Molded articles, methods for manufacturing the same, and recycling methods.

Abstract

To provide a molding which enables mass production while using a limited amount of an impact-resistant resin composition and a method for manufacturing the same, and a recycling method.SOLUTION: A molding 1 has a non-foamed design layer 11, a foamed intermediate layer 12, and a non-foamed rear face layer 13 laminated in this order, wherein each of the layers is formed of a first resin composition, a second resin composition and a third resin composition which contain polyolefin as a main component, the first resin composition is an impact-resistant resin composition containing polyolefin, polyamide, and a polyolefin-based modified elastomer having a reactive group to polyamide. A method for manufacturing a molding includes: an arrangement step of arranging a first support layer as a design layer and a third support layer as a rear face layer so as to face each other at an interval; an interposing step of interposing the second resin composition to which foamability is imparted in a gap between the first support layer and the third support layer; and an intermediate layer formation step of expanding the interval and forming an intermediate layer while foaming the second resin composition.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a molded body, a method for manufacturing the same, and a recycling method. More specifically, it relates to a molded body using a polyolefin-based recycled resin, a method for manufacturing the same, and a recycling method.

Background Art

[0002] Resin compositions imparted with impact resistance using polyolefin, polyamide, and a modified elastomer having a reactive group for polyamide are disclosed in Patent Documents 1 and 2 below. Further, a molded body and a manufacturing method using such a resin composition imparted with impact resistance as a recycling material are disclosed in Patent Document 3 below.

Prior Art Documents

Patent Documents

[0003] [[ID=ID=21]]

Patent Document 1

Patent Document 2

Patent Document 3

Summary of the Invention

Problems to be Solved by the Invention

[0004] Conventionally, a mixed resin, that is, a resin alloy, which is enhanced in performance by combining various resins and the like, has been used. Although a resin alloy can exhibit excellent performance, when it is to be reused, there is a problem that it is difficult to handle because its composition, properties, etc. are not constant. Therefore, in recent years, from the viewpoint of improving the recyclability of resin products, there has been an increasing demand for simplifying the resin types constituting resin products, that is, for single-materialization.

[0005] In this regard, the resin compositions disclosed in Patent Documents 1 and 2 are extremely superior materials from the viewpoint of resin performance and monomaterialization, as they can exhibit excellent impact resistance even at high polyolefin concentrations. Furthermore, it has been found that these resin compositions can be advantageously reused using the technology disclosed in Patent Document 3. However, the current production volume of this resin composition is limited, and the amount manufactured to date is also not large. Therefore, even if a polyolefin-based recycled resin is obtained using this resin composition, it is difficult to secure a sufficient quantity for mass production of the product.

[0006] This invention has been made in view of the above circumstances, and aims to provide a molded article that can be mass-produced using a limited amount of impact-resistant resin composition, a method for manufacturing the same, and a method for recycling the molded article, and further, to provide a recycling method that can utilize a polyolefin-based recycled resin composition while using a limited amount of impact-resistant resin composition. [Means for solving the problem]

[0007] In other words, the present invention includes the following: [1] A molded body comprising a non-foamed design layer, a foamed intermediate layer, and a non-foamed back layer, laminated in this order, The design layer, the intermediate layer, and the back layer are each formed from a first resin composition, a second resin composition, and a third resin composition, respectively, which mainly consist of polyolefin. The molded article is characterized in that the first resin composition is an impact-resistant resin composition comprising a polyolefin, a polyamide, and a polyolefin-based modified elastomer having a reactive group for the polyamide. [2] The molded article according to [1], wherein the intermediate layer is a core-back foamed layer in which the second resin composition is core-back foamed between the design layer and the back layer. [3] The second resin composition is a polyolefin-based recycled resin composition, as described in [1] or [2] above. [4] The molded article according to any one of [1] to [3] above, wherein the third resin composition is an impact-resistant resin composition comprising a polyolefin, a polyamide, and a polyolefin-based modified elastomer having a reactive group for the polyamide. [5] A method for manufacturing a molded article as described in any of [1] to [4] above, Arrangement step of arranging the first support layer which will be the design layer and the third support layer which will be the back surface layer at a distance from each other and facing each other, An interposition step involves interposing the second resin composition, which has been imparted with foaming properties, in the gap between the first support layer and the third support layer. A method for manufacturing a molded article, comprising: an intermediate layer forming step of expanding the gap while foaming the second resin composition to form the intermediate layer. [6] A method for recycling polyolefin resin compositions, A placement step of arranging a first support layer formed from a first resin composition containing a polyolefin, a polyamide, and a polyolefin-based modified elastomer having a reactive group for the polyamide, and a third support layer formed from a third resin composition mainly composed of polyolefin, spaced apart and facing each other. An interposition step involves interposing a polyolefin-based recycled resin composition that has been imparted with foaming properties in the gap between the first support layer and the third support layer, The process involves an intermediate layer formation step, in which the polyolefin-based recycled resin composition is foamed while the gap is expanded to form an intermediate layer, A method for recycling a polyolefin resin composition, characterized by obtaining a molded article comprising a non-foamed design layer consisting of the first support layer, a foamed intermediate layer, and a non-foamed back layer consisting of the third support layer, laminated in this order. [7] A method for recycling a molded article as described in any of [1] to [4] above, A method for recycling a molded article, characterized by comprising a subdivision step of subdividing the molded article to obtain a polyolefin-based recycled resin. [Effects of the Invention]

[0008] According to the present invention, the molded article can be mass-produced using a limited amount of impact-resistant resin composition. According to the method for manufacturing molded articles of the present invention, it is possible to mass-produce molded articles using a limited amount of impact-resistant resin composition. According to the recycling method for molded articles of the present invention, the molded articles of the present invention can be usefully utilized as polyolefin-based recycled resins. According to the recycling method using the molded article of the present invention, the molded article of the present invention can be utilized as a polyolefin-based recycled resin. According to the recycling method using the polyolefin-based recycled resin composition of the present invention, it is possible to mass-produce molded articles using a limited amount of impact-resistant resin composition and the polyolefin-based recycled resin composition. [Brief explanation of the drawing]

[0009] [Figure 1] This is an explanatory diagram illustrating an example of a molded product. [Figure 2] This is an explanatory diagram illustrating another example of a molded body. [Figure 3] This is an explanatory diagram illustrating variations in molded products. [Figure 4] This is an explanatory diagram illustrating the placement process in the manufacturing and recycling methods of molded products. [Figure 5] This is an explanatory diagram illustrating the intermediary confirmation and intermediate layer formation processes in the manufacturing method and recycling method of molded products. [Modes for carrying out the invention]

[0010] The matters presented herein are illustrative and illustrative to illustrate embodiments of the present invention, and are intended to provide what is considered to be the most effective and readily understandable explanation of the principles and conceptual features of the present invention. In this regard, it is not intended to show structural details of the present invention beyond what is necessary for a fundamental understanding of the invention, and the description, in conjunction with the drawings, will make it clear to those skilled in the art how some forms of the present invention are actually embodied.

