Masterbatch, resin composition, molded article, and methods for producing the same

Abstract

Provided are a molded article having excellent antibacterial and antiviral activities and a method for producing the same with good processability, a masterbatch which makes it possible to provide the molded article and the production method, a thermoplastic resin composition, and methods for producing the same. More specifically, provided are: a masterbatch which contains an antibacterial / antiviral agent which is at least one selected from the group consisting of a fatty acid metal salt, a metal complex of a hetero-atom-containing ligand and a metal ion, and a metal complex of a hetero-atom-containing ligand and a fatty acid metal salt, wherein the metal in each of the fatty acid metal salt, the metal complex of a hetero-atom-containing compound ligand and a metal ion, and the metal complex of a hetero-atom-containing compound ligand and a fatty acid metal salt is independently a lanthanoid, bismuth, manganese, magnesium, lead, yttrium, cobalt, or copper; a resin composition prepared by melt-kneading the masterbatch with a thermoplastic resin; a molded article produced by melt-molding the resin composition; and methods for producing the same.

Description

[Technical Field]

[0001] The present disclosure relates to a masterbatch, a resin composition, a molded article, and methods for producing the same. [Background technology]

[0002] The spread of COVID-19 has rapidly increased public awareness of hygiene. There is also a growing global need for antibacterial and antiviral properties in everyday products to reduce the risk of infection from pathogens and viruses. For example, surfaces such as smartphone exteriors, smartphone touchscreens, handrails, doorknobs, sinks, elevator buttons, and the interiors of public transportation are expected to be used multiple times a day, so there is a strong demand for antibacterial and antiviral properties.

[0003] As an antibacterial and antiviral agent, a silver-supported substance, in particular silver-supported zirconium phosphate, is known (for example, Patent Document 1), and it is known that it is used by being blended with plastics such as polyester and polystyrene. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] International Publication No. 2005 / 037296 Summary of the Invention [Problem to be solved by the invention]

[0005] However, silver-loaded particles have room for improvement in terms of compatibility with thermoplastic resins, and they do not maintain sufficient transparency when melt-kneaded to form a resin composition. Furthermore, particle aggregation can cause defects in the appearance of molded products, and filter pressure rises during melt processing, potentially reducing processability. As a result, shear heating occurs during kneading with the particles, which accelerates material degradation and potentially leads to poor processability and reduced physical properties.

[0006] Therefore, the problem to be solved by the present invention is to provide a molded article having excellent antibacterial properties, antiviral properties, transparency, and surface appearance, a thermoplastic resin composition capable of providing the molded article and having excellent processability, and a method for producing them.A second problem to be solved by the present invention is to provide a masterbatch capable of providing the thermoplastic resin composition and a method for producing the same. [Means for solving the problem]

[0007] As a result of intensive research to solve the above-mentioned problems, the present inventors have found that a thermoplastic resin composition containing a specific fatty acid metal salt or metal complex can provide a molded article having excellent antibacterial properties, antiviral properties, transparency, and surface appearance. The present inventors have also found that a thermoplastic resin composition produced using a masterbatch containing a thermoplastic resin and ...

[0008] That is, [1] The present disclosure provides a masterbatch containing a thermoplastic resin and an antibacterial and antiviral agent, the antibacterial and antiviral agent is contained in an amount of 0.03 to 90 parts by mass per 100 parts by mass of the total of the thermoplastic resin and the antibacterial and antiviral agent in the masterbatch, or the content of the metal derived from the antibacterial and antiviral agent is contained in an amount of 0.0015 to 45 parts by mass per 100 parts by mass of the total of the thermoplastic resin and the antibacterial and antiviral agent in the masterbatch; The present invention relates to a masterbatch characterized in that the antibacterial and antiviral agent is one or more selected from the group consisting of a fatty acid metal salt, a metal complex of a heteroatom-containing ligand and a metal ion, and a metal complex of a heteroatom-containing ligand and a fatty acid metal salt, and the metals in the fatty acid metal salt, the metal complex of a heteroatom-containing compound ligand and a metal ion, and the metal complex of a heteroatom-containing compound ligand and a fatty acid metal salt are each independently a lanthanoid, bismuth, manganese, magnesium, lead, yttrium, cobalt, or copper.

[0009] The present disclosure also provides a masterbatch containing a thermoplastic resin and an antibacterial and antiviral agent, the antibacterial and antiviral agent is contained in an amount of 0.03 to 90 parts by mass per 100 parts by mass of the total of the thermoplastic resin and the antibacterial and antiviral agent in the masterbatch; The antibacterial and antiviral agent may be one or more selected from the group consisting of a fatty acid metal salt, a metal complex of a heteroatom-containing ligand and a metal ion, and a metal complex of a heteroatom-containing ligand and a fatty acid metal salt, and the metals in the fatty acid metal salt, the metal complex of a heteroatom-containing compound ligand and a metal ion, and the metal complex of a heteroatom-containing compound ligand and a fatty acid metal salt may each independently be a lanthanoid, bismuth, manganese, magnesium, lead, yttrium, cobalt, or copper.

[0010] The present disclosure also provides a masterbatch containing a thermoplastic resin and an antibacterial and antiviral agent, the content of the metal derived from the antibacterial and antiviral agent is in the range of 0.0015 to 45 parts by mass per 100 parts by mass of the thermoplastic resin and the antibacterial and antiviral agent in the masterbatch; The antibacterial and antiviral agent may be one or more selected from the group consisting of a fatty acid metal salt, a metal complex of a heteroatom-containing ligand and a metal ion, and a metal complex of a heteroatom-containing ligand and a fatty acid metal salt, and the metals in the fatty acid metal salt, the metal complex of a heteroatom-containing compound ligand and a metal ion, and the metal complex of a heteroatom-containing compound ligand and a fatty acid metal salt may each independently be a lanthanoid, bismuth, manganese, magnesium, lead, yttrium, cobalt, or copper.

[0011] [2] The present disclosure relates to the masterbatch according to [1], wherein the metal of the fatty acid metal salt, the metal of the metal complex of the heteroatom-containing compound ligand and a metal ion, and the metal of the metal complex of the heteroatom-containing compound ligand and a fatty acid metal salt are each independently a lanthanoid, bismuth, manganese, or magnesium.

[0012] [3] The present disclosure relates to the masterbatch according to any one of [1] and [2], wherein the fatty acid metal salt is a metal salt of a fatty acid having 2 to 31 carbon atoms.

[0013] [4] The present disclosure relates to the masterbatch according to any one of [1] to [3], wherein the fatty acid metal salt is a metal salt of capric acid, lauric acid, myristic acid, palmitic acid, stearic acid, arachidic acid, behenic acid, lignoceric acid, cerotic acid, montanic acid, or melissic acid.

[0014] [5] The present disclosure relates to the masterbatch according to any one of [1] to [5], wherein the heteroatom-containing ligand is one or more amine ligands selected from picolinic acid, 2-{[(2-dimethylamino)ethyl]methylamino}ethanol, 1,2-propanediamine, 1,2-cyclohexanediamine, monoethanolamine, diethanolamine, triethanolamine, imidazole, 1-methylimidazole, 2-methylimidazole, 4-methylimidazole, 2,4-dimethylimidazole, 1,4-diethylimidazole, 8-quinolinol, 5-chloro-8-quinolinol, 2,2'-bipyridyl and derivatives thereof, and 2,2'-[propane-1,2-diylbis(azanylylidenemethanylylidene)]diphenol and derivatives thereof.

[0015] [6] The present disclosure provides a method for producing a masterbatch, comprising a step of blending and melt-kneading a thermoplastic resin and an antibacterial and antiviral agent, blending the antibacterial and antiviral agent in an amount within the range of 0.03 to 90 parts by mass per 100 parts by mass of the total of the thermoplastic resin and the antibacterial and antiviral agent in the masterbatch, or blending the antibacterial and antiviral agent so that the content of metals derived from the antibacterial and antiviral agent is within the range of 0.0015 to 45 parts by mass per 100 parts by mass of the thermoplastic resin and the antibacterial and antiviral agent in the masterbatch; The present invention relates to a method for producing a masterbatch, wherein the antibacterial and antiviral agent is one or more selected from the group consisting of a fatty acid metal salt, a metal complex of a heteroatom-containing ligand and a metal ion, and a metal complex of a heteroatom-containing ligand and a fatty acid metal salt, and the metals in the fatty acid metal salt, the metal complex of a heteroatom-containing compound ligand and a metal ion, and the metal complex of a heteroatom-containing compound ligand and a fatty acid metal salt are each independently a lanthanoid, bismuth, manganese, magnesium, lead, yttrium, cobalt, or copper.

[0016] The present disclosure also provides a method for producing a masterbatch, the method comprising a step of blending and melt-kneading a thermoplastic resin and an antibacterial and antiviral agent, the content of the antibacterial and antiviral agent is in the range of 0.03 to 90 parts by mass per 100 parts by mass of the total of the thermoplastic resin and the antibacterial and antiviral agent in the masterbatch; The antibacterial and antiviral agent may be one or more selected from the group consisting of a fatty acid metal salt, a metal complex of a heteroatom-containing ligand and a metal ion, and a metal complex of a heteroatom-containing ligand and a fatty acid metal salt, and the metals in the fatty acid metal salt, the metal complex of a heteroatom-containing compound ligand and a metal ion, and the metal complex of a heteroatom-containing compound ligand and a fatty acid metal salt may each independently be a lanthanoid, bismuth, manganese, magnesium, lead, yttrium, cobalt, or copper.

