or more. The molecular weight distribution of the random polymer of propylene and a monomer other than propylene is preferably 10.0 or less, more preferably 7.0 or less. The molecular weight distribution of the random polymer of propylene and a monomer other than propylene is preferably 3.0 or more and 10.0 or less, more preferably 4.0 or more and 7.0 or less.

[0040] The random copolymer of propylene and a monomer other than propylene can be produced, for example, by polymerizing propylene and a monomer other than propylene according to the polymerization catalyst, polymerization method, polymerization system, and polymerization conditions that can be used in the production of the above-mentioned propylene homopolymer.

[0041] (Heterophagic propylene polymer material) The heterophasic propylene polymerization material is a mixture containing polymer I containing 80% by mass or more of monomer units derived from propylene (wherein the total mass of polymer I is taken as 100% by mass), and polymer II containing monomer units derived from at least one α-olefin selected from the group consisting of ethylene and α-olefins having 4 to 12 carbon atoms, and monomer units derived from propylene.

[0042] The heterophasic propylene polymer material can be produced, for example, by carrying out a first polymerization step of polymerizing polymer I and a second polymerization step of polymerizing polymer II. These polymerization steps can be carried out according to the polymerization catalyst, polymerization method, polymerization scheme, and polymerization conditions that can be used in the production of the above-mentioned propylene homopolymer.

[0043] The heterophasic propylene polymerization material may be such that the sum of polymer I and polymer II contained in the heterophasic propylene polymerization material is 100% by mass relative to the total mass of the heterophasic propylene polymerization material (100% by mass).

[0044] As described above, polymer I contains 80% by mass or more of monomer units derived from propylene (where the total mass of polymer I is taken as 100% by mass). 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 monomer units may be, for example, 0.01% by mass or more and less than 20% by mass with respect to the total mass of polymer I, 100% by mass.

[0045] Examples of the monomer other than propylene include ethylene and α-olefins having 4 or more carbon atoms. Examples of the α-olefins having 4 or more carbon atoms include 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1-dodecene, 4-methyl-1-pentene, and 4-methyl-1-hexene.

[0046] The monomer other than propylene is preferably at least one selected from the group consisting of ethylene and α-olefins having 4 to 10 carbon atoms, more preferably at least one selected from the group consisting of ethylene, 1-butene, 1-hexene, and 1-octene, and even more preferably at least one selected from the group consisting of ethylene and 1-butene.

[0047] Examples of polymer I 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.

[0048] From the viewpoint of improving the dimensional stability of the molded body, 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.

[0049] The isotactic pentad fraction of the polymer I is preferably 1.000 or less, and may be, for example, 0.998 or less, 0.995 or less, 0.990 or less, or 0.985 or less. The lower limit of the isotactic pentad fraction is not particularly limited, and may be, for example, 0.900 or more, 0.925 or more, 0.930 or more, 0.961 or more, 0.965 or more, or 0.968 or more.

[0050] The content of polymer I is preferably 50% by mass or more and 99% by mass or less, and more preferably 60% by mass or more and 95% by mass or less, based on the total mass (100% by mass) of the heterophasic propylene polymerization material.

[0051] As described above, polymer II contains monomer units derived from at least one α-olefin selected from the group consisting of ethylene and α-olefins having 4 to 12 carbon atoms, and monomer units derived from propylene. Examples of α-olefins having 4 to 12 carbon atoms include 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1-dodecene, 4-methyl-1-pentene, and 4-methyl-1-hexene.

[0052] Polymer II preferably contains 30% by mass or more of monomer units derived from at least one α-olefin selected from the group consisting of ethylene and α-olefins having 4 to 12 carbon atoms, and also contains monomer units derived from propylene (where the total mass of Polymer II is taken as 100% by mass).

[0053] In polymer II, the content of monomer units derived from at least one α-olefin selected from the group consisting of ethylene and α-olefins having 4 to 12 carbon atoms may be 30% by mass or more and 70% by mass or less, or 35% by mass or more and 60% by mass or less (where the total mass of polymer II is taken as 100% by mass).