[0011] [1] Molded body The molded article (1) of the present invention is a molded article (1) comprising a non-foamed design layer (11), a foamed intermediate layer (12), and a non-foamed back layer (13) laminated in this order, The design layer (11), the intermediate layer (12), and the back layer (13) are formed from a first resin composition, a second resin composition, and a third resin composition, respectively, which mainly consist of polyolefin. The first resin composition is characterized by being an impact-resistant resin composition comprising a polyolefin, a polyamide, and a polyolefin-based modified elastomer having a reactive group for the polyamide.

[0012] Currently, it is difficult to mass-produce recycled impact-resistant resin compositions consisting solely of impact-resistant resin compositions. As mentioned above, this is because the production and distribution volume of impact-resistant resin compositions is limited. For this reason, in the present invention, the impact-resistant resin composition is usually a newly produced resin composition. Furthermore, since the impact-resistant resin composition has polyolefin as its main component (containing 50% by mass or more of polyolefin relative to the entire resin composition), it has excellent affinity with other resin compositions that have polyolefin as their main component (containing 50% by mass or more of polyolefin relative to the entire resin composition).

[0013] On the other hand, polyolefin-based recycled resin compositions are recycled resin compositions whose main component is polyolefin (containing 50% or more by mass of polyolefin relative to the entire resin composition). These are resin compositions manufactured using molded articles formed from resin compositions with polyolefin as the main component as raw materials. Because polyolefin-based recycled resin compositions are recycled resin compositions, they are generally colored. In other words, it is currently impossible to restore the color of a polyolefin resin composition that has been used for coloring back to colorless or white. Therefore, because recycled resin compositions are colored, it is difficult to use them in design layers where aesthetic appeal is important.

[0014] Therefore, by using the impact-resistant resin composition as a non-foamed design layer 11, and using polyolefin-based recycled resin compositions or other resin compositions mainly composed of polyolefins as the intermediate layer 12 and back layer 13, it is possible to mass-produce molded articles using a limited amount of impact-resistant resin composition. In this case, the resulting molded article can be given excellent impact resistance and design properties by the non-foamed design layer 11, while the foamed intermediate layer provides thickness, lightness, and material efficiency as a molded article. Furthermore, because the structure consists of a foamed intermediate layer 12 sandwiched between the non-foamed design layer 11 and the back layer 13, excellent overall rigidity can be obtained. Furthermore, since the first resin composition (impact-resistant resin) constituting the design layer 11, and the resin compositions constituting the intermediate layer 12 (second resin composition) and the back layer 13 (third resin composition) are all resin compositions mainly composed of polyolefin, excellent bonding properties can be obtained between the layers. In other words, the two can be firmly bonded together without the use of separate adhesives or the like.

[0015] Specifically, by core-back foaming a second resin composition (a polyolefin-based recycled resin composition) between the design layer 11 and the back layer 13 to form an intermediate layer 12, which is a core-back foamed layer, between the design layer 11 and the back layer 13, the three layers can be integrated. In this case, after obtaining each layer separately, there is no need to laminate them. That is, the lamination process is not required. Also, no adhesive is required for use at that time. For this reason, while reducing the number of man-hours, the objective of mono-materialization can be achieved more highly, and a molded body can be obtained.

[0016] Furthermore, various materials can be used for the third resin composition that constitutes the back layer 13 as needed. For example, when higher mechanical strength is required for the molded body 1, an impact-resistant resin composition can be used as the third resin composition. On the other hand, from the perspective of increasing the usage amount of the polyolefin-based recycled resin composition, a polyolefin-based recycled resin can be used as the third resin composition. In addition, when an impact-resistant resin composition is used as the third resin composition, the impact-resistant resin composition as the third resin composition may be the same as or different from the impact-resistant resin composition as the first resin composition.

[0017] Hereinafter, the molded body of the present invention will be described in more detail. (1) Molded body The above-mentioned "molded body (1)" includes a design layer 11, an intermediate layer 12, and a back layer 13 laminated in this order (see FIGS. 1 to 3). The molded body may include other layers in addition to these three layers, but it can be made without including them. When no other layers are included, the molded body 1 is composed only of the above three layers.

[0018] The thickness of each layer constituting the molded body 1 is not limited, but when the thickness of the design layer 11 is D 11 , the thickness of the intermediate layer 12 is D 12 , and the thickness of the back layer 13 is D 13 , it can be set as D 11 ≦D 12 , and it is preferable that D 11 <D 12 . Also, it can be set as D 13 ≦D 12 and D13 <D 12 It is preferable that this is the case. Furthermore, (D 11 +D 13 )≦D 12 It can be done as follows. 11 and D 13 The correlation with thickness is not limited. More specifically, for example, D 11 It can be set to 0.1 to 0.9 mm. Also, D 12 It can be 1.0 to 3.0 mm. Furthermore, D 13 This can be 0.1 to 0.9 mm. The overall thickness D of the molded body 1 is not limited, but for example, D can be 1.2 to 4.8 mm, 2.0 to 4.0 mm, or 2.5 to 3.5 mm.

[0019] The shape of the molded body is not limited and can be appropriately selected depending on the purpose and application, but for example, it can be a plate-like body (board), a sheet-like body, a cylindrical body, a semi-cylindrical body, a rod-like body, a linear body, a block-like body, etc. Furthermore, it may also be a shaped body that has been given these shapes. That is, for example, in the case of a plate-like body, a shaped body with irregularities in the thickness direction of the plate can be mentioned. Examples of such molded bodies include interior materials for vehicles, which will be described later. The applications of the molded body will be described in more detail later. Furthermore, the molded body 1 may have the intermediate layer 12 throughout its entirety, but it may also be a molded body having both areas with the intermediate layer 12 and areas without the intermediate layer 12, as illustrated in Figure 3.

[0020] (2) Design layer The "design layer (11)" described above is a non-foaming layer and is formed from the first resin composition. The first resin composition mainly consists of polyolefin. That is, when the entire first resin composition is considered to be 100% by mass, it contains 50% by mass or more of polyolefin. Furthermore, the term "polyolefin" as used herein includes polyolefin-based modified elastomers, as described later, and other polyolefins excluding these. In other words, this polyolefin is a polyolefin regardless of whether or not it has reactive groups that can react with polyamides. It is also a polyolefin regardless of whether or not it is an elastomer.