[0017] The present disclosure also provides a method for producing a masterbatch, the method comprising a step of blending and melt-kneading a thermoplastic resin and an antibacterial and antiviral agent, the antibacterial and antiviral agent is blended so that the content of the metal derived from the antibacterial and antiviral agent is in the range of 0.0015 to 45 parts by mass per 100 parts by mass of the thermoplastic resin and the antibacterial and antiviral agent in the masterbatch; The antibacterial and antiviral agent may be one or more selected from the group consisting of a fatty acid metal salt, a metal complex of a heteroatom-containing ligand and a metal ion, and a metal complex of a heteroatom-containing ligand and a fatty acid metal salt, and the metals in the fatty acid metal salt, the metal complex of a heteroatom-containing compound ligand and a metal ion, and the metal complex of a heteroatom-containing compound ligand and a fatty acid metal salt may each independently be a lanthanoid, bismuth, manganese, magnesium, lead, yttrium, cobalt, or copper.

[0018] [7] The present disclosure provides a thermoplastic resin composition containing a thermoplastic resin and an antibacterial and antiviral agent, the thermoplastic resin composition contains an antibacterial and antiviral agent in an amount of 0.01 to 30 parts by mass relative to a total of 100 parts by mass of the thermoplastic resin and the antibacterial and antiviral agent in the thermoplastic resin composition, or contains an antibacterial and antiviral agent so that the content of metals derived from the antibacterial and antiviral agent is in a range of 0.0005 to 15 parts by mass relative to a total of 100 parts by mass of the thermoplastic resin and the antibacterial and antiviral agent in the thermoplastic resin composition; The thermoplastic resin composition is characterized in that the antibacterial and antiviral agent is one or more selected from the group consisting of a fatty acid metal salt, a metal complex of a heteroatom-containing ligand and a metal ion, and a metal complex of a heteroatom-containing ligand and a fatty acid metal salt, and the metals in the fatty acid metal salt, the metal complex of a heteroatom-containing compound ligand and a metal ion, and the metal complex of a heteroatom-containing compound ligand and a fatty acid metal salt are each independently a lanthanoid, bismuth, manganese, magnesium, lead, yttrium, cobalt, or copper.

[0019] The present disclosure provides a thermoplastic resin composition containing a thermoplastic resin and an antibacterial and antiviral agent, the antibacterial and antiviral agent is contained in an amount of 0.01 to 30 parts by mass per 100 parts by mass of the total of the thermoplastic resin and the antibacterial and antiviral agent in the thermoplastic resin composition; The antibacterial and antiviral agent may be one or more selected from the group consisting of a fatty acid metal salt, a metal complex of a heteroatom-containing ligand and a metal ion, and a metal complex of a heteroatom-containing ligand and a fatty acid metal salt, and the metals in the fatty acid metal salt, the metal complex of a heteroatom-containing compound ligand and a metal ion, and the metal complex of a heteroatom-containing compound ligand and a fatty acid metal salt may each independently be a lanthanoid, bismuth, manganese, magnesium, lead, yttrium, cobalt, or copper.

[0020] The present disclosure also provides a thermoplastic resin composition containing a thermoplastic resin and an antibacterial and antiviral agent, the content of the metal derived from the antibacterial and antiviral agent is in the range of 0.0005 to 15 parts by mass per 100 parts by mass of the thermoplastic resin and the antibacterial and antiviral agent in the thermoplastic resin composition; The antibacterial and antiviral agent may be one or more selected from the group consisting of a fatty acid metal salt, a metal complex of a heteroatom-containing ligand and a metal ion, and a metal complex of a heteroatom-containing ligand and a fatty acid metal salt, and the metals in the fatty acid metal salt, the metal complex of a heteroatom-containing compound ligand and a metal ion, and the metal complex of a heteroatom-containing compound ligand and a fatty acid metal salt may each independently be a lanthanoid, bismuth, manganese, magnesium, lead, yttrium, cobalt, or copper.

[0021] [8] The present disclosure also provides a method for producing a thermoplastic resin composition, comprising the step of blending a thermoplastic resin as a diluent resin with the masterbatch according to any one of [1] to [5] above, and melt-kneading the blend, The present invention relates to a method for producing a thermoplastic resin composition, characterized by blending a masterbatch and a diluent resin so that the antibacterial and antiviral agent is present in an amount ranging from 0.01 to 30 parts by mass per 100 parts by mass of the thermoplastic resin, antibacterial and antiviral agent, and diluent resin in the masterbatch combined, or blending a masterbatch and a diluent resin so that the content of metals derived from the antibacterial and antiviral agent is in the range of 0.0005 to 15 parts by mass per 100 parts by mass of the thermoplastic resin, antibacterial and antiviral agent, and diluent resin in the masterbatch combined.

[0022] The present disclosure also provides a method for producing a thermoplastic resin composition, the method comprising the steps of blending a thermoplastic resin as a diluent resin with the masterbatch according to any one of [1] to [5] above, and melt-kneading the blend, The masterbatch and the diluent resin may be blended together so that the antibacterial and antiviral agent is in a range of 0.01 to 30 parts by mass per 100 parts by mass of the total of the thermoplastic resin and antibacterial and antiviral agent in the masterbatch and the diluent resin.

[0023] The present disclosure also provides a method for producing a thermoplastic resin composition, the method comprising the steps of blending a thermoplastic resin as a diluent resin with the masterbatch according to any one of [1] to [5] above, and melt-kneading the blend, The masterbatch and the diluent resin may be blended so that the content of the metal derived from the antibacterial and antiviral agent is in the range of 0.0005 to 15 parts by mass per 100 parts by mass of the total of the thermoplastic resin and antibacterial and antiviral agent in the masterbatch and the diluent resin.

[0024] [9] The present disclosure also provides a method for producing a thermoplastic resin composition, comprising a step of blending and melt-kneading a thermoplastic resin and an antibacterial and antiviral agent, blending the antibacterial and antiviral agent in an amount within a range of 0.01 to 30 parts by mass per 100 parts by mass of the total of the thermoplastic resin and the antibacterial and antiviral agent in the thermoplastic resin composition, or blending the thermoplastic resin and the antibacterial and antiviral agent so that the content of the metal derived from the antibacterial and antiviral agent is within a range of 0.0005 to 15 parts by mass per 100 parts by mass of the total of the thermoplastic resin and the antibacterial and antiviral agent in the thermoplastic resin composition; The present invention relates to a method for producing a thermoplastic resin composition, wherein the antibacterial and antiviral agent is at least one selected from the group consisting of a fatty acid metal salt, a metal complex of a heteroatom-containing ligand and a metal ion, and a metal complex of a heteroatom-containing ligand and a fatty acid metal salt, and the metals in the fatty acid metal salt, the metal complex of a heteroatom-containing compound ligand and a metal ion, and the metal complex of a heteroatom-containing compound ligand and a fatty acid metal salt are each independently a lanthanoid, bismuth, manganese, magnesium, lead, yttrium, cobalt, or copper.

[0025] The present disclosure also provides a method for producing a thermoplastic resin composition, the method comprising a step of blending and melt-kneading a thermoplastic resin and an antibacterial and antiviral agent, blending the antibacterial and antiviral agent in an amount of 0.01 to 30 parts by mass per 100 parts by mass of the total of the thermoplastic resin and the antibacterial and antiviral agent in the thermoplastic resin composition; The antibacterial and antiviral agent may be one or more selected from the group consisting of a fatty acid metal salt, a metal complex of a heteroatom-containing ligand and a metal ion, and a metal complex of a heteroatom-containing ligand and a fatty acid metal salt, and the metals in the fatty acid metal salt, the metal complex of a heteroatom-containing compound ligand and a metal ion, and the metal complex of a heteroatom-containing compound ligand and a fatty acid metal salt may each independently be a lanthanoid, bismuth, manganese, magnesium, lead, yttrium, cobalt, or copper.

[0026] The present disclosure also provides a method for producing a thermoplastic resin composition, the method comprising a step of blending and melt-kneading a thermoplastic resin and an antibacterial and antiviral agent, blending a thermoplastic resin and an antibacterial and antiviral agent so that the content of the metal derived from the antibacterial and antiviral agent is in the range of 0.0005 to 15 parts by mass per 100 parts by mass of the total of the thermoplastic resin and the antibacterial and antiviral agent in the thermoplastic resin composition; The antibacterial and antiviral agent may be one or more selected from the group consisting of a fatty acid metal salt, a metal complex of a heteroatom-containing ligand and a metal ion, and a metal complex of a heteroatom-containing ligand and a fatty acid metal salt, and the metals in the fatty acid metal salt, the metal complex of a heteroatom-containing compound ligand and a metal ion, and the metal complex of a heteroatom-containing compound ligand and a fatty acid metal salt may each independently be a lanthanoid, bismuth, manganese, magnesium, lead, yttrium, cobalt, or copper.

[0027]

[10] The present disclosure relates to a molded article obtained by molding the thermoplastic resin composition described in [7] above.