[0054] In polymer II, the at least one α-olefin selected from the group consisting of ethylene and α-olefins having 4 to 12 carbon atoms is preferably at least one selected from the group consisting of ethylene and α-olefins having 4 to 10 carbon atoms, 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 the polymer II include a propylene-ethylene copolymer, a propylene-ethylene-1-butene copolymer, a propylene-ethylene-1-hexene copolymer, a propylene-ethylene-1-octene copolymer, a propylene-ethylene-1-decene copolymer, a propylene-1-butene copolymer, a propylene-1-hexene copolymer, a propylene-1-octene copolymer, a propylene-1-decene copolymer, etc. Among these, the polymer II is preferably a propylene-ethylene copolymer, a propylene-1-butene copolymer, or a propylene-ethylene-1-butene copolymer, and more preferably a propylene-ethylene copolymer.

[0056] The content of the polymer II is preferably 1% by mass or more and 50% by mass or less, and more preferably 5% by mass or more and 40% by mass or less, based on the total mass (100% by mass) of the heterophasic propylene polymerization 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 α-olefins having 4 to 12 carbon atoms may be 0.3 mass% or more and 35 mass% or less, or 0.7 mass% or more and 24 mass% or less (wherein the total mass of the heterophasic propylene polymerization material is 100 mass%).

[0058] The content of xylene insoluble components (CXIS components) in the heterophasic propylene polymerization material is preferably 50% by mass or more and 99% by mass or less, and more preferably 60% by mass or more and 95% by mass or less, based on 100% by mass of the total mass of the heterophasic propylene polymerization material.

[0059] The content of xylene soluble components (CXS components) in the heterophasic propylene polymerization material is preferably 1 mass% or more and 50 mass% or less, and more preferably 5 mass% or more and 40 mass% or less, relative to the total mass of the heterophasic propylene polymerization material (100 mass%).

[0060] In this specification, the xylene insoluble component (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 about 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.

[0061] In this specification, the xylene soluble component (CXS component) means a component other than the "CXIS component" in the polymer.

[0062] In this embodiment, it is considered that the CXIS component in the heterophasic propylene polymerization material is mainly composed of polymer I, and the CXS component in the heterophasic propylene polymerization material is mainly composed of polymer II.

[0063] Examples of the heterophasic propylene polymeric material include (propylene)-(propylene-ethylene) polymeric material, (propylene)-(propylene-ethylene-1-butene) polymeric material, (propylene)-(propylene-ethylene-1-hexene) polymeric material, (propylene)-(propylene-ethylene-1-octene) polymeric material, (propylene)-(propylene-1-butene) polymeric material, (propylene)-(propylene-1-hexene) polymeric material, (propylene)-(propylene-1-octene) polymeric material, and (propylene)-(propylene-1-decene) polymeric material. materials, (propylene-ethylene)-(propylene-ethylene) polymerization materials, (propylene-ethylene)-(propylene-ethylene-1-butene) polymerization materials, (propylene-ethylene)-(propylene-ethylene-1-hexene) polymerization materials, (propylene-ethylene)-(propylene-ethylene-1-octene) polymerization materials, (propylene-ethylene)-(propylene-ethylene-1-decene) polymerization materials, (propylene-ethylene)-(propylene-1-butene) polymerization materials, (propylene-ethylene)-(propylene-1-hexene) polymerization materials, (propylene-ethylene (propylene)-(propylene-1-octene) polymerization materials, (propylene-ethylene)-(propylene-1-decene) polymerization materials, (propylene-1-butene)-(propylene-ethylene) polymerization materials, (propylene-1-butene)-(propylene-ethylene-1-butene) polymerization materials, (propylene-1-butene)-(propylene-ethylene-1-hexene) polymerization materials, (propylene-1-butene)-(propylene-ethylene-1-octene) polymerization materials, (propylene-1-butene)-(propylene-ethylene-1-decene) polymerization materials, (propylene-1-butene)-(propylene-ethylene-1-decene) polymerization materials, (propylene-1-butene)-(propylene (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,(propylene-1-octene)-(propylene-1-decene) polymer materials.

[0064] 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.

[0065] The heterophasic propylene polymeric material is preferably a (propylene)-(propylene-ethylene) polymeric material, a (propylene)-(propylene-ethylene-1-butene) polymeric material, a (propylene-ethylene)-(propylene-ethylene) polymeric material, a (propylene-ethylene)-(propylene-ethylene-1-butene) polymeric material, or a (propylene-1-butene)-(propylene-1-butene) polymeric material, and more preferably a (propylene)-(propylene-ethylene) polymeric material.