[0021] Polyolefins (including polyolefin-based modified elastomers) are homopolymers of olefins and / or copolymers of olefins. The olefins constituting the polyolefins are not limited and include ethylene, propylene, 1-butene, 3-methyl-1-butene, 1-pentene, 3-methyl-1-pentene, 4-methyl-1-pentene, 1-hexene, 1-octene, etc. These may be used individually or in combination of two or more. Specifically, examples of polyolefins include polyethylene, polypropylene, poly-1-butene, poly-1-hexene, and poly-4-methyl-1-pentene. These polymers may be used individually or in combination of two or more. In other words, the polyolefin may be a mixture of the above polymers.

[0022] Of the above, polyethylene includes ethylene homopolymers and copolymers of ethylene with other olefins. The latter include ethylene-1-butene copolymers, ethylene-1-hexene copolymers, ethylene-1-octene copolymers, and ethylene-4-methyl-1-pentene copolymers. In addition, in copolymers of ethylene with other olefins, more than 50% of the total constituent units are derived from ethylene.

[0023] Among the above, polypropylene includes propylene homopolymers and copolymers of propylene with other olefins. Other olefins include the various olefins mentioned above (except propylene). Of these, ethylene and 1-butene are preferred. Specifically, propylene-ethylene copolymers and propylene-1-butene copolymers are preferred. Furthermore, the copolymer of propylene and other olefins may be a random copolymer or a block copolymer. Of these, block copolymers are preferred from the viewpoint of excellent impact resistance. In particular, propylene-ethylene block copolymers in which the other olefin is ethylene are preferred. This propylene-ethylene block copolymer is a block copolymer polypropylene having ethylene blocks as a dispersed phase. That is, it is a polypropylene resin in which homopolypropylene is the continuous phase and a dispersed phase containing polyethylene exists within this continuous phase. Such block copolymer polypropylene having ethylene blocks as a dispersed phase is also called impact copolymer, polypropylene impact copolymer, heterophagic polypropylene, heterophagic block polypropylene, etc. This block copolymer polypropylene is preferred from the viewpoint of excellent impact resistance. Furthermore, in copolymers of propylene and other olefins, more than 50% of the total constituent units are derived from propylene.

[0024] The first resin composition comprises a polyolefin (a polyolefin that does not include a polyolefin-based modified elastomer), a polyamide, and a polyolefin-based modified elastomer having a reactive group for the polyamide. The polyolefin contained in the first resin composition is a polymer having a main chain (polyolefin skeleton) derived from an olefin. This polyolefin is excluding the polyolefin-based modified elastomer described later and differs from the polyolefin-based modified elastomer in that it is a polyolefin that does not have reactive groups that can react with polyamide. The polyolefin contained in the first resin composition differs from the polyolefin as a main component described above only in that it does not contain polyolefins having reactive groups that can react with polyamides, but in other respects it is the same as the polyolefin as a main component described above. That is, the description of the polyolefin as a main component described above can be applied. Furthermore, the polyolefin contained in the first resin composition may be one type or two or more types.

[0025] The weight-average molecular weight (polystyrene equivalent) of the polyolefin contained in the first resin composition, determined by gel permeation chromatography (GPC), is not limited, but can be, for example, 10,000 to 700,000, preferably 100,000 to 650,000, and more preferably 200,000 to 600,000.

[0026] This weight-average molecular weight (in polystyrene equivalent) can also be changed within the above range to correspond to the type of polyamide described later. For example, the polyamide contained in the first resin composition may be polyamide 6 (PA6), polyamide 66 (PA66), polyamide 610 (PA610), polyamide 612 (PA612), polyamide 614 (PA614), polyamide 6T (PA6T), polyamide 6I (PA6I), polyamide M5T (PAM5T), polyamide MXD6 (PAMXD6), polyamide 6T / 66 (PA6T / 66), When the polyamide is polyamide 6T / 6I (PA6T / 6I), polyamide 6T / 6I / 66 (PA6T / 6I / 66), polyamide 6T / 2M-5T (PA6T / 2M-5T), etc., the weight-average molecular weight of the polyolefin contained in the first resin composition can be 35,000 to 700,000, 450,000 to 650,000, or 510,000 to 600,000.

[0027] Furthermore, for example, if the polyamide contained in the first resin composition is polyamide 11 (PA11), polyamide 12 (PA12), polyamide 610 (PA610), polyamide 612 (PA612), polyamide 614 (PA614), polyamide 9T (PA9T), polyamide 1010 (PA1010), polyamide 1012 (PA1012), polyamide 10T (PA10T), polyamide 9T / 2M-8T (PA9T / 2M-8T), etc., the weight-average molecular weight of the polyolefin contained in the first resin composition can be 10,000 to 450,000, 100,000 to 400,000, or 200,000 to 400,000.

[0028] Furthermore, the melt flow rate (MFR) of the polyolefin contained in the first resin composition is not limited, but can be, for example, 1 to 1000 g / 10 min, preferably 2 to 500 g / 10 min, and more preferably 3 to 250 g / 10 min. The MFR of the polyolefin is measured in accordance with JIS K7210, under conditions of a temperature of 230°C and a load of 21.18 N (2.16 kgf).

[0029] This MFR can also be changed within the above range to correspond to the type of polyamide described later. For example, if the polyamide contained in the first resin composition is polyamide 6 (PA6), polyamide 66 (PA66), polyamide 610 (PA610), polyamide 612 (PA612), polyamide 614 (PA614), polyamide 6T (PA6T), polyamide 6I (PA6I), polyamide M5T (PAM5T), polyamide MXD6 (PAMXD6), polyamide 6T / 66 (PA6T / 66), polyamide 6T / 6I (PA6T / 6I), polyamide 6T / 6I / 66 (PA6T / 6I / 66), polyamide 6T / 2M-5T (PA6T / 2M-5T), etc., then the MFR of the polyolefin contained in the first resin composition can be 1 to 25 g / 10 min, 2 to 16 g / 10 min, or 3 to 8 g / 10 min.

[0030] Furthermore, for example, if the polyamide contained in the first resin composition is polyamide 11 (PA11), polyamide 12 (PA12), polyamide 610 (PA610), polyamide 612 (PA612), polyamide 614 (PA614), polyamide 9T (PA9T), polyamide 1010 (PA1010), polyamide 1012 (PA1012), polyamide 10T (PA10T), polyamide 9T / 2M-8T (PA9T / 2M-8T), etc., then the MFR of the polyolefin contained in the first resin composition can be 10 to 1000 g / 10 min, 13 to 500 g / 10 min, or 17 to 250 g / 10 min.

[0031] The polyamide contained in the first resin composition is a polymer having a chain-like skeleton formed by the polymerization of multiple monomers via amide bonds (-NH-CO-). The polyamide contained in the first resin composition may be one type or two or more types. Monomers that make up polyamides include amino acids such as 6-aminocaproic acid, 11-aminoundecanoic acid, 12-aminododecanoic acid, and para-aminomethylbenzoic acid, and lactams such as ε-caprolactam, undecanolactam, and ω-lauryllactam. These can be used individually or in combination of two or more.