[0028]

[11] The present disclosure relates to a method for producing a molded article, which includes a step of melt-molding the resin composition described in [7] above. [Effects of the Invention]

[0029] According to the present disclosure, it is possible to provide a molded article having excellent antibacterial properties, antiviral properties, transparency, and surface appearance, a thermoplastic resin composition capable of providing the molded article and having excellent processability, and a method for producing the same. Furthermore, according to the present disclosure, it is possible to provide a masterbatch capable of providing the thermoplastic resin composition and a method for producing the same. DETAILED DESCRIPTION OF THE INVENTION

[0030] ·Thermoplastic resin The thermoplastic resin used in the present disclosure is not particularly limited as long as it does not impair the effects of the present disclosure, and examples thereof include polyolefin resins, polycarbonate resins, polystyrene resins, acrylic resins, polyoxymethylene resins, polyester resins, vinyl chloride resins, cycloolefin polymers (COP), and thermoplastic elastomers. The thermoplastic resin used in the present disclosure may be a single type, or a mixture of two or more types. When two or more types are mixed, it is preferable to use a combination of resins that are highly compatible with each other.

[0031] The polyolefin resin is a polyolefin resin obtained by polymerizing at least one kind of olefin, and may be a homopolymer or a copolymer. Examples of such olefins include α-olefins having 4 to 12 carbon atoms, including ethylene, propylene, isobutylene, and isobutene (1-butene), butadiene, isoprene, (meth)acrylic acid esters, (meth)acrylic acid, (meth)acrylamide, vinyl alcohol, vinyl acetate, vinyl chloride, styrene, and acrylonitrile.

[0032] Examples of the α-olefins having 4 to 12 carbon atoms include 1-butene, 2-methyl-1-propene, 2-methyl-1-butene, 3-methyl-1-butene, 1-hexene, 2-ethyl-1-butene, 2,3-dimethyl-1-butene, 2-methyl-1-pentene, 3-methyl-1-pentene, 4-methyl-1-pentene, 3,3-dimethyl-1-butene, 1-heptene, methyl-1-hexene, and dimethyl 1-pentene, ethyl-1-pentene, trimethyl-1-butene, methylethyl-1-butene, 1-octene, methyl-1-pentene, ethyl-1-hexene, dimethyl-1-hexene, propyl-1-heptene, methylethyl-1-heptene, trimethyl-1-pentene, propyl-1-pentene, diethyl-1-butene, 1-nonene, 1-decene, 1-undecene, 1-dodecene, and the like.

[0033] The polyolefin resin is not particularly limited, but examples thereof include polyethylene resin, polypropylene resin, polymethylpentene resin, polyisobutylene resin, polyisobutene resin, polyisoprene resin, polybutadiene resin, etc. Among these resins, polyethylene resin, polypropylene resin, and polymethylpentene resin are preferred.

[0034] When classified by density or shape, examples include high-density polyethylene (HDPE), low-density polyethylene (LDPE), very-low-density polyethylene (VLDPE), linear low-density polyethylene (LLDPE), and ultra-high-molecular-weight polyethylene (UHMW-PE), of which high-density polyethylene, linear low-density polyethylene, and low-density polyethylene are preferred.

[0035] Examples of polycarbonate resins include polycarbonate (PC), etc. Examples of polystyrene resins include polystyrene (PS), imide-modified polystyrene, acrylonitrile-butadiene-styrene (ABS) resin, imide-modified ABS resin, styrene-acrylonitrile copolymer (SAN) resin, and acrylonitrile-ethylene-propylene-diene-styrene (AES) resin.

[0036] Examples of acrylic resins include polyacrylic acid, polymethacrylic acid, polymethyl acrylate, polymethyl methacrylate (PMMA), polyethyl methacrylate, etc. Examples of polyoxymethylene resins include polyoxymethylene (POM), etc. Examples of polyester resins include aromatic polyester resins such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), polyethylene naphthalate (PEN), and polybutylene naphthalate.

[0037] Examples of vinyl chloride resins include polyvinyl chloride (PVC), vinyl chloride-vinyl acetate copolymer resin, etc. Examples of thermoplastic elastomers include polyurethane thermoplastic elastomers, polyester thermoplastic elastomers, styrene thermoplastic elastomers, olefin thermoplastic elastomers, etc.

[0038] Antibacterial and antiviral agents The antibacterial and antiviral agent used in the present disclosure is one or more selected from the group consisting of fatty acid metal salts, metal complexes of heteroatom-containing ligands and metal ions, and metal complexes of heteroatom-containing ligands and fatty acid metal salts, wherein the metals in the fatty acid metal salts, the metal complexes of heteroatom-containing compound ligands and metal ions, and the metal complexes of heteroatom-containing compound ligands and fatty acid metal salts are each independently lanthanoid, bismuth, manganese, magnesium, lead, yttrium, cobalt, or copper.

[0039] The antibacterial and antiviral agent used in the present disclosure takes the form of a fatty acid metal salt or metal complex, and due to the antibacterial and antiviral properties of the metal and the high compatibility of the fatty acid or complex ligand with organic substances, when blended with a thermoplastic resin, it is thought that the antibacterial and antiviral properties are imparted to the resulting thermoplastic resin composition while at the same time reducing the impact on appearance of a molded product, such as loss of transparency, caused by the antibacterial and antiviral agent.

[0040] In the present disclosure, "antibacterial" means an effect of reducing the number of bacteria, an effect of suppressing the growth of the number of bacteria, etc. Similarly, in the present disclosure, "antiviral" means an effect of reducing the number of viruses, an effect of inactivating viruses, an effect of reducing the infectivity of viruses, etc. In the present disclosure, "antibacterial and antiviral agent" means a substance that exerts "antibacterial" and "antiviral" effects.

[0041] In the present disclosure, the target bacteria for antibacterial treatment are not particularly limited and may be either bacteria or fungi. Examples of bacteria include gram-negative bacteria such as Escherichia coli, Pseudomonas aeruginosa, Salmonella, Moraxella, and Legionella; and gram-positive bacteria such as Staphylococcus aureus and Clostridium bacteria. Examples of fungi include yeasts such as Candida, Rhodotorula, and baker's yeast; and molds such as red mold and black mold.

[0042] In the present disclosure, the viruses to be treated against are not particularly limited, and may be any of known enveloped viruses (viruses with an envelope) and non-enveloped viruses (viruses without an envelope).

[0043] Examples of the enveloped viruses include coronavirus, influenza virus, rubella virus, Ebola virus, measles virus, varicella-zoster virus, herpes virus, mumps virus, arbovirus, respiratory syncytial virus, SARS virus, hepatitis virus (e.g., hepatitis A virus, hepatitis B virus, hepatitis C virus, hepatitis D virus, hepatitis E virus, etc.), yellow fever virus, AIDS virus, rabies virus, hantavirus, dengue virus, Nipah virus, and lyssavirus.

[0044] Examples of the non-enveloped viruses include adenovirus, norovirus, rotavirus, human papillomavirus, poliovirus, enterovirus, coxsackievirus, human parvovirus, encephalomyocarditis virus, polyomavirus, BK virus, rhinovirus, and feline calicivirus.

[0045] The antibacterial and antiviral agents used in the present disclosure will be described below.

[0046] (Fatty acid metal salts) The antibacterial and antiviral agent used in the present disclosure may be a fatty acid metal salt. The fatty acid metal salt is a metal salt of a fatty acid, and the metals constituting the metal salt may each independently be lanthanoid, bismuth, manganese, magnesium, lead, yttrium, cobalt, or copper. Lanthanoids are elements belonging to Group 3A of the periodic table, and are a collective term for 15 elements with atomic numbers 57 to 71, i.e., lanthanum to lutetium. Among these metals, lanthanoids, bismuth, and magnesium are preferred from the viewpoint of making it difficult for coloration to occur due to the addition of an antibacterial and antiviral agent. Of the lanthanoids, lanthanum, praseodymium, neodymium, samarium, and gadolinium are particularly preferred.

[0047] Preferably, the fatty acid has 2 to 31 carbon atoms. The fatty acid may have a linear, branched, or alicyclic structure.

[0048] The fatty acid having 2 to 31 carbon atoms has a carboxy group (COOH) and a fatty acid residue (carboxylic acid residue) having 1 to 30 carbon atoms. Examples of such fatty acids include saturated fatty acids and unsaturated fatty acids. More specifically, examples of saturated fatty acids include saturated fatty acids with a straight chain structure such as acetic acid, propionic acid, butanoic acid, pentanoic acid, capric acid, lauric acid, myristic acid, palmitic acid, stearic acid, arachidic acid, behenic acid, lignoceric acid, cerotic acid, montanic acid, and melissic acid, and saturated fatty acids with a branched or alicyclic structure such as octylic acid (2-ethylhexanoic acid), neodecanoic acid, isostearic acid, naphthenic acid, and isononanoic acid. Examples of unsaturated fatty acids include monounsaturated fatty acids such as acrylic acid, methacrylic acid, palmitoleic acid, oleic acid, elaidic acid, paccenic acid, and erucic acid, and polyunsaturated fatty acids derived from vegetable oils such as tung oil acid, tall oil fatty acid, coconut oil fatty acid, soybean oil fatty acid, linseed oil fatty acid, safflower oil fatty acid, dehydrated castor oil fatty acid, and tung oil fatty acid.