[0066] The intrinsic viscosity number ([η]I) of polymer I is preferably 0.10 dL / g or more and 4.00 dL / g or less, more preferably 0.50 dL / g or more and 3.00 dL / g or less, and even more preferably 0.70 dL / g or more and 2.00 dL / g or less.

[0067] The intrinsic viscosity number ([η]II) of the polymer II is preferably 1.00 dL / g or more and 10.00 dL / g or less, more preferably 2.00 dL / g or more and 10.00 dL / g or less, and even more preferably 2.00 dL / g or more and 9.00 dL / g or less.

[0068] 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 or more and 20 or less, more preferably 1 or more and 10 or less.

[0069] The intrinsic viscosity number ([η]I) of polymer I can be measured, for example, by extracting polymer I from a reactor in which polymer I is polymerized and measuring the intrinsic viscosity number of the polymer.

[0070] The intrinsic viscosity number ([η]II) of polymer II can be calculated, for example, from 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, according to the following formula (i).

[0071] [η]II=([η]Total-[η]I×XI) / XII ···(i) [η]Total: Intrinsic viscosity number of heterophasic propylene polymer material (dL / g) [η]I: Intrinsic viscosity number of polymer I (dL / g) XI: Ratio of the mass of polymer I to the total mass of the heterophasic propylene polymer material (mass of polymer I / mass of heterophasic propylene polymer material) XII: Ratio of the mass of polymer II to the total mass of the heterophasic propylene polymer material (mass of polymer II / mass of heterophasic propylene polymer material)

[0072] Here, XI and XII can be determined from the material balance during polymerization.

[0073] Incidentally, XII may be calculated by measuring the heat of fusion of the polymer I and the heat of fusion of the heterophasic propylene polymer material and using the following formula. XII = 1-(ΔHf)T / (ΔHf)P (ΔHf)T: Heat of fusion of the heterophasic propylene polymer material (J / g) (ΔHf)P: Heat of fusion of polymer I (J / g)

[0074] The intrinsic viscosity number ([η]CXIS) of the CXIS component is preferably 0.10 dL / g or more and 4.00 dL / g or less, more preferably 0.50 dL / g or more and 3.00 dL / g or less, and even more preferably 0.70 dL / g or more and 2.00 dL / g or less.

[0075] The intrinsic viscosity number ([η]CXS) of the CXS component is preferably 1.00 dL / g or more and 10.00 dL / g or less, more preferably 2.00 dL / g or more and 10.00 dL / g or less, and even more preferably 2.00 dL / g or more and 9.00 dL / g or less.

[0076] 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 or more and 20 or less, more preferably 1 or more and 10 or less.

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

[0078] 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.

[0079] From the viewpoint of improving the moldability of the resin composition, the melt flow rate (MFR) of the propylene polymer is preferably 0.1 g / 10 min or more, more preferably 1 g / 10 min or more and 300 g / 10 min or less. The melt flow rate (MFR) of the propylene polymer may be 5 g / 10 min or more and 100 g / 10 min or less, or 10 g / 10 min or more and 50 g / 10 min or less.

[0080] In this specification, the melt flow rate (MFR) of the propylene-based polymer is measured by Method A under conditions of a temperature of 230° C. and a load of 2.16 kg in accordance with the method specified in JIS K7210-1995.

[0081] The raw material of the resin composition may be a crushed material. The crushed material is obtained by crushing a molded body. The molded body may be collected from the market. Examples of the raw material of the collected crushed material include automobile parts, packaging containers (food retort pouches, refill pouches, detergent bottles, etc.), housings of household electrical appliances, office supplies (trays, etc.), and household daily necessities (contact lens cases, etc.). Examples of the automobile parts include automobile interior parts (instrument panels, door trims, etc.), automobile exterior parts (bumpers, pillars, etc.), and other automobile parts (battery cases, etc.).

[0082] When the raw material for the resin composition is a crushed material, the raw material for the resin composition preferably further contains a virgin propylene-based polymer from the viewpoint of improving the rigidity and impact resistance of a molded product. The virgin propylene-based polymer means a propylene-based polymer that 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 production of the propylene-based polymer by a process including a polymerization step.