[0032] Furthermore, polyamides can also be obtained by copolymerization of diamines and dicarboxylic acids. In this case, the diamine monomers include ethylenediamine, 1,3-diaminopropane, 1,4-diaminobutane, 1,6-diaminohexane, 1,7-diaminoheptane, 1,8-diaminooctane, 1,9-diaminononane, 1,10-diaminodecane, 1,11-diaminoundecane, 1,12-diaminododecane, 1,13-diaminotridecane, 1,14-diaminotetradecane, 1,15-diaminopentadecane, and 1,16-diaminohexadecane. Examples include aliphatic diamines such as n, 1,17-diaminoheptadecane, 1,18-diaminooctadecane, 1,19-diaminononadecane, 1,20-diaminoeicosane, 2-methyl-1,5-diaminopentane, and 2-methyl-1,8-diaminooctane; alicyclic diamines such as cyclohexanediamine and bis-(4-aminocyclohexyl)methane; and aromatic diamines such as xylylenediamine (p-phenylenediamine and m-phenylenediamine, etc.). These may be used individually or in combination of two or more.

[0033] Furthermore, examples of dicarboxylic acids as monomers include aliphatic dicarboxylic acids such as oxalic acid, malonic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, undecanediic acid, dodecanediic acid, brassic acid, tetradecanediic acid, pentadecanediic acid, and octadecanediic acid; alicyclic dicarboxylic acids such as cyclohexanedicarboxylic acid; and aromatic dicarboxylic acids such as phthalic acid, terephthalic acid, isophthalic acid, and naphthalenedicarboxylic acid. These may be used individually or in combination of two or more.

[0034] Specifically, polyamides include polyamide 6 (PA6), polyamide 66 (PA66), polyamide 11 (PA11), polyamide 610 (PA610), polyamide 612 (PA612), polyamide 614 (PA614), polyamide 12 (PA12), polyamide 6T (PA6T), polyamide 6I (PA6I), polyamide 9T (PA9T), polyamide M5T (PAM5T), and polyamide 1010 (P Examples include polyamide A1010, polyamide 1012 (PA1012), polyamide 10T (PA10T), polyamide MXD6 (PAMXD6), polyamide 6T / 66 (PA6T / 66), polyamide 6T / 6I (PA6T / 6I), polyamide 6T / 6I / 66 (PA6T / 6I / 66), polyamide 6T / 2M-5T (PA6T / 2M-5T), polyamide 9T / 2M-8T (PA9T / 2M-8T), etc. These polyamides may be used individually or in combination of two or more.

[0035] Furthermore, among the various polyamides mentioned above, from the viewpoint of carbon neutrality and environmental protection, plant-derived polyamides using monomers obtained from plant-derived components such as vegetable oils can be suitably used. Examples of plant-derived polyamides include PA11, polyamide 610 (PA610), polyamide 612 (PA612), polyamide 614 (PA614), polyamide 1010 (PA1010), polyamide 1012 (PA1012), and polyamide 10T (PA10T). These may be used individually or in combination of two or more. Furthermore, among the various polyamides mentioned above, polyamide 6 and polyamide 66 can be suitably used from the viewpoint of versatility and cost-effectiveness.

[0036] The polyolefin-based modified elastomer contained in the first resin composition is an elastomer having reactive groups for polyamides as described above. That is, the polyolefin-based modified elastomer has a main chain (polyolefin skeleton) derived from an olefin, and further has reactive groups for polyamides. For this reason, although it is a type of polyolefin, it can exhibit affinity for both polyolefin and polyamide components and can function as a compatibilizer for both of these components. Furthermore, the polyolefin-based modified elastomer contained in the first resin composition may be one type or two or more types. Furthermore, while the elongation at break (elongation rate at break) of polyolefin-based modified elastomers is not limited, the tensile fracture strain (according to ASTM D638) is typically 400% or more, and can be, for example, 700% or more.

[0037] Furthermore, examples of reactive groups for polyamides include acid anhydride groups (-CO-O-OC-), carboxyl groups (-COOH), epoxy groups {-C2O (a three-membered ring structure consisting of two carbon atoms and one oxygen atom)}, oxazoline groups (-C3H4NO), and isocyanate groups (-NCO). These may be used individually or in combination of two or more. The degree of modification is not limited; the polyolefin-based modified elastomer only needs to have one or more reactive groups in one molecule, but it is preferably between 1 and 50, more preferably between 3 and 30, and particularly preferably between 5 and 20.

[0038] Examples of monomers into which reactive groups can be introduced include monomers having a polymerizable unsaturated bond and an acid anhydride group, monomers having a polymerizable unsaturated bond and a carboxyl group, and monomers having a polymerizable unsaturated bond and an epoxy group. Specifically, examples include acid anhydrides such as maleic anhydride, itaconic anhydride, succinic anhydride, glutaric anhydride, adipic anhydride, citraconic anhydride, tetrahydrophthalic anhydride, and butenyl succinic anhydride, and carboxylic acids such as maleic acid, itaconic acid, fumaric acid, acrylic acid, and methacrylic acid. These may be used individually or in combination of two or more. Among these compounds, acid anhydrides are preferred, maleic anhydride and itaconic anhydride are more preferred, and maleic anhydride is particularly preferred.

[0039] Furthermore, the polyolefin skeleton of the polyolefin-modified elastomer may be a homopolymer of olefins, but as mentioned above, from the viewpoint of obtaining elastomer properties, it is usually an olefin copolymer (a copolymer using two or more different olefin monomers). The type of olefin forming the polyolefin skeleton of the polyolefin-modified elastomer is not limited, and examples include ethylene, propylene, and α-olefins having 4 to 8 carbon atoms. Among these, examples of α-olefins having 4 to 8 carbon atoms include 1-butene, 3-methyl-1-butene, 1-pentene, 3-methyl-1-pentene, 4-methyl-1-pentene, 1-hexene, and 1-octene. Among these, copolymers of ethylene and α-olefins having 3 to 8 carbon atoms, and copolymers of propylene and α-olefins having 4 to 8 carbon atoms are preferred. By using polyolefin-modified elastomers having these polyolefin skeletons, the first resin composition (and furthermore, the design layer 11) can have superior impact resistance properties.

[0040] Among the above, copolymers of ethylene and α-olefins having 3 to 8 carbon atoms include ethylene-propylene copolymer (EPR), ethylene-1-butene copolymer (EBR), ethylene-1-pentene copolymer, and ethylene-1-octene copolymer (EOR). Copolymers of propylene and α-olefins having 4 to 8 carbon atoms include propylene-1-butene copolymer (PBR), propylene-1-pentene copolymer, and propylene-1-octene copolymer (POR). These can be used individually or in combination of two or more.