[0049] Of the fatty acids having 2 to 31 carbon atoms, from the viewpoint of ease of handling the compound and the ability to suppress thermal degradation such as burning and scorching of the agent when processed into a masterbatch or pellets of a thermoplastic resin composition, as well as the resulting contamination with foreign matter (hereinafter referred to as "thermal degradation suppression"), more preferred are fatty acids having 11 to 31 carbon atoms, and most preferred are capric acid, lauric acid, myristic acid, palmitic acid, stearic acid, arachidic acid, behenic acid, lignoceric acid, cerotic acid, montanic acid, melissic acid, etc.

[0050] More specifically, the fatty acid metal salt used as the antibacterial and antiviral agent in the present disclosure is preferably, for example, a compound represented by the following general formula (1).

[0051] [ka] (In the general formula (1), R 1 is a hydrogen atom or a hydrocarbon group having 1 to 30 carbon atoms, n1 is an integer ranging from 1 to 4, M 1 is a lanthanide, bismuth, manganese, magnesium, lead, yttrium, cobalt, or copper.

[0052] In the general formula (1), when n1 is an integer of 2 or more, a plurality of R 1 may be the same as or different from each other.

[0053] R 1 The hydrocarbon group having 1 to 30 carbon atoms may be a straight-chain hydrocarbon group, a branched hydrocarbon group, or may contain an alicyclic structure.

[0054] R 1 The hydrocarbon group having 1 to 30 carbon atoms is R 1 It corresponds to a fatty acid residue (carboxylic acid residue) obtained by removing a carboxy group (COOH) from a carboxylic acid having 2 to 31 carbon atoms, represented by COOH. Therefore, examples of the fatty acid residue (carboxylic acid residue) include residues obtained by removing a carboxy group from the fatty acids listed above.

[0055] R 1 The hydrocarbon group having 1 to 30 carbon atoms is preferably an alkyl group having 10 to 30 carbon atoms, from the viewpoint of ease of handling the compound and of suppressing thermal degradation when processed into a masterbatch or pellets of the thermoplastic resin composition, and more preferably a capric acid residue, lauric acid residue, myristic acid residue, palmitic acid residue, stearic acid residue, arachidic acid residue, behenic acid residue, lignoceric acid residue, cerotic acid residue, montanic acid residue, melissic acid residue, or the like.

[0056] M 1 is a lanthanide, bismuth, manganese, magnesium, lead, yttrium, cobalt or copper.

[0057] n1 is M 1 is a value determined by the ionic valence of the metal atom, for example, M 1 If is neodymium, n1 is 3, and M 1If is cobalt, n1 is 2.

[0058] The fatty acid metal salt that is the antibacterial and antiviral agent of the present disclosure may also be in the form of a fatty acid metal borate, such as a compound represented by the following general formula (2):

[0059] [ka] (In the general formula (2), R 2 is a hydrogen atom or a hydrocarbon group having 1 to 30 carbon atoms, M 2 is a lanthanide, bismuth, manganese, magnesium, lead, yttrium, cobalt, or copper.

[0060] In the general formula (2), R 2 The hydrocarbon group having 1 to 30 carbon atoms is R 1 Similarly, in the general formula (2), M 2 The metal is M in the general formula (1). 1 It is the same as the metal.

[0061] When a fatty acid metal salt is used as the antibacterial and antiviral agent used in the present disclosure, one type of fatty acid metal salt may be used alone, or two or more types of fatty acid metal salts different in structure may be used.

[0062] The fatty acid metal salt can be produced by a known method, or a commercially available product may be used.

[0063] (metal complexes) The antibacterial and antiviral agents used in the present disclosure may be metal complexes of heteroatom-containing ligands and metal ions, and metal complexes of heteroatom-containing ligands and fatty acid metal salts, which may be compounds in which a metal ion or a fatty acid metal salt and a heteroatom-containing ligand form a complex via a coordinate bond.

[0064] The metal ion with which the heteroatom-containing ligand forms a metal complex can be the same metal ion as the metal in the fatty acid metal salt described as the antibacterial and antiviral agent used in the present disclosure. As the fatty acid metal salt in which the heteroatom-containing ligand forms a metal complex, the same fatty acid metal salts as those described as the antibacterial and antiviral agents used in the present disclosure can be used.

[0065] The heteroatom-containing ligand that forms the metal complex may be a ligand that contains one or more heteroatoms selected from the group consisting of nitrogen, oxygen, sulfur, and phosphorus in the molecule. Examples of such heteroatom-containing ligands include N-methylmorpholine, pyridine, 1,8-diazabicyclo[5.4.0]undecene-7 (DBU), 1,5-diazabicyclo[4.3.0]nonene-5 (DBN), 1,4-diazabicyclo[2.2.2]octane (DABCO), 4-dimethylaminoamine (DMAP), dicyandiamide (DICY), tri-n-butylamine, dimethylbenzylamine, butylamine, 1,2-propanediamine, 1,2-cyclohexanediamine, octylamine, monoethanolamine, diethanolamine, triethanolamine, 2-[[(2-dimethylamino)ethyl]methylamino]ethanol, picolinic acid, 2,2'-[propane-1,2-diylbis(azanylylidenemethanylylidene)]diphenoxyethanol alcohol, imidazole, 1-methylimidazole, 2-methylimidazole, 4-methylimidazole, 2,4-dimethylimidazole, 1,4-diethylimidazole, 3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, 3-(N-phenyl)aminopropyltrimethoxysilane, 3-(2-aminoethyl)aminopropyltrimethoxysilane, 3-(2-aminoethyl)aminopropylmethyldimethoxysilane, tetramethylammonium hydroxide, 8-quinolinol amine compounds such as 5-chloro-8-quinolinol, 2,2'-bipyridyl and its derivatives, 2,2'-[propane-1,2-diylbis(azanylylidenemethanylylidene)]diphenol and its derivatives, and 2,2'-methylenebis[6-(2h-benzotriazol-2-yl)-4-tert-octylphenol]; quaternary ammonium salts such as trioctylmethylammonium chloride and trioctylmethylammonium acetate; phosphine compounds such as trimethylphosphine, tributylphosphine, and triphenylphosphine; phosphonium salts such as tetramethylphosphonium chloride, tetraethylphosphonium chloride, tetrapropylphosphonium chloride, tetrabutylphosphonium chloride, tetrabutylphosphonium bromide, trimethyl(2-hydroxypropyl)phosphonium chloride, triphenylphosphonium chloride, and benzylphosphonium chloride; and sulfur-based compounds such as thiolactic acid, 2-aminothiophenol, and 2,2'-dithiodianiline.

[0066] The heteroatom-containing ligand is preferably one or more amine ligands selected from picolinic acid, 2-{[(2-dimethylamino)ethyl]methylamino}ethanol, 1,2-propanediamine, 1,2-cyclohexanediamine, monoethanolamine, diethanolamine, triethanolamine, imidazole, 1-methylimidazole, 2-methylimidazole, 4-methylimidazole, 2,4-dimethylimidazole, 1,4-diethylimidazole, 8-quinolinol, 5-chloro-8-quinolinol, 2,2′-bipyridyl and its derivatives, and 2,2′-[propane-1,2-diylbis(azanylylidenemethanylylidene)]diphenol and its derivatives.

[0067] The heteroatom-containing ligand that forms the metal complex may be of one type alone or of two or more types that are different in structure from each other.

[0068] In the metal complex, the ratio (molar ratio) of the metal ion or fatty acid metal salt to the heteroatom-containing ligand is, for example, in the range of 0.1 to 12 moles, preferably 0.3 to 10 moles, and more preferably 0.5 to 10 moles, of the heteroatom-containing ligand per mole of the metal atom of the metal ion or fatty acid metal salt.

[0069] The melting points of the fatty acid metal salt, the metal complex of the heteroatom-containing compound ligand and a metal ion, and the metal complex of the heteroatom-containing compound ligand and a fatty acid metal salt contained in the antibacterial and antiviral agent used in the present disclosure are not particularly limited, but from the viewpoint of ease of handling the compounds and suppression of thermal degradation when processed into master batches or pellets of the thermoplastic resin composition, they are preferably solid in the working environment (0°C to 45°C), more preferably have a melting point of 50°C or higher, even more preferably 60°C or higher, and particularly preferably 70°C or higher. The upper limit is not particularly limited, but may be 250°C or lower.

[0070] The content of the fatty acid metal salt, the metal complex of the heteroatom-containing compound ligand and a metal ion, and the metal derived from the metal complex of the heteroatom-containing compound ligand and a fatty acid metal salt (hereinafter sometimes referred to as the "metal derived from the antibacterial and antiviral agent" or simply as the "metal") contained in the antibacterial and antiviral agent used in the present disclosure is not particularly limited, but is preferably 5 parts by mass or more, more preferably 7.5 parts by mass or more, and particularly preferably 10 parts by mass or more, relative to 100 parts by mass of the antibacterial and antiviral agent. The content is also preferably 50 parts by mass or less, more preferably 40 parts by mass or less, and even more preferably 30 parts by mass or less.

[0071] The antibacterial and antiviral agent used in the present disclosure is preferably a water-insoluble antibacterial and antiviral agent. Because the antibacterial and antiviral agent is water-insoluble, it has excellent durability of antibacterial and antiviral properties even when exposed to water such as rain. In the present application, "water-insoluble" means that the amount of water required to dissolve 1 g of the antibacterial and antiviral agent at 20°C is 10 ml or more.