[0083] The content of the virgin propylene-based polymer is preferably 15% by mass or more, more preferably 30% by mass or more, based on 100% by mass of the total mass of the raw materials of the resin composition. The content of the virgin propylene-based polymer is preferably 85% by mass or less, more preferably 70% by mass or less, based on 100% by mass of the total mass of the raw materials of the resin composition.

[0084] In addition, when the raw material of the resin composition is a crushed material, the raw material of the resin composition preferably further contains an ethylene-α-olefin copolymer from the viewpoint of increasing impact resistance. The raw material of the resin composition may contain a recycled ethylene-α-olefin copolymer as the ethylene-α-olefin copolymer. The recycled ethylene-α-olefin copolymer means an ethylene-α-olefin copolymer that is once subjected to processing such as molding or used for some final application, and then passes through a recovery process and is reused.

[0085] The ethylene-α-olefin copolymer may be an ethylene-α-olefin random copolymer. Note that the ethylene-α-olefin copolymer refers to a copolymer containing monomer units derived from ethylene and monomer units derived from an α-olefin having 4 or more carbon atoms, and substantially not containing monomer units derived from propylene.

[0086] In the ethylene-α-olefin copolymer, the sum of the content of monomer units derived from ethylene and the content of monomer units derived from an α-olefin having 4 or more carbon atoms may be 100% by mass, relative to the total mass of the copolymer (100% by mass).

[0087] Examples of the α-olefins having 4 or more carbon atoms include α-olefins having 4 to 12 carbon atoms. Examples of the α-olefins having 4 to 12 carbon atoms include 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene, 1-octene, and 1-decene. The α-olefins having 4 to 12 carbon atoms are preferably 1-butene, 1-hexene, or 1-octene. The α-olefins having 4 to 12 carbon atoms may be α-olefins having a cyclic structure, such as vinylcyclopropane and vinylcyclobutane.

[0088] Examples of ethylene-α-olefin copolymers 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.

[0089] In the ethylene-α-olefin copolymer, the content of monomer units derived from α-olefins having 4 or more carbon atoms is preferably 1% by mass or more and 49% by mass or less, more preferably 5% by mass or more and 49% by mass or less, and even more preferably 24% by mass or more and 49% by mass or less, relative to the total mass of the ethylene-α-olefin copolymer (100% by mass).

[0090] The density of the ethylene-α-olefin copolymer is preferably 0.850 g / cm from the viewpoint of impact resistance of the molded product. 3 More than 0.890g / cm 3 More preferably, it is 0.850 g / cm or less. 3 More than 0.880g / cm 3 More preferably, it is 0.850 g / cm or less. 3 More than 0.870g / cm 3 The following is the result.

[0091] The melt flow rate of the ethylene-α-olefin copolymer is preferably 0.1 g / 10 min or more and 80 g / 10 min or less at a temperature of 190° C. and a load of 2.16 kg. The melt flow rate of the ethylene-α-olefin copolymer can be measured by Method A under conditions of a temperature of 190° C. and a load of 2.16 kg in accordance with the method specified in JIS K7210-1995.

[0092] The content of the ethylene-α-olefin copolymer is preferably 1% by mass or more, more preferably 5% by mass or more, based on 100% by mass of the total mass of the raw materials of the resin composition. The content of the ethylene-α-olefin copolymer is preferably 40% by mass or less, more preferably 30% by mass or less, based on 100% by mass of the total mass of the raw materials of the resin composition.

[0093] Ethylene-α-olefin copolymers can be produced by polymerizing ethylene and an α-olefin having 4 or more carbon atoms using a polymerization catalyst.

[0094] Examples of the polymerization catalyst include homogeneous catalysts such as metallocene catalysts, and Ziegler-Natta type catalysts.

[0095] Examples of homogeneous catalysts include 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 catalysts modified 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 minerals, etc.).

[0096] An example of the Ziegler-Natta type catalyst is a catalyst that combines a titanium-containing solid transition metal component with an organometallic component.

[0097] The ethylene-α-olefin copolymer may be a commercially available product. Examples of commercially available ethylene-α-olefin copolymers include Engage (registered trademark) manufactured by Dow Chemical Japan, Tafmer (registered trademark) manufactured by Mitsui Chemicals, Neozex (registered trademark) and Ultzex ​​(registered trademark) manufactured by Prime Polymer Co., Ltd., Excellen FX (registered trademark), Sumikathen (registered trademark), and Esprene SPO (registered trademark) manufactured by Sumitomo Chemical Co., Ltd.