[0041] The weight-average molecular weight (in polystyrene equivalent) of the polyolefin-based modified elastomer contained in the first resin composition, determined by gel permeation chromatography (GPC), is not limited, but can be, for example, 10,000 to 500,000, preferably 35,000 to 500,000, and more preferably 35,000 to 300,000.

[0042] The proportions of polyolefin, polyamide, and polyolefin-based modified elastomer contained in the first resin composition are not limited, but for example, they can be as follows. When the total amount of polyolefin, polyamide, and polyolefin-based modified elastomer contained in the first resin composition is taken as 100% by mass, the proportion of polyolefin can be 2 to 99.5% by mass, preferably 5 to 99% by mass, more preferably 10 to 98% by mass, more preferably 20 to 97% by mass, more preferably 25 to 96% by mass, and more preferably 35 to 95% by mass. In particular, when the first resin composition is used as a composition with a higher proportion of polyolefin, the proportion of polyolefin can be 65 to 99.5% by mass, preferably 68 to 99% by mass, more preferably 72 to 98% by mass, more preferably 75 to 97% by mass, more preferably 82 to 96% by mass, and more preferably 85 to 95% by mass.

[0043] When the total amount of polyolefin, polyamide, and polyolefin-based modified elastomer contained in the first resin composition is taken as 100% by mass, the proportion of polyamide and polyolefin-based modified elastomer (some or all of these may be reacted with each other) can be 0.5 to 98% by mass, preferably 1 to 95% by mass, more preferably 2 to 90% by mass, more preferably 3 to 80% by mass, more preferably 4 to 75% by mass, and more preferably 5 to 65% by mass. In particular, when the first resin composition is used as a composition with a higher proportion of polyolefin, the ratio of polyamide to polyolefin-based modified elastomer can be 0.5 to 35% by mass, preferably 1 to 32% by mass, more preferably 2 to 28% by mass, more preferably 3 to 25% by mass, more preferably 4 to 18% by mass, and more preferably 5 to 15% by mass.

[0044] When the total amount of polyolefin, polyamide, and polyolefin-based modified elastomer contained in the first resin composition is taken as 100% by mass, the proportion of polyamide can be 0.05 to 75% by mass, preferably 0.1 to 70% by mass, more preferably 0.5 to 65% by mass, more preferably 1 to 60% by mass, more preferably 2 to 50% by mass, and more preferably 3 to 40% by mass. In particular, when the first resin composition is used as a composition with a higher proportion of polyolefin, the proportion of polyamide can be 0.05 to 28% by mass, preferably 0.1 to 22% by mass, more preferably 0.5 to 16% by mass, more preferably 1 to 12% by mass, more preferably 2 to 10% by mass, and more preferably 3 to 8% by mass.

[0045] When the total amount of polyolefin, polyamide, and polyolefin-based modified elastomer contained in the first resin composition is taken as 100% by mass, the proportion of polyolefin-based modified elastomer can be 0.05 to 60% by mass, preferably 0.1 to 55% by mass, more preferably 0.5 to 45% by mass, more preferably 1 to 40% by mass, more preferably 1.5 to 38% by mass, and more preferably 2 to 35% by mass. In particular, when the first resin composition is used as a composition with a higher proportion of polyolefin, the proportion of polyolefin-based modified elastomer can be 0.05 to 26% by mass, preferably 0.1 to 20% by mass, more preferably 0.5 to 14% by mass, more preferably 1 to 11% by mass, more preferably 1.5 to 9% by mass, and more preferably 2 to 7% by mass.

[0046] The first resin composition may exhibit any phase structure, and its phase structure is not limited, but for example, it may have the following phase structures (1) to (3). Phase structure (1): A phase structure comprising a continuous phase (A) containing polyolefin and a dispersed phase (B) containing polyamide and polyolefin-based modified elastomer dispersed in the continuous phase (A). Note that other phase structures containing a continuous phase containing polyamide and a dispersed phase dispersed in this continuous phase cannot coexist. Phase structure (2): A phase structure comprising a continuous phase (A) containing polyamide and a dispersed phase (B) containing polyolefin dispersed within this continuous phase (A). However, other phase structures having a continuous phase containing polyolefin and a dispersed phase dispersed within this continuous phase are not permitted to coexist. Phase structure (3): A continuous phase (A1) containing polyolefins, and a dispersed phase (B) containing polyamides and polyolefin-based modified elastomers dispersed in the continuous phase (A1). A1 ) and a continuous phase (A2) containing a polyamide resin, and a dispersed phase (B) containing a polyolefin-based modified elastomer dispersed in the continuous phase (A2). A2 A phase structure having ) and . That is, it exhibits a co-continuous phase structure in which two continuous phases, continuous phase (A1) and continuous phase (A2), coexist.

[0047] In phase structure (1), the dispersed phase (B) may further comprise a continuous phase (B1) containing polyamide and a finely dispersed phase (B2) dispersed within the continuous phase (B1) containing a polyolefin-based modified elastomer. In this case, phase structure (1) exhibits a multiphase structure having a further finely dispersed phase (B1) within the dispersed phase (B). In phase structure (1), the polyolefin-based modified elastomer may be unreacted, a reaction product with polyamide, or a mixture thereof.

[0048] Phase structure (3) consists of a dispersed phase (B) within a continuous phase (A1). A1 ) is this dispersed phase (B A1 A continuous phase within ) containing a polyamide (B A11) and this continuous phase (B A11 A finely dispersed phase dispersed within ) and containing a polyolefin-based modified elastomer (B A12 ) and can have. In this case, the phase structure (3) is the dispersed phase (B A1 ) contains a further finely dispersed phase (B A12 This results in a multiphase structure having ). In phase structure (3), the polyolefin-based modified elastomer may be unreacted, a reaction product with polyamide, or a mixture thereof.

[0049] Furthermore, in the first resin composition, the reactive groups of the polyolefin-based modified elastomer can react with the polyamide resin to form a reactant. In this case, the reactant can exist, for example, at the interface between the continuous phase (A) and the dispersed phase (B) in phase structure (1), and / or at the interface between the continuous phase (B1) and the finely dispersed phase (B2). Similarly, in phase structure (3), for example, at the interface between the continuous phase (A1) and the continuous phase (A2), and between the continuous phase (A1) and the dispersed phase (B A1 ) interface with continuous phase (B A11 ) and the finely dispersed phase (B A12 It can exist at interfaces with, etc.

[0050] The various phase structures can be observed using a field emission scanning electron microscope (FE-SEM) on the treated surface of a specimen that has been subjected to oxygen plasma etching and then osmium coating. In particular, the dispersed phase and the microdispersed phase can be observed in images magnified to 1,000 times or more (usually 10,000 times or less) using this method. Furthermore, the components constituting each phase can be identified by performing energy-dispersive X-ray analysis (EDS) during observation using a field emission scanning electron microscope (FE-SEM).