[0072] The antibacterial and antiviral agents, such as a metal complex of a heteroatom-containing ligand and a metal ion, and a metal complex of a heteroatom-containing ligand and a fatty acid metal salt, can be produced by a known method, such as by reacting a metal or a fatty acid metal salt with a heteroatom-containing ligand. Furthermore, commercially available metal complexes may also be used.

[0073] Masterbatch (Masterbatch) The masterbatch of the present disclosure contains a thermoplastic resin and an antibacterial and antiviral agent. The masterbatch of the present disclosure contains an antibacterial and antiviral agent in a range of 0.03 to 90 parts by mass per 100 parts by mass of the thermoplastic resin and antibacterial and antiviral agent in the masterbatch combined, or contains the antibacterial and antiviral agent so that the content of metals derived from the antibacterial and antiviral agent is in a range of 0.0015 to 45 parts by mass per 100 parts by mass of the thermoplastic resin and antibacterial and antiviral agent in the masterbatch combined.

[0074] More specifically, the compositional ratio of the thermoplastic resin and antibacterial and antiviral agent contained in the masterbatch of the present disclosure is preferably 0.03 parts by mass or more, more preferably 0.15 parts by mass or more, and even more preferably 0.3 parts by mass or more, per 100 parts by mass of the thermoplastic resin and antibacterial and antiviral agent in the masterbatch in total, from the viewpoint of imparting excellent dispersibility and antiviral properties to a molded article obtained via the masterbatch, but, taking into consideration the suppression of thermal degradation during processing into the masterbatch and cost benefits during transportation, is preferably 90 parts by mass or less, more preferably 75 parts by mass or less, and even more preferably 60 parts by mass or less.

[0075] The content of the metal derived from the antibacterial and antiviral agent contained in the masterbatch of the present disclosure is not particularly limited, but can be calculated taking into account the content of the metal contained in the antibacterial and antiviral agent and the composition ratio of the antibacterial and antiviral agent contained in the masterbatch. That is, per 100 parts by mass of the total of the thermoplastic resin and antibacterial and antiviral agent contained in the masterbatch, the content of the metal is preferably 0.0015 parts by mass or more, more preferably 0.0075 parts by mass or more, even more preferably 0.015 parts by mass or more, and preferably 45 parts by mass or less, more preferably 37.5 parts by mass or less, and even more preferably 30 parts by mass or less. When the content of the metal contained in the masterbatch is within the above range, excellent dispersibility, transparency, and antibacterial and antiviral properties can be imparted to a molded article obtained via the masterbatch.

[0076] In addition to the thermoplastic resin and antibacterial and antiviral agent components described above, the masterbatch of the present disclosure may also contain various known additives as optional components within a range that does not impair the effects of the present disclosure. Examples of optional additives include antiblocking agents such as silica, flame retardants such as halogen-based flame retardants, nitrogen-based flame retardants, phosphate ester-based flame retardants, inorganic flame retardants such as metal hydroxides and oxides, and silicone-based flame retardants, antioxidants such as hindered phenol compounds, hydroquinone compounds, phosphite compounds, and their substituted derivatives, weather resistance agents such as resorcinol compounds, salicylate compounds, benzotriazole compounds, benzophenone compounds, and hindered amine compounds, release agents or lubricants such as aliphatic alcohols, aliphatic amides, aliphatic bisamides, bis-urea compounds, and polyethylene wax, pigments such as phthalocyanine and carbon black, dyes such as nigrosine and aniline black, talc, silica, kaolin, and chlorine. Examples of suitable fillers include crystal nucleating agents such as acrylate, plasticizers such as octyl p-oxybenzoate and N-butylbenzenesulfonamide, antistatic agents such as alkyl sulfate-type anionic antistatic agents, quaternary ammonium salt-type cationic antistatic agents, nonionic antistatic agents such as polyoxyethylene sorbitan monostearate, and betaine-type amphoteric antistatic agents, various particulate, needle-like, and plate-like fillers such as graphite, barium sulfate, magnesium sulfate, calcium carbonate, magnesium carbonate, antimony oxide, aluminum oxide, zinc oxide, iron oxide, zinc sulfide, zinc, lead, nickel, aluminum, iron, stainless steel, bentonite, montmorillonite, and synthetic mica, and reinforcing materials such as glass fiber, glass flakes, carbon fiber, boron nitride, potassium titanate, and aluminum borate.

[0077] When various additives are added as optional components, their compositional ratios are not particularly limited as long as they do not impair the effects of the present disclosure. However, by adjusting the types and amounts of these additives, preferably within a range of 0.01 parts by mass or more and 300 parts by mass or less relative to 100 parts by mass of the thermoplastic resin and antibacterial and antiviral agent in the masterbatch in total, the desired functions can be freely adjusted.

[0078] (Masterbatch manufacturing method) The method for producing a masterbatch according to the present disclosure includes a step of blending a thermoplastic resin and an antibacterial and antiviral agent as essential components, followed by melt-kneading.

[0079] The method for producing a masterbatch according to the present disclosure comprises blending an antibacterial and antiviral agent in an amount ranging from 0.03 to 90 parts by mass per 100 parts by mass of the thermoplastic resin and antibacterial and antiviral agent in the masterbatch together, or blending an antibacterial and antiviral agent so that the content of metals derived from the antibacterial and antiviral agent is in the range of 0.0015 to 45 parts by mass per 100 parts by mass of the thermoplastic resin and antibacterial and antiviral agent in the masterbatch together.

[0080] More specifically, when producing the masterbatch of the present disclosure, the blending ratio may be adjusted and blended so that the antibacterial and antiviral agent is preferably 0.03 parts by mass or more, more preferably 0.15 parts by mass or more, and even more preferably 0.3 parts by mass or more, relative to 100 parts by mass of the thermoplastic resin and antibacterial and antiviral agent in the masterbatch combined, and preferably 90 parts by mass or less, more preferably 75 parts by mass or less, and even more preferably 60 parts by mass or less.

[0081] Although the content of the metal contained in the masterbatch of the present disclosure is not particularly limited, the antibacterial and antiviral agent can be blended in consideration of the content of the metal contained in the antibacterial and antiviral agent and the composition ratio of the antibacterial and antiviral agent contained in the masterbatch. That is, the thermoplastic resin and the antibacterial and antiviral agent can be blended so that the content of the metal is preferably 0.0015 parts by mass or more, more preferably 0.0075 parts by mass or more, and even more preferably 0.015 parts by mass or more, and preferably 45 parts by mass or less, more preferably 37.5 parts by mass or less, and even more preferably 30 parts by mass or less, relative to 100 parts by mass of the thermoplastic resin and antibacterial and antiviral agent contained in the masterbatch combined.

[0082] More specifically, the above-mentioned components are premixed as needed using a mixer such as a V-type blender, ribbon blender, or Henschel mixer, and then melt-kneaded using a known mixer such as a single-screw extrusion mixer, open roll mixer, pressure kneader, Banbury mixer, or twin-screw extrusion mixer, with the resin set temperature set to the melting point or higher. Among these, twin-screw extrusion mixers are preferred in terms of kneading ability and productivity. After melt-kneading, the masterbatch of the present disclosure is obtained by processing the mixture into pellets or the like using a conventional method.

[0083] ·Thermoplastic resin composition (Thermoplastic resin composition) The thermoplastic resin composition of the present disclosure contains a thermoplastic resin and an antibacterial and antiviral agent. The thermoplastic resin composition of the present disclosure contains an antibacterial and antiviral agent in a range of 0.01 to 30 parts by mass per 100 parts by mass of the thermoplastic resin and the antibacterial and antiviral agent combined, or contains the antibacterial and antiviral agent such that the content of metals derived from the antibacterial and antiviral agent is in a range of 0.0005 to 15 parts by mass per 100 parts by mass of the thermoplastic resin and the antibacterial and antiviral agent combined in the thermoplastic resin composition.

[0084] More specifically, from the viewpoint of imparting excellent dispersibility and antiviral properties to a molded article obtained using the thermoplastic resin composition of the present disclosure, the compositional ratio of the antibacterial and antiviral agent contained in the thermoplastic resin composition of the present disclosure is preferably in the range of 0.01 parts by mass or more, more preferably 0.05 parts by mass or more, and even more preferably 0.1 parts by mass or more, to preferably 30 parts by mass or less, more preferably 25 parts by mass or less, and even more preferably 20 parts by mass or less, per 100 parts by mass of the thermoplastic resin and antibacterial and antiviral agent in the thermoplastic resin composition combined.

[0085] The content of the metal derived from the antibacterial and antiviral agent contained in the thermoplastic resin composition of the present disclosure is not particularly limited, but can be calculated taking into account the content of the metal contained in the antibacterial and antiviral agent and the composition ratio of the antibacterial and antiviral agent contained in the thermoplastic resin composition. That is, per 100 parts by mass of the total of the thermoplastic resin and the antibacterial and antiviral agent contained in the thermoplastic resin composition, the content of the metal is preferably 0.0005 parts by mass or more, more preferably 0.0025 parts by mass or more, even more preferably 0.005 parts by mass or more, and preferably 15 parts by mass or less, more preferably 12.5 parts by mass or less, and even more preferably 10 parts by mass or less. When the content of the metal contained in the thermoplastic resin composition is within the above range, the final molded article obtained can be imparted with excellent dispersibility, transparency, and antibacterial and antiviral properties.