[0098] The raw material of the resin composition may further contain other components, such as a neutralizing agent, an antioxidant, an ultraviolet absorber, a nucleating agent, a lubricant, an antistatic agent, an antiblocking agent, a processing aid, an organic peroxide, a colorant (inorganic pigment, organic pigment, pigment dispersant, etc.), a foaming agent, a foam nucleating agent, a plasticizer, a flame retardant, a crosslinking agent, a crosslinking aid, a brightness enhancer, an antibacterial agent, a light diffusing agent, etc.

[0099] In the melt-kneading step, the temperature during melt-kneading may be 180°C or higher, may be 180°C or higher and 300°C or lower, or may be 180°C or higher and 250°C or lower.

[0100] For melt kneading, a Banbury mixer, a single screw extruder, a twin screw co-rotating extruder, etc. can be used. The raw material of the resin composition is, for example, charged from a hopper, weighed in a weighing section, and then sent to an extruder or the like via a feeder. When the raw material of the resin composition is a crushed material, a mechanism for charging the crushed material crushed using a crushing device such as a cutter compactor into the hopper may be provided, or the crushed material crushed at another location may be charged into the hopper. The crushed material is, for example, crushed to 15 mm or less.

[0101] The order of kneading the raw material components is not particularly limited. For example, all the components may be kneaded at once, or some of the components may be kneaded and then the resulting mixture may be kneaded with the other components.

[0102] <Filtration process> The filtration step includes a primary filtration step in which the kneaded mixture is first filtered, and a secondary filtration step in which the kneaded mixture that has been subjected to the primary filtration is filtered using a filter having finer openings than that used in the primary filtration step.

[0103] The filtration device used in the filtration step includes a supply port for supplying the kneaded material and a filter having a filtration surface. More specifically, the supply port is provided at a position opposite to the filtration surface, and a space is provided between the supply port and the filtration surface.

[0104] At least one of the filtration devices performing the secondary filtration step has a flow path expanded from the supply port toward the filtration surface. With such a configuration, most of the fibrous foreign matter contained in the kneaded material enters obliquely with respect to the filtration surface, making it difficult for the fibrous foreign matter to pass through the filter. As a result, since many of the fibrous foreign matter contained in the kneaded material can be removed, a molded product having excellent surface impact strength can be obtained. Note that there may be a plurality of filtration devices performing the secondary filtration step, and it is sufficient that at least one of the filtration devices has a flow path expanded from the supply port toward the filtration surface.

[0105] At least one of the filtration devices performing the secondary filtration step preferably has a V / S of less than 1 cm and an S / A of 20 or more. At least one of the filtration devices performing the secondary filtration step has an expanded flow path so that the V / S is less than 1 cm and the S / A is 20 or more, so that more fibrous foreign matter contained in the kneaded material can be removed, and a molded product with superior dart impact strength can be obtained. V / S is more preferably 0.01 cm or more and 0.7 cm or less, and even more preferably 0.1 cm or more and 0.5 cm or less. Moreover, S / A is more preferably 22 or more and 150 or less, and even more preferably 25 or more and 100 or less.

[0106] Here, V is the volume of the space from the supply port to the filtration surface, for example, 10 cm 3 More than 40000cm 3 S is the area of ​​the filtration surface, e.g. 10 cm 2 More than 2000cm 2 A is the area of ​​the inlet, i.e., the area of ​​the inlet projected onto a plane parallel to the filtration surface, e.g., 10 cm 2 More than 2000cm 2 It can be as follows:

[0107] In at least one of the filtration devices performing the secondary filtration step, the ratio of the area of ​​the filtration surface to the amount of the kneaded material fed is preferably 0.1 cm 2 ·hr / kg or more 0.4cm 2 hr / kg or less, and more preferably 0.2 cm 2 ·hr / kg or more 0.3cm 2 hr / kg or less.

[0108] The number of filtration devices performing the secondary filtration step can be, for example, from 1 to 5, and is preferably from 1 to 2.