[0051] The size of the dispersed phase of the first resin composition is not particularly limited, but its dispersion diameter (average dispersion diameter) is preferably 10,000 nm or less, more preferably 50 to 8,000 nm, and even more preferably 100 to 4,000 nm. The dispersion diameter of this dispersed phase can be measured in magnified images of 1000x or more obtained using an electron microscope. Specifically, the longest diameter of each of 20 dispersed phases randomly selected from a predetermined region within the image is measured, and the average of the obtained longest diameters is taken as the first mean value. Then, the further average of the first mean values ​​measured in five different regions within the image is the mean dispersion diameter of the dispersed phase (major axis mean dispersion diameter).

[0052] Dispersed phase of the first resin composition (dispersed phase B, dispersed phase B A1 (etc.) Microdispersive phases contained within (microdispersive phase B2, microdispersive phase B A12 The size of the particles is not limited, but the dispersion diameter (average dispersion diameter) is preferably 5 to 1000 nm, more preferably 5 to 600 nm, even more preferably 10 to 400 nm, and particularly preferably 15 to 350 nm. The dispersion diameter of this microdispersive phase can be measured in magnified images of 1000x or more obtained using an electron microscope. Specifically, the longest diameter of each of 20 microdispersive phases randomly selected from a predetermined region within the image is measured, and the average of the obtained longest diameters is taken as the first mean value. Then, the average of the first mean values ​​measured in five different regions within the image is the mean dispersion diameter of the microdispersive phase (major axis mean dispersion diameter).

[0053] Furthermore, the proportion of polyolefin when the total of the aforementioned polyolefin, polyamide, and polyolefin-based modified elastomer is set to 100% by mass is equal to the proportion of continuous phase (A) when the entire phase in phase structure (1) is set to 100% by mass, and is equal to the proportion of continuous phase (A1) when the entire phase in phase structure (3) is set to 100% by mass. The proportions referred to here are volume proportions, but are in effect equal to area proportions (the same applies hereafter).

[0054] Furthermore, when the total of the aforementioned polyolefin, polyamide, and polyolefin-based modified elastomer is set to 100% by mass, the proportion of polyamide and polyolefin-based modified elastomer is equal to the proportion of dispersed phase (B) when the entire phase in phase structure (1) is set to 100% by mass, and the proportion of dispersed phase (B) when the entire phase in phase structure (3) is set to 100% by mass. A1) and continuous phase (A2) and dispersed phase (B A2 It is equal to the sum of the two.

[0055] Furthermore, the proportion of polyamide resin when the total of the aforementioned polyolefin, polyamide, and polyolefin-based modified elastomer is set to 100% by mass is equal to the proportion of continuous phase (B1) when the entire phase in phase structure (1) is set to 100% by mass, and the proportion of continuous phase (A2) and continuous phase within dispersed phase (B) when the entire phase in phase structure (3) is set to 100% by mass is equal to the proportion of continuous phase (A2) and continuous phase within dispersed phase (B) A11 It is equal to the sum of the two.

[0056] Furthermore, when the total of the aforementioned polyolefin, polyamide, and polyolefin-based modified elastomer is set to 100% by mass, the proportion of the polyolefin-based modified elastomer is equal to the proportion of the finely dispersed phase (B2) when the entire phase in phase structure (1) is set to 100% by mass, and the proportion of the finely dispersed phase (B) when the entire phase in phase structure (3) is set to 100% by mass. A12 ) and dispersed phase (B A2 It is equal to the sum of the two.

[0057] Furthermore, the first resin composition may contain other components in addition to polyolefins, polyamides, and polyolefin-based modified elastomers. Other ingredients include antioxidants, heat stabilizers, weathering agents, light stabilizers, plasticizers, UV absorbers, antistatic agents, flame retardants, flame retardant enhancers, slip agents, antiblocking agents, antifogging agents, lubricants, antibacterial agents, fillers (reinforcing fillers), colorants, dispersants, copper damage inhibitors, neutralizing agents, anti-foaming agents, weld strength improvers, natural oils, synthetic oils, waxes, etc. These may be used individually or in combination of two or more.

[0058] The first resin composition may be a composition that does not contain fillers, even among the other components mentioned above. Examples of fillers include glass components (glass fibers, glass beads, glass flakes, etc.), silica, inorganic fibers (glass fibers, alumina fibers, carbon fibers), graphite, silicate compounds (calcium silicate, aluminum silicate, montmorillonite, kaolin, talc, clay, etc.), metal oxides (iron oxide, titanium oxide, zinc oxide, antimony oxide, alumina, etc.), carbonates and sulfates of metals such as lithium, calcium, magnesium, and zinc, metals (aluminum, iron, silver, copper, etc.), hydroxides (aluminum hydroxide, magnesium hydroxide, etc.), sulfides (barium sulfate, etc.), carbides (charcoal, bamboo charcoal, etc.), titanides (potassium titanate, barium titanate, etc.), organic fibers (aromatic polyester fibers, aromatic polyamide fibers, fluororesin fibers, polyimide fibers, plant fibers, etc.), and celluloses (cellulose microfibrils, cellulose acetate, etc.). These may be used individually or in combination of two or more.

[0059] (3) Middle class The above-mentioned "intermediate layer (12)" is a foamed layer and is formed from the second resin composition. The second resin composition mainly consists of polyolefin. That is, when the entire second resin composition is considered to be 100% by mass, it contains 50% or more by mass of polyolefin. This second resin composition may be a novel polyolefin (virgin material), but it is preferably a polyolefin-based recycled resin composition or a mixture of a novel polyolefin and a polyolefin-based recycled resin composition. The polyolefin-based recycled resin composition may be a mixture of various polyolefins. In other words, the polyolefin that is the main component of the second resin composition may have any polyolefin backbone, and is not limited to any other structure. Therefore, this includes polyolefins contained in the first resin composition, as well as polyolefin-based modified elastomers contained in the first resin composition.

[0060] Furthermore, if the second resin composition is a polyolefin-based recycled resin composition, it may contain other thermoplastic resins and / or other thermoplastic elastomers other than polyolefins (i.e., thermoplastic resins and / or thermoplastic elastomers that do not have a polyolefin backbone). Examples of other thermoplastic resins and thermoplastic elastomers include polyester, polystyrene, polyurethane, polyethylene terephthalate, polyamide, polycarbonate, acrylic resin, methacrylic resin, polyacrylate, polymethacrylate, polyacetal, and ABS. These may be used individually or in combination of two or more. In addition, these other thermoplastic resins and thermoplastic elastomers may have reactive groups. Specifically, examples include carboxyl groups, acid anhydride groups (maleic anhydride, phthalic anhydride, succinic anhydride, etc.), hydroxyl groups, isocyanate groups, amino groups, halogen groups, etc. These may be used individually or in combination of two or more.