[0086] (Method of producing thermoplastic resin composition) The method for producing a thermoplastic resin composition according to the present disclosure includes a step of blending the masterbatch with a thermoplastic resin for dilution (hereinafter sometimes referred to as a "diluent resin") and melt-kneading the blend. By obtaining a thermoplastic resin composition via a masterbatch in this manner, the antibacterial and antiviral agent can be stably and uniformly dispersed and can also be added at a high concentration, thereby imparting excellent antibacterial and antiviral effects to a molded article.

[0087] The thermoplastic resin in the masterbatch and the thermoplastic resin in the diluent resin used in the present disclosure may be the same type of resin or different types of resin depending on the purpose, but it is preferable to use the same type of resin from the viewpoint of compatibility.

[0088] The method for producing a thermoplastic resin composition according to the present disclosure comprises blending an antibacterial and antiviral agent in an amount ranging from 0.01 to 30 parts by mass relative to a total of 100 parts by mass of the thermoplastic resin and the antibacterial and antiviral agent, or blending an antibacterial and antiviral agent so that the content of metals derived from the antibacterial and antiviral agent is in the range of 0.0005 to 15 parts by mass relative to a total of 100 parts by mass of the thermoplastic resin and the antibacterial and antiviral agent in the thermoplastic resin composition.

[0089] More specifically, when producing a thermoplastic resin composition of the present disclosure from the masterbatch of the present disclosure, the blending ratio may be, for example, such that the masterbatch of the present disclosure and a diluent resin are prepared and blended such that the amount of the antibacterial and antiviral agent is preferably 0.01 part by mass or more, more preferably 0.05 parts by mass or more, and even more preferably 0.1 part by mass or more, and preferably 30 parts by mass or less, more preferably 25 parts by mass or less, and even more preferably 20 parts by mass or less, per 100 parts by mass of the thermoplastic resin and antibacterial and antiviral agent in the masterbatch and the diluent resin combined.

[0090] The metal content in the thermoplastic resin composition of the present disclosure is not particularly limited, but the masterbatch and diluent resin may be blended in consideration of the metal content in the antibacterial and antiviral agent and the composition ratio of the antibacterial and antiviral agent in the thermoplastic resin composition. That is, the masterbatch and diluent resin may be blended so that the metal content is preferably 0.0005 parts by mass or more, more preferably 0.0025 parts by mass or more, and even more preferably 0.005 parts by mass or more, and preferably 15 parts by mass or less, more preferably 12.5 parts by mass or less, and even more preferably 10 parts by mass or less, per 100 parts by mass of the thermoplastic resin, antibacterial and antiviral agent, and diluent resin in the masterbatch combined.

[0091] Note that, as described above, the thermoplastic resin composition of the present disclosure is preferably produced by blending and melt-kneading the masterbatch of the present disclosure with a diluent resin, because this allows the antibacterial and antiviral agent to be stably and uniformly dispersed, enables the agent to be added at a high concentration, and imparts excellent transparency and surface appearance to a molded article; however, the composition can also be produced without using a masterbatch.

[0092] That is, when a thermoplastic resin composition is produced without using a masterbatch, the method for producing the thermoplastic resin composition of the present disclosure includes a step of blending and melt-kneading a thermoplastic resin and an antibacterial and antiviral agent as raw materials to a predetermined compositional ratio. When a thermoplastic resin composition of the present disclosure is produced without using a masterbatch, the blending ratio may be, for example, adjusted and blended so that the antibacterial and antiviral agent is preferably 0.01 parts by mass or more, more preferably 0.05 parts by mass or more, even more preferably 0.1 parts by mass or more, and preferably 30 parts by mass or less, more preferably 25 parts by mass or less, and even more preferably 20 parts by mass or less, per 100 parts by mass of the thermoplastic resin and the antibacterial and antiviral agent in the thermoplastic resin composition combined. Furthermore, the thermoplastic resin and the antibacterial and antiviral agent can be blended in consideration of the metal content in the antibacterial and antiviral agent and the compositional ratio of the antibacterial and antiviral agent in the thermoplastic resin composition. That is, the thermoplastic resin and the antibacterial and antiviral agent may be blended so that the content of the metal is preferably 0.0005 part by mass or more, more preferably 0.0025 part by mass or more, even more preferably 0.005 part by mass or more, and preferably 15 parts by mass or less, more preferably 12.5 parts by mass or less, and even more preferably 10 parts by mass or less, relative to a total of 100 parts by mass of the thermoplastic resin and the antibacterial and antiviral agent in the thermoplastic resin composition.

[0093] In the method for producing a thermoplastic resin composition according to the present disclosure, the melt-kneading method is not particularly limited, and for example, the same method as in the method for producing the masterbatch can be adopted. The thermoplastic resin composition obtained by melt-kneading can then be temporarily processed into pellets or the like according to a conventional method.

[0094] In addition to the thermoplastic resin and antibacterial and antiviral agent components described above, the thermoplastic resin composition of the present disclosure may also contain various known additives as optional components within a range that does not impair the effects of the present disclosure. Examples of the various additives to be added as optional components include the same additives as those that can be added to the above-mentioned polymer masterbatch. Among these, from the viewpoint of suppressing blocking, it is preferable to further add an antiblocking agent such as silica.

[0095] When various additives are added as optional components, their composition ratios are not particularly limited as long as they do not impair the effects of the present disclosure, but the desired function can be freely adjusted by adjusting the types and amounts of these additives, preferably within a range of 0.01 to 300 parts by mass per 100 parts by mass of the thermoplastic resin and the antibacterial and antiviral agent in the thermoplastic resin composition. For example, when an antiblocking agent is further added, it is preferably added in an amount of 0.01 to 3 parts by mass per 100 parts by mass of the thermoplastic resin and the antibacterial and antiviral agent in the thermoplastic resin composition.

[0096] Molded body (Molded body) The molded article of the present disclosure has excellent antiviral and antibacterial properties and can be used in applications requiring these activities. Therefore, the molded article of the present disclosure is suitable for applications such as films, sheets, fibers, and tubes. It can also be laminated to form multilayer films or sheets, or woven fabrics. It can also be used in known molding processes such as injection molding, compression molding, extrusion molding, pultrusion molding, blow molding, and transfer molding. Furthermore, it is possible to form three-dimensional objects using fused deposition modeling (FDM), stereolithography (STL), selective laser sintering (SLS), inkjet printing, inkjet powder lamination, and the like. For example, a molding material based on the resin composition of the present disclosure can be melted at a temperature above the melting temperature of the resin, and the molten molding material can be extruded from a nozzle in a head unit to form a shape. Multiple layers of this material can be stacked to form a three-dimensional object.

[0097] The fabric may be in any form, such as woven fabric, knitted fabric, nonwoven fabric, etc. Furthermore, if necessary, the fabric may be colored with disperse dyes, acid dyes, direct dyes, reactive dyes, pigments, etc. The fabric of the present disclosure can be used in a variety of textile products, including, for example, clothing for general use, innerwear, sports, medical use, etc., bedding materials such as futon covers and sheets, interior goods such as curtains, carpets, chairs, cushion covers, and wallpaper, industrial materials such as tent sheets, flags, and curtains, sheet materials for transportation vehicles such as automobiles, aircraft, and railway vehicles, sanitary materials, textile materials for air treatment, and textile materials for water treatment.

[0098] Furthermore, the molded articles can be processed and used in products that are likely to be touched by human hands, such as food packaging containers, bathtubs, building materials, and housings for cash registers, personal computers, and smartphones. They can also be used in medical applications, particularly stents, coil obturators, catheter tubes, syringes (needles and bodies), shunt tubes, drain tubes, and implanted medical devices.

[0099] The diameter (number average fiber diameter) of the fibers obtained by melt spinning the resin composition of the present disclosure varies depending on the application and can be any diameter. However, since smaller fiber diameters result in better antiviral activity, the diameter is preferably 100 μm or less, more preferably 40 μm or less, even more preferably 20 μm or less, and particularly preferably 10 μm or less. The lower limit is not limited, but is preferably 0.01 μm or more, more preferably 0.1 μm or more, and even more preferably 1 μm or more. Of these, ultrafine fibers such as fibers in the range of 8 μm or less (referred to as microfibers in the present disclosure) are particularly preferred because they tend to have a large surface area and therefore high antiviral activity. The fiber length is also not limited, and may be a long fiber length, so-called filament (long fiber), or a short fiber length, so-called staple (short fiber).

[0100] Furthermore, the thickness of the sheet or film obtained by molding the resin composition of the present disclosure into a sheet or film varies depending on the application and can be any thickness, but is preferably 1 μm or more, more preferably 3 μm or more, even more preferably 5 μm or more, particularly preferably 10 μm or more, and preferably 200 μm or less, more preferably 150 μm or less. The terms "sheet" and "film" used in this disclosure are not intended to strictly distinguish between sheets and films, but are used to clarify that they include both. As long as they have the characteristics of the present disclosure, the terms "sheet" and "film" can be interpreted as broadly as possible, and the term "sheet" also includes what is referred to as a plate or board, as long as they have the characteristics of the present disclosure. However, if it is necessary to distinguish between sheets and films, within the above range, "sheet" is typically used when the thickness exceeds about 0.5 mm, and "film" is typically used when the thickness is up to about 500 μm.