[0109] The S / A of the filtration device performing the primary filtration step is preferably 1 or more and 10 or less, and more preferably 1. That is, the filtration device performing the primary filtration step more preferably does not have a flow path that is enlarged from the supply port toward the filtration surface. The filtration device performing the primary filtration step can remove relatively large foreign matter due to such a configuration, and therefore, in the filtration device performing the subsequent secondary filtration step, fibrous foreign matter can be efficiently removed.

[0110] In the filtration device performing the primary filtration process, for example, V is set to 50 cm 3 More than 40000cm 3 In the following, S is 10 cm 2 More than 2000cm 2 In the following, A is 10 cm 2 More than 2000cm 2 It can be as follows:

[0111] The mesh size of the filter in the filtration device performing the primary filtration step is preferably 70 μm or more, more preferably 80 μm or more and 200 μm or less. The mesh size of the filter in the filtration device performing the secondary filtration step is preferably 10 μm or more and 60 μm or less, more preferably 20 μm or more and 40 μm or less. In one aspect, the method for producing a resin composition according to the present embodiment obtains a molded product having excellent dart impact strength, so that the mesh size of the filter in the filtration device performing the primary filtration step is 70 μm or more, and the mesh size of the filter in the filtration device performing the secondary filtration step is 10 μm or more and 60 μm or less.

[0112] The material of the filter is not particularly limited, and for example, stainless steel, copper, nickel, polypropylene, polyethylene, polyethylene terephthalate, etc. can be used.

[0113] In the method for producing a resin composition according to the present embodiment, a booster pump may be provided between the filtration device performing the primary filtration step and the filtration device performing the secondary filtration step in the filtration step. With this configuration, the method for producing a resin composition can efficiently perform the primary filtration step and the secondary filtration step continuously.

[0114] The method for producing a resin composition according to this embodiment includes a melt-kneading process in which the raw materials of the resin composition are melt-kneaded, and a filtration process in which the melt-kneaded mixture is filtered using a filtration device. The filtration device has a supply port for supplying the mixture and a filter having a filtration surface. The filtration process includes a primary filtration process in which the mixture is first filtered, and a secondary filtration process in which the mixture that has undergone primary filtration is filtered using a filter with finer mesh than that of the primary filtration process. At least one of the filtration devices for performing the secondary filtration process has an expanded flow path from the supply port toward the filtration surface, thereby making it possible to obtain a molded product with relatively excellent surface impact strength.

[0115] [Pellet manufacturing method] The method for producing pellets according to the present embodiment includes a pelletizing step in which the resin composition obtained by the method for producing a resin composition described above is extruded by an extruder to obtain pellets. More specifically, in the method for producing pellets, the resin composition described above may be extruded through a die hole of the extruder to extrude a strand. The obtained strand may be guided to a cooling water tank and cooled. Furthermore, the cooled strand may be cut by a strand cutter to obtain pellets.

[0116] The method for producing the pellets includes a pelletizing step in which the resin composition obtained by the method for producing the resin composition described above is extruded by an extruder to obtain pellets, and the obtained pellets can be used to obtain a molded product having excellent surface impact strength.

[0117] [Resin composition] The resin composition according to the present embodiment can be obtained by the above-mentioned method for producing a resin composition. By obtaining the resin composition by the above-mentioned method for producing a resin composition, a molded article having excellent dart impact strength can be obtained by using the resin composition.

[0118] The resin composition obtained by the above-mentioned method for producing a resin composition can be molded, for example, by injection molding to obtain a molded article.

[0119] Examples of the injection molding method 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. The shape of the injection molded article is not particularly limited. The injection molded article can be used, for example, for automotive materials, home appliance materials, and containers, and is preferably used for automotive interior and exterior applications.