[0061] When the second resin composition is a polyolefin-based recycled resin composition, it is preferable that the second resin composition contains 50% by mass or more (it may be 100% by mass) of polyolefin when the entire second resin composition is considered to be 100% by mass, but it can be 55-99% by mass, 60-98% by mass, 65-97% by mass, 70-96% by mass, or 80-95% by mass.

[0062] Furthermore, the second resin composition may contain antioxidants, heat stabilizers, weathering agents, light stabilizers, plasticizers, ultraviolet absorbers, antistatic agents, flame retardants, flame retardant enhancers, slip agents, antiblocking agents, antifogging agents, lubricants, antibacterial agents, fillers (reinforcing fillers), colorants, dispersants, copper damage inhibitors, neutralizing agents, anti-foaming agents, weld strength improvers, natural oils, synthetic oils, waxes, etc. These may be used individually or in combination of two or more. In addition, as fillers, the various fillers exemplified in the description of the first resin composition may be used in the same manner, and may be used individually or in combination of two or more.

[0063] The intermediate layer 12 may be a foamed layer formed from the second resin composition, but it is particularly preferable that it be a core-back foamed layer formed by core-back foaming of the second resin composition between the design layer 11 and the back layer 13. When the intermediate layer 12 is a core-back foamed layer, there is no need to bond the layers together after obtaining them separately, thus eliminating the need for a bonding process. Furthermore, no adhesive is required for bonding. As a result, a molded body can be obtained while reducing the number of steps and achieving the objective of monomaterialization to a higher degree. Moreover, because foaming occurs between the pre-formed design layer 11 and back layer 13, surface irregularities such as swirl marks and uneven foaming, and other appearance defects do not occur on the design surface of the molded body 1. In other words, core-back foaming can be performed during the production of the intermediate layer 12 without requiring measures to address surface irregularities or appearance defects in the foamed layer.

[0064] Core back foaming can be carried out in any way, for example, the first support layer 11 which will become the design layer 11 F And the third support layer 13 which becomes the back layer 13 F After interposing a second resin composition with foaming properties into the gap 2 (usually by injecting the second resin composition with foaming properties into the cavity), the gap 2 can be expanded to reduce the pressure inside the gap 2, causing the second resin composition to foam and form a core-back foam layer (see Figures 4-5). Furthermore, the first support layer 11 F and the third support layer 13 F The gap 2 can be expanded in any way; it can be expanded by increasing the distance between the first and third supporting layers, or it can be expanded by receding the other cavity walls while maintaining the distance between the first and third supporting layers.

[0065] The foamability of the second resin composition may be imparted in any manner, and a chemical foaming agent may be blended, a physical foaming agent may be blended, or both of these may be used. Among these, examples of the chemical foaming agent include azo compounds such as azodicarbonamide, nitroso compounds such as N,N'-dinitrosopentamethylenetetramine, and hydrazine derivatives such as 4,4'-oxybis(benzenesulfonylhydrazide). These may be used alone or in combination of two or more. On the other hand, examples of the physical foaming agent include water, nitrogen gas, carbon dioxide, and supercritical fluids. Among these, examples of the supercritical fluid include inert gases such as carbon dioxide, nitrogen, argon, and helium. These may be used alone or in combination of two or more.

[0066] The expansion ratio T (times) of the intermediate layer 12 is not limited, but for example, it can be 1.0 < T ≤ 5.0, it can be 1.1 ≤ T ≤ 3.0, further it can be 1.2 ≤ T ≤ 2.7, and further it can be 1.3 ≤ T ≤ 2.5.

[0067] (4) Back surface layer The above-mentioned "back surface layer (13)" is Non a foamed of layer and is formed from the third resin composition. The third resin composition is mainly composed of polyolefin. That is, when the entire third resin composition is 100% by mass, it means containing 50% by mass or more of polyolefin. Also, the polyolefin that is the main component of the third resin composition may have a polyolefin skeleton and is not limited in other structures. Therefore, the polyolefin contained in the first resin composition, the polyolefin-based modified elastomer contained in the first resin composition, etc. are included.

[0068] The third resin composition is not limited except that it is mainly composed of polyolefin. Therefore, as the third resin composition, a novel polyolefin (virgin material), the above-mentioned polyolefin-based recycled resin composition, the above-mentioned impact-resistant resin composition, etc. can be appropriately used according to the purpose and application. That is, for example, if the back layer 13 is a layer that does not require aesthetic design and furthermore does not require any particular mechanical strength such as impact resistance, then as the third resin composition, a polyolefin-based recycled resin composition or a mixture of a new polyolefin and a polyolefin-based recycled resin composition can be used, similar to the second resin composition. In other words, the third resin composition and the second resin composition can be the same (see Figure 1). Furthermore, for example, if the back layer 13 is a layer that requires aesthetic appeal but not exceptional mechanical strength such as impact resistance, a novel polyolefin (virgin material) can be used as the third resin composition (see Figure 1). Furthermore, for example, if the back layer 13 requires mechanical strength such as impact resistance, an impact-resistant resin composition can be used as the third resin composition. That is, the third resin composition and the first resin composition can be the same (see Figure 2).

[0069] (5) Uses of molded products The applications of the molded articles of the present invention are not limited, but they can be suitably used as various accessories for vehicles such as automobiles (including two-wheeled, three-wheeled, and four-wheeled vehicles), railway vehicles, bicycles, aircraft, and ships. Among these, automotive parts include exterior parts, interior parts, engine parts, and electrical parts. Specifically, exterior parts include roof rails, fenders, fender liners, garnishes, bumpers, door panels, roof panels, hood panels, trunk lids, fuel lids, door mirror stays, spoilers, hood louvers, wheel covers, wheel caps, grille apron cover frames, lamp bezels, door handles (pull handles), door moldings, rear finishers, wipers, engine undercovers, floor undercovers, rocker moldings, cowl louvers, cowls, etc.

[0070] Interior components include trim parts such as door trim base materials (FR, RR, BACK), pockets, armrests, switch bases, decorative panels, ornament panels, EA materials, speaker grilles, and quarter trim base materials; pillar garnishes; cowl side garnishes (cowl side trims); seat components such as shields, back panels, dynamic dampers, and side airbag surround components; instrument panel components such as center clusters, registers, center boxes (doors), grab doors, cup holders, and airbag surround components; center consoles; overhead consoles; sun visors; deck boards (luggage boards), under trays; package trays; high-mount stop lamp covers; CRS covers; seat side garnishes; scuff plates; room lamps; assist grips; safety belt components; register blades; washer levers; window regulator handles; window regulator handle knobs; and passing light levers.

[0071] Furthermore, engine components include alternator terminals, alternator connectors, IC regulators, light dew potentiometer bases, exhaust gas valves, fuel pipes, cooling pipes, brake pipes, wiper pipes, exhaust pipes, intake pipes, hoses, tubes, air intake nozzle snorkels, intake manifolds, fuel pumps, engine coolant joints, carburetor main bodies, carburetor spacers, exhaust gas sensors, coolant sensors, oil temperature sensors, brake pad wear sensors, throttle position sensors, crankshaft position sensors, air flow meters, brake pad wear sensors, brake pistons, solenoid bobbins, engine oil filters, ignition system cases, torque control levers, and more.