[0101] Molded articles obtained by melt-molding the resin composition of the present disclosure, in particular films, sheets, or fibers molded into a sheet, film, or fiber, are produced by first masterbatching the antibacterial and antiviral agent with a thermoplastic resin and then blending a dilution resin to produce a thermoplastic resin composition and a molded article thereof. This allows the antibacterial and antiviral agent to be stably dispersed at a high concentration and with good uniformity. As a result, not only are excellent antiviral and antibacterial activities exhibited, but these effects can also be prolonged, resulting in significantly improved washability, safety to the human body, heat resistance, weather resistance, and water resistance. Furthermore, the generation of coarse particles (lumps) is suppressed, and by increasing the specific surface area of ​​the antibacterial and antiviral agent particles, the activity of the particle surfaces can be effectively utilized while improving the surface appearance and surface smoothness of the particle molded article. Furthermore, tearing of the film or sheet is suppressed, and thread breakage of the fiber can be suppressed.

[0102] (Method of manufacturing a molded body) The method for producing a molded article of the present disclosure includes a step of feeding the thermoplastic resin composition, either directly as a molten product or after being processed into pellets or the like by a conventional method, to a melt molding machine and melt-mixing or melt-kneading the resin at a set temperature above the melting point. The thermoplastic resin composition molten in the melt molding machine is then molded into a molded article using various known molding methods such as extrusion molding, injection molding, calendar molding, blow molding, vacuum molding, pressure molding, melt spinning, sheet molding, and film molding. [Example]

[0103] The present disclosure will be described in more detail below based on examples, but the present disclosure is not limited to these examples.

[0104] (Synthesis Example 1) Preparation of fatty acid metal salt (Nd) 224.8 parts by mass of neodecanoic acid and 60.0 parts by mass of neodymium oxide were reacted at 130°C, followed by dehydration under reduced pressure at 130°C. 306.9 parts by mass of cyclohexane was added to obtain 570.0 parts by mass of a neodymium neodecanoate solution. The solvent from the obtained solution was distilled off at 130°C to obtain neodymium neodecanoate (sometimes referred to as "fatty acid metal salt (Nd)"). The neodymium content in the obtained neodymium neodecanoate was 18.7% by mass. The obtained neodymium neodecanoate had a melting point below -30°C (not solid at 0 to 45°C). The melting point was measured using a DSC6220 (trade name) manufactured by SII Nano Technology Co., Ltd. 10 mg of the sample was weighed into an aluminum container, and the temperature was measured at a heating rate of 10°C / min over a range of -30 to 200°C, where the temperature was the apex of the melting peak.

[0105] (Synthesis Example 2) Preparation of fatty acid metal salt (Bi) 330.6 parts by mass of 2-ethylhexanoic acid and 125.0 parts by mass of bismuth oxide were reacted at 130°C, and after dehydration under reduced pressure at 130°C, 439.5 parts by mass of a bismuth 2-ethylhexanoate solution (sometimes referred to as "fatty acid metal salt (Bi)") was obtained. The bismuth content in the obtained fatty acid metal salt (Bi) was 25% by mass. The melting point of the bismuth 2-ethylhexanoate in the fatty acid metal salt (Bi) was less than -30°C (not solid at 0 to 45°C).

[0106] (Synthesis Example 3) Preparation of fatty acid metal salt (La) A flask was charged with 862.3 parts by mass of distilled water, 100.0 parts by mass of stearic acid, and 72.5 parts by mass of 20% caustic soda. After saponification at 90°C for 30 minutes, 97.0 parts by mass of an aqueous lanthanum chloride solution was added and the mixture was allowed to react at 90°C for 1 hour. The by-product, Glauber's salt (sodium sulfate), was removed by filtration while washing with water. The residue on the filter paper was recovered and then dried at 150°C for 3 hours to obtain 104.8 parts by mass of lanthanum stearate (sometimes referred to as "fatty acid metal salt (La)"). The lanthanum content in the resulting fatty acid metal salt (La) was 13.6% by mass. The melting point of lanthanum stearate was 120°C.

[0107] (Production Example 1) A polyethylene resin ("Petrothene" manufactured by Tosoh Corporation, hereinafter abbreviated as "PE resin") and the fatty acid metal salt (Nd) prepared in Synthesis Example 1 were blended so that the metal content was 3.0 mass%, and the mixture was melt-kneaded (set temperature 160°C) in a twin-screw kneader ("TEM" manufactured by Shibaura Machine Co., Ltd.) to obtain a melt. The obtained melt was extruded in the form of strands and pelletized to obtain a masterbatch (1).

[0108] (Production Example 2) A masterbatch (2) was obtained in the same manner as in Production Example 1, except that the fatty acid metal salt (Bi) prepared in Synthesis Example 2 was used instead of the fatty acid metal salt (Nd) prepared in Synthesis Example 1.

[0109] (Production Example 3) A masterbatch (3) was obtained in the same manner as in Production Example 1, except that the fatty acid metal salt (La) prepared in Synthesis Example 3 was used instead of the fatty acid metal salt (Nd) prepared in Synthesis Example 1.

[0110] (Production Example 4) Masterbatch (4) was obtained in the same manner as in Production Example 1, except for two points: "polyethylene terephthalate (MA-2101M manufactured by Unitika Ltd., intrinsic viscosity (IV) 0.63), hereinafter abbreviated as "PET resin")" was used instead of "polyethylene resin (Petrothene manufactured by Tosoh Corporation), and the set temperature of the melt kneading was changed from 160°C to 280°C.

[0111] (Comparative Manufacturing Example 1) A comparative masterbatch (c1) was obtained in the same manner as in Production Example 1, except that "silver-supported zirconium phosphate (Novalon IV1000, manufactured by Toa Gosei Co., Ltd., silver ion content 10 wt%)" was added instead of "the fatty acid metal salt (Nd) prepared in Synthesis Example 1."

[0112] (Comparative Manufacturing Example 2) A comparative masterbatch (c2) was obtained in the same manner as in Production Example 1, except that the "fatty acid metal salt (Nd) prepared in Synthesis Example 1" was not added.

[0113] (Comparative Manufacturing Example 3) A comparative masterbatch (c3) was obtained in the same manner as in Production Example 4, except that the "fatty acid metal salt (Nd) prepared in Synthesis Example 1" was not added.

[0114] (Examples 1 to 3, Comparative Examples 1 and 2) Production of Film PE resin was dry-mixed as a diluent with masterbatches (1) to (3) and comparative masterbatches (c1) and (c2) so that the metal content in the film was 1 wt%, and then melt-mixed in a twin-screw kneader ("TEM" manufactured by Shibaura Machine Co., Ltd.) Next, melt film formation was carried out at a film formation temperature of 160°C using a 20 mm twin-screw extruder (manufactured by Toyo Seiki Co., Ltd., filter installed) connected to a 100 mm wide T-die, to obtain 100 μm films (1) to (3) and comparative films (c1) and (c2), respectively.

[0115] (Example 4, Comparative Example 3) Film (4) and comparative film (c3) were obtained in the same manner as in Examples 1 to 3 and Comparative Examples 1 and 2, except for three points: "Masterbatch (4)" was used instead of "Masterbatches (1) to (3) and comparative masterbatches (c1) and (c2)," "PET resin" was used instead of "PE resin" as the dilution resin, and the film formation temperature was changed from 160°C to 280°C.

[0116] Next, the resin films obtained in Examples 1 to 4 and Comparative Examples 1 to 3 were measured and evaluated by the following methods.

[0117] (Measurement example 1) Antibacterial property The film obtained above was subjected to an antibacterial test using Escherichia coli in accordance with JIS Z 2801. The test bacteria culture conditions for the sample were 35°C, 90% RH, and 24 hours. After the culture, the number of bacteria in the washed-out liquid was measured, and the antibacterial activity value was calculated according to the following formula.

[0118] Formula: Antibacterial activity value = log(1cm of untreated sample) 2 Number of viable bacteria after incubation per 1cm of antibacterial treated sample) - log( 2 (Number of viable bacteria after incubation per 100ml)

[0119] Evaluation criteria for antibacterial properties: If the antibacterial activity value is 2.0 or greater, the antibacterial property is evaluated as "Good." If the antibacterial activity value is 2.0 > 1.0, the antibacterial property is evaluated as "Average." If the antibacterial activity value is 1.0 or greater, the antibacterial property is evaluated as "Poor."

[0120] (Measurement example 2) Antiviral The film obtained above was subjected to an antiviral test using bacteriophage Qβ in accordance with JIS R 1756. The virus inoculation conditions for the sample were a dark place at 25°C for 4 hours. After the test, the infectivity titer of bacteriophage Qβ in the washed-out liquid was measured, and the antiviral activity value was calculated according to the following formula.

[0121] Formula: Antiviral activity value = log (infectivity value of untreated sample / infectivity value of antibacterial and antiviral treated sample) Antiviral evaluation: If the antiviral activity value is 2.0 or greater, the antiviral activity is evaluated as "Good." If the antiviral activity value is 2.0 > 1.0, the antiviral activity is evaluated as "Poor." If the antiviral activity value is 1.0 > 1.0, the antiviral activity is evaluated as "Poor."