[0120] The present invention includes the following aspects. [1] A melt-kneading step of melt-kneading raw materials of a resin composition; A filtration step of filtering the melt-kneaded mixture using a filtering device, The filtering device includes a supply port for supplying the kneaded material and a filter having a filtering surface, The filtration step includes a primary filtration step of first filtering the kneaded mixture, and a secondary filtration step of filtering the kneaded mixture that has been subjected to the primary filtration using a filter having finer openings than that of the primary filtration step, A method for producing a resin composition, wherein at least one of the filtration devices performing the secondary filtration step has a flow path that expands from the supply port toward the filtration surface. [2] In the filtration device, when the volume of the space from the supply port to the filtration surface is V, the area of ​​the filtration surface is S, and the area of ​​the supply port is A, The method for producing a resin composition according to [1], wherein at least one of the filtration devices performing the secondary filtration step has a V / S of less than 1 cm and an S / A of 20 or more. [3] The method for producing a resin composition according to [1] or [2], wherein a raw material of the resin composition contains a propylene-based polymer. [4] The method for producing a resin composition according to [3], wherein the raw material of the resin composition contains a heterophasic propylene polymerization material as the propylene-based polymer. [5] The method for producing a resin composition according to any one of [1] to [4], wherein in the filtration step, a booster pump is provided between a filtration device performing the primary filtration step and a filtration device performing the secondary filtration step. [6] The method for producing a resin composition according to any one of [1] to [5], wherein the filter in the filtration device performing the primary filtration step has a filter opening of 70 μm or more, and the filter in the filtration device performing the secondary filtration step has a filter opening of 10 μm or more and 60 μm or less. [7] In at least one of the filtration devices performing the secondary filtration step, the ratio of the area of ​​the filtration surface to the amount of the kneaded material fed is 0.1 cm 2 ·hr / kg or more 0.4cm 2 The method for producing a resin composition according to any one of [1] to [6], wherein the resin composition is produced in a temperature range of 100° C. to 300° C. [8] The method for producing a resin composition according to any one of [1] to [7], wherein the raw material of the resin composition is a crushed material. [9] The method for producing a resin composition according to [8], wherein the raw material of the resin composition further contains a virgin propylene-based polymer.

[10] The method for producing a resin composition according to [8], wherein the raw material of the resin composition further contains an ethylene-α-olefin copolymer.

[11] The method for producing a resin composition according to

[10] , wherein the raw material of the resin composition contains a recycled ethylene-α-olefin copolymer as the ethylene-α-olefin copolymer.

[12] A method for producing pellets, comprising a pelletizing step of extruding, with an extruder, a resin composition obtained by the method for producing a resin composition according to any one of [1] to

[11] to obtain pellets.

[13] A resin composition obtained by the method for producing a resin composition according to any one of [1] to

[11] . EXAMPLES

[0121] The present invention will be described in more detail below with reference to examples, although the present invention is not limited to these examples.

[0122] In the examples and comparative examples, the following raw materials were used. Sample 1 (Examples 1 and 2, Comparative Example 1): Automobile pillar material crushed to under 15 mm (resin composition containing a propylene-based polymer) Sample 2 (Examples 3 and 4, Comparative Example 2): Automobile bumper material crushed to under 15 mm (resin composition containing a propylene-based polymer)

[0123] (Examples 1, 3, and 4) The sample was fed to a single screw extruder at a total feed rate of 450 kg / hr and melted at a cylinder temperature of 200°C. Next, the molten sample was filtered through a first stage filter (set temperature 200°C) connected to the tip of the extruder (primary filtration process), passed through a screw pump, and filtered through a second stage filter (secondary filtration process), passed through a diverter valve, and passed through a die connected downstream of the diverter valve to an underwater cut type granulation unit, where it was granulated and cooled to solidify.

[0124] Details of each filter are shown below, where S is the area of ​​the filtration surface, A is the area of ​​the supply port, and V is the volume of the space from the supply port to the filtration surface. 1st stage filter: S=1200cm 2 , A=1200cm 2 , V=37000cm 3 , filter aperture 80μm Second stage filter: S=1480cm 2 , A=19.6cm 2 , V=560cm 3 , filter aperture 20 or 40 μm

[0125] Example 2 The sample filtered using the first stage filter (primary filtration step) described above was fed to a 35 mm single screw extruder at a total feed rate of 20 kg / hr and melted at a cylinder temperature of 200°C. Next, the molten sample was fed to a filter (S = 100 cm) connected to the tip of the extruder. 2 , A=4.9cm 2 , V=30cm 3 The resin was filtered through a filter (20 μm mesh) (secondary filtration step), and then the strand-shaped resin was cooled in a strand bath and granulated using a pelletizer.