[0122] (Measurement Example 3) Film Transparency The haze of the film obtained above was measured using a haze meter (manufactured by Nippon Denshoku Industries Co., Ltd., device name "NDH 7000II") and evaluated according to the following criteria. Transparency evaluation: If the haze value is less than +2.0% of the PE resin blank film (c2) or PET resin blank film (c3), the transparency is evaluated as "○". Similarly, if the value is +2.0% or more but less than +3.0%, the transparency is evaluated as "△". Similarly, if the value is +3.0% or more, the transparency is evaluated as "×".

[0123] (Measurement Example 4) Film processability (pressure increase) A 50 μm filter was installed in the twin-screw extruder during melt film formation, and the pressure rise when 1 kg of film was produced was evaluated according to the following criteria: The maximum pressure during film formation was read from a pressure gauge (gauge pressure) attached immediately upstream of the filter. Evaluation of pressure increase: "No pressure increase (but in the range of less than 0.5 MPa)" is marked as "○". "Pressure increase in the range of 0.5 to 2.0 MPa" is marked as "△". "Pressure increase in the range of more than 2.0 MPa" is marked as "×".

[0124] (Measurement Method 5) Film Surface Observation (Particles) Twenty randomly selected points on the film obtained above were observed under an optical microscope (magnification 200x) at a 100cm 2 The number of agglomerated particles (circle equivalent diameter) of 50 μm or more present per spot was counted, the number average per spot was calculated, and the surface appearance of the film was evaluated according to the following criteria. Evaluation of surface appearance: 3 or less marks are marked as "○", more than 3 marks to 6 marks or more are marked as "△", and more than 6 marks are marked as "×".

[0125] [Table 1]

[0126] [Table 2]

[0127] The film obtained in Comparative Example 1 had an antibacterial activity value of 2.0 or more (antibacterial), indicating that it had antibacterial properties, and an antiviral activity value of 2.0 or more (antiviral), indicating that it had antiviral properties. However, the film obtained in Comparative Example 1 had a haze value of +3.0% or more compared to the blank film, indicating that it had poor transparency. Furthermore, the film obtained in Comparative Example 1 had a pressure increase of approximately 3 MPa, indicating that it had poor film processability. Furthermore, both of the films obtained in Comparative Example 1 had the occurrence of bumps upon observation of their surfaces, indicating that they had poor surface appearance. On the other hand, the films obtained in Comparative Examples 2 and 3 both had antibacterial activity values ​​of 1.0 or less (no antibacterial properties), indicating that they did not have antibacterial properties, and antiviral activity values ​​of 1.0 or less (no antiviral properties), indicating that they did not have antiviral properties.

[0128] In contrast, the films obtained in Examples 1 to 4 had antibacterial activity values ​​of 2.0 or more (antibacterial), indicating antibacterial properties, and antiviral activity values ​​of 2.0 or more (antiviral), indicating antiviral properties. Furthermore, the films obtained in Examples 1 to 4 had haze values ​​within +2.0% of the blank film, indicating excellent transparency. Furthermore, all of the films obtained in Examples 1 to 4 could be formed without increasing pressure, indicating excellent film processability. Furthermore, surface observation of the films obtained in Examples 1 to 4 indicated that the occurrence of lumps was suppressed, indicating excellent surface appearance. Furthermore, masterbatch (3) in particular exhibited less thermal degradation during processing than masterbatches (1) and (2), and there was less burning and scorching of the agent, as well as less generation of foreign matter and decomposition gases thought to result from such burning and scorching.

[0129] As described above, it was revealed that the silver-loaded particles used in the comparative examples had insufficient compatibility with polyethylene resins and did not maintain sufficient transparency when melt-kneaded to form a resin composition. Furthermore, particle aggregation caused poor appearance in molded products, and filter pressure buildup during melt processing reduced processability. Therefore, kneading with the particles generated shear heat, which accelerated material degradation and potentially led to poor processability and a decline in physical properties. In contrast, the fatty acid metal salts or metal complexes used in Examples 1 to 4 were highly compatible with both polar and non-polar thermoplastic resins, such as polyethylene resin and PET resin, and maintained transparency as resin compositions after melt-kneading. Furthermore, they suppressed the generation of aggregation (particles) and prevented the generation of aggregates, resulting in nogglomerates and thus excellent molded product appearance. They also suppressed filter pressure buildup during processing, which in turn suppressed nozzle and die clogging, thereby reducing thread breakage, film rupture, and other problems. These results demonstrated excellent processability and improved productivity. It was also revealed that suppressing filter pressure buildup during processing reduced heat generation during molding, suppressed material degradation, and reduced physical property degradation.

Claims

1. A masterbatch containing a thermoplastic resin and an antibacterial and antiviral agent, the antibacterial and antiviral agent is contained in an amount of 0.03 to 90 parts by mass per 100 parts by mass of the total of the thermoplastic resin and the antibacterial and antiviral agent in the masterbatch, or the antibacterial and antiviral agent is contained so that the content of metal derived from the antibacterial and antiviral agent is in the range of 0.0015 to 45 parts by mass per 100 parts by mass of the thermoplastic resin and the antibacterial and antiviral agent in the masterbatch; The antibacterial and antiviral agent is a fatty acid metal salt, the fatty acid metal salt is a metal salt of a fatty acid having 2 to 31 carbon atoms; and A masterbatch characterized in that the metals in the fatty acid metal salts are each independently a lanthanoid, bismuth, or yttrium.

2. 2. The masterbatch according to claim 1, wherein the fatty acid metal salt is a metal salt of capric acid, lauric acid, myristic acid, palmitic acid, stearic acid, arachidic acid, behenic acid, lignoceric acid, cerotic acid, montanic acid, or melissic acid.

3. A method for producing a masterbatch, comprising a step of blending and melt-kneading a thermoplastic resin and an antibacterial and antiviral agent, blending the antibacterial and antiviral agent in an amount within the range of 0.03 to 90 parts by mass per 100 parts by mass of the total of the thermoplastic resin and the antibacterial and antiviral agent in the masterbatch, or blending the antibacterial and antiviral agent so that the content of metal derived from the antibacterial and antiviral agent is within the range of 0.0015 to 45 parts by mass per 100 parts by mass of the thermoplastic resin and the antibacterial and antiviral agent in the masterbatch; The antibacterial and antiviral agent is a fatty acid metal salt, the fatty acid metal salt is a metal salt of a fatty acid having 2 to 31 carbon atoms; and 10. A method for producing a masterbatch, wherein the metals in the fatty acid metal salts are each independently lanthanoid, bismuth, or yttrium.

4. A thermoplastic resin composition containing a thermoplastic resin and an antibacterial and antiviral agent, the thermoplastic resin composition contains an antibacterial and antiviral agent in an amount of 0.01 to 30 parts by mass per 100 parts by mass of the thermoplastic resin and the antibacterial and antiviral agent in total, or contains an antibacterial and antiviral agent so that the content of metal derived from the antibacterial and antiviral agent is in the range of 0.0005 to 15 parts by mass per 100 parts by mass of the thermoplastic resin and the antibacterial and antiviral agent in total, The antibacterial and antiviral agent is a fatty acid metal salt, the fatty acid metal salt is a metal salt of a fatty acid having 2 to 31 carbon atoms; and A thermoplastic resin composition, wherein the metals in the fatty acid metal salts are each independently a lanthanoid, bismuth, or yttrium.

5. A method for producing a thermoplastic resin composition, comprising a step of blending the masterbatch according to claim 1 with a thermoplastic resin as a diluent resin and melt-kneading the blend, A method for producing a thermoplastic resin composition, comprising blending a masterbatch and a diluent resin so that the antibacterial and antiviral agent is contained in an amount of 0.01 to 30 parts by mass per 100 parts by mass of the thermoplastic resin, antibacterial and antiviral agent, and diluent resin in the masterbatch combined; or blending the masterbatch and a diluent resin so that the content of metal derived from the antibacterial and antiviral agent is in the range of 0.0005 to 15 parts by mass per 100 parts by mass of the thermoplastic resin, antibacterial and antiviral agent, and diluent resin in the masterbatch combined.

6. A method for producing a thermoplastic resin composition, comprising a step of blending and melt-kneading a thermoplastic resin and an antibacterial and antiviral agent, blending an antibacterial and antiviral agent in an amount ranging from 0.01 to 30 parts by mass relative to a total of 100 parts by mass of the thermoplastic resin and the antibacterial and antiviral agent in the thermoplastic resin composition, or blending a thermoplastic resin and an antibacterial and antiviral agent so that the content of a metal derived from the antibacterial and antiviral agent is in a range of from 0.0005 to 15 parts by mass relative to a total of 100 parts by mass of the thermoplastic resin and the antibacterial and antiviral agent in the thermoplastic resin composition; The antibacterial and antiviral agent is a fatty acid metal salt, the fatty acid metal salt is a metal salt of a fatty acid having 2 to 31 carbon atoms; and A method for producing a thermoplastic resin composition, wherein the metals in the fatty acid metal salts are each independently lanthanoid, bismuth, or yttrium.

7. A molded article obtained by molding the thermoplastic resin composition according to claim 4.

8. A method for producing a molded article, comprising the step of melt-molding the resin composition according to claim 4.

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