[0126] (Comparative Examples 1 and 2) The sample was fed to a 40 mm single screw extruder at a total feed rate of 10 kg / hr and melted at a cylinder temperature of 200° C. The molten sample was then passed through a mesh filter (S=12.5 cm ) connected to the tip of the extruder. 2 , A=12.5cm 2 , V=50cm 3 The first filtration was performed using a mesh filter (80 μm mesh size), and the strand-shaped resin was cooled in a strand bath and pelletized using a pelletizer. After that, the mesh size of the above-mentioned mesh filter was changed to 10 μm, and the second filtration was performed.

[0127] <Production of injection molded products for puncture impact test evaluation> The pellet-shaped resin compositions obtained in each Example and Comparative Example were injection molded under the following conditions within the range specified in JIS K7152 to produce injection molded articles for puncture impact test evaluation. The resin compositions melted in an injection molding machine were supplied from the gate into the mold cavity using a small square plate type D12 mold specified in JIS K7139 by the injection molding machine. Injection molding machine: SE130DU manufactured by Sumitomo Heavy Industries, Ltd. Cylinder temperature: 197℃ Mold temperature: 40℃ Injection speed: 13.5mm / sec Cooling time: 8 seconds Molding cycle: 60 seconds Injection molded body: Type D12 flat plate (length 60 mm x width 60 mm x thickness 2 mm)

[0128] <Evaluation of puncture impact test> The puncture energy (unit: J) of the obtained flat plate-like molded body was measured under the following conditions using a HITS-P10 manufactured by Shimadzu Science East Japan Co., Ltd. Striker diameter: 1 / 2 inch Holder diameter: 1.5 inches Measurement speed: 2.8m / sec Measurement temperature: 23℃, -30℃ Measurement value: Calculate the average value of N=6

[0129] [Table 1]

[0130] As can be seen from the results in Table 1, the molded bodies obtained by the manufacturing methods of each embodiment that satisfy all of the constituent requirements of the present invention have excellent dart impact strength, and in particular, have excellent dart impact strength in an environment of -30°C, which is representative of cold regions.

Claims

1. A melt-kneading step of melt-kneading raw materials of a resin composition; A filtration step of filtering the melt-kneaded mixture using a filtering device, The filtering device includes a supply port for supplying the kneaded material and a filter having a filtering surface, The filtration step includes a primary filtration step of first filtering the kneaded mixture, and a secondary filtration step of filtering the kneaded mixture that has been subjected to the primary filtration using a filter having finer openings than that of the primary filtration step, At least one of the filtration devices performing the secondary filtration step has a flow path expanding from the supply port toward the filtration surface, In the filtration device, when the volume of the space from the supply port to the filtration surface is V, the area of ​​the filtration surface is S, and the area of ​​the supply port is A, A method for producing a resin composition, wherein at least one of the filtration devices performing the secondary filtration step has a V / S of less than 1 cm and an S / A of 20 or more.

2. The method for producing a resin composition according to claim 1 , wherein a raw material of the resin composition contains a propylene-based polymer.

3. The method for producing a resin composition according to claim 2 , wherein the raw material of the resin composition contains a heterophasic propylene polymer material as the propylene-based polymer.

4. The method for producing a resin composition according to claim 1 , wherein in the filtration step, a booster pump is provided between a filtration device performing the primary filtration step and a filtration device performing the secondary filtration step.

5. The filter opening in the filtration device performing the primary filtration step is 70 μm or more, The method for producing a resin composition according to claim 1, wherein the mesh size of the filter in the filtering device for performing the secondary filtration step is 10 μm or more and 60 μm or less.

6. In at least one of the filtration devices performing the secondary filtration step, the ratio of the area of ​​the filtration surface to the amount of the kneaded material fed is 0.1 cm ２ ・HR / kg or more 0.4cm ２ hr / kg or less.

7. The method for producing a resin composition according to claim 1 , wherein the raw material of the resin composition is a crushed material.

8. The method for producing a resin composition according to claim 7, wherein the raw material of the resin composition further contains a virgin propylene-based polymer.

9. The method for producing a resin composition according to claim 7, wherein the raw material of the resin composition further contains an ethylene-α-olefin copolymer.

10. The method for producing a resin composition according to claim 9, wherein the raw material of the resin composition contains a recycled ethylene-α-olefin copolymer as the ethylene-α-olefin copolymer.

11. A method for producing pellets, comprising a pelletizing step of extruding the resin composition obtained by the method for producing a resin composition according to any one of claims 1 to 10 with an extruder to obtain pellets.

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