[0072] Other electrical components include battery peripherals, air conditioning thermostats, heating hot air flow control valves, radiator motor brush holders, water pump impellers, turbine vanes, wiper motor related parts, distributors, starter switches, starter relays, transmission wire harnesses, windshield washer nozzles, air conditioning panel switch boards, fuel-related solenoid valve coils, wire harness connectors, SMJ connectors, PCB connectors, door grommet connectors, various connectors such as fuse connectors, horn terminals, electrical component insulating plates, stepper motor rotors, lamp sockets, lamp reflectors, lamp housings, cleaner cases, filter cases, and powertrain components.

[0073] Furthermore, the molded articles of the present invention can be suitably used as various goods and other items in non-vehicle applications other than those described above. That is, for example, industrial and commercial materials such as transport containers, trays, transport carts, and other general materials; Electronic components such as connectors, coils, sensors, LED lamps, sockets, resistors, relay cases, miniature switches, coil bobbins, capacitors, variable capacitor cases, optical pickups, oscillators, various terminal boards, transformers, plugs, printed circuit boards, tuners, speakers, microphones, headphones, miniature motors, miniature variable gears, magnetic head bases, power modules, semiconductors, LCDs, FDD carriages, FDD chassis, motor brush holders, parabolic antennas, and computer-related parts; Electrical equipment such as generators, electric motors, transformers, current transformers, voltage regulators, rectifiers, inverters, relays, power contacts, switches, circuit breakers, knife switches, other-pole rods, and electrical component cabinets;

[0074] Housings for industrial robots, housings for caregiving robots, housings for drones (flying objects that fly by remote control, flying objects that fly autonomously), VTR parts, television parts, irons, hair dryers, rice cooker parts, microwave oven parts, audio parts, audio / LD parts, CD / DVD parts, lighting parts, refrigerator parts, washing machine parts, air conditioner parts, typewriter / word processor parts, office computer parts, PCs, game consoles, tablet devices, mobile phones, smartphones, telephones and related parts, facsimile parts, photocopier parts, cleaning / washing equipment, motor parts, and other home appliances and office products; Optical and precision instruments such as cameras, watches, microscopes, binoculars, telescopes, and eyeglasses; Food trays, storage boxes, storage trays, attaché cases, suitcases, helmets, water bottles, bottles and other storage cases, toiletries, writing instruments, stationery, bookstands, skincare tools and equipment, tableware, laundry supplies, cleaning supplies, clothes hangers, food containers, lids (for glass bottles, etc.), and other daily necessities and household goods;

[0075] Toys and other entertainment items; Lawn mower casings and covers, power tool casings and covers, various clips, and other general machinery and parts; Sports equipment such as tennis racket strings, skis and snowboards, protectors (baseball, soccer, motorsports), shoes, shoe soles (outs of shoes, soles for sports shoes), and outdoor and mountaineering equipment; Furniture-related items such as clothing storage boxes, tables, chairs, shoe boxes, kitchen utensils, toiletries, and bathing equipment; Interior and exterior walls and roofs, insulation materials, door and gate related parts, window related parts, floor related parts, seismic isolation and vibration control parts, shutters, gutters, water supply and sewage related parts (lifeline related), parking garages, gas and electricity related parts (lifeline related), civil engineering parts, traffic signal equipment, road signs, pylons, center poles, guardrails (guard wires), construction equipment, and other housing and civil engineering supplies; Medical supplies such as mouthpieces, medical devices, and pharmaceutical containers; Shoes and other clothing-related items, Examples include agricultural machinery, farming tools, flower pots (planters), fishing gear, aquaculture equipment, forestry tools, and other agricultural, forestry, and fisheries-related supplies.

[0076] [2] Method for recycling molded products The present invention provides a method for recycling a molded article, characterized by comprising a subdivision step to obtain a polyolefin-based recycled resin by subdividing the molded article 1.

[0077] As described above, the molded body 1 of the present invention comprises a non-foamed design layer 11, a foamed intermediate layer 12, and a non-foamed back layer 13, laminated in this order. These design layer 11, intermediate layer 12, and back layer 13 are formed from a first resin composition, a second resin composition, and a third resin composition, respectively, which mainly consist of polyolefin. Therefore, by subdividing the molded body 1, it can be reused as a polyolefin-based recycled resin. In particular, it is preferable to use a molded body composed of only the three layers of the design layer 11, intermediate layer 12, and back layer 13 as a raw material for polyolefin-based recycled resin.

[0078] Furthermore, if necessary, the subdivided parts of the molded body 1 can be homogenized by melt kneading. That is, after the subdivision step, a melt kneading step may be included in which the polyolefin-based recycled resin is melt kneaded to obtain a polyolefin-based recycled resin composition with homogenized components. Furthermore, if the components are homogenized, the melt-mixed resin composition may be used in its molten state or it may be pelletized. That is, after the melt-mixing step, a pelletizing step may be included in which the polyolefin-based recycled resin composition is converted into polyolefin-based recycled pellets.

[0079] The uses of the polyolefin-based recycled resin (and furthermore, polyolefin-based recycled resin composition and polyolefin-based recycled pellets) obtained by this method are not limited, but for example, it can be used as a second resin composition or as a raw material for a second resin composition. Similarly, the polyolefin-based recycled resin obtained by this method can be used as a third resin composition or as a raw material for a third resin composition.

[0080] [3] Method for manufacturing a molded article The present invention provides a method for manufacturing a molded article, comprising a first support layer 11 which becomes a design layer 11. F And the third support layer 13 which becomes the back layer 13 F The arrangement process involves arranging the two objects opposite each other with a gap between them, 1st support layer 11 F and the third support layer 13 F A second resin composition 12 is provided with foaming properties in the gap 2 between the two. M An intervening process that involves, Second resin composition 12 M The present invention is characterized by comprising an intermediate layer formation step, which involves expanding the gap 2 while foaming the material to form an intermediate layer 12 (see Figures 4-5).

[0081] In other words, the intermediate layer formation process is performed by forming the first support layer 11 F and the third support layer 13 F This process involves expanding the gap 2 formed by the process to cause the second resin composition to undergo core-back foaming. By forming the intermediate layer 12 through core-back foaming in this way, it is not necessary to separately obtain each layer and then bond them together. That is, although it is possible to obtain the molded body 1 by separately forming the design layer 11, the intermediate layer 12, and the back layer 13 and then bonding them together, this bonding process is not required. Furthermore, the adhesive used in that process is not required. As a result, it is possible to obtain a molded body while reducing the number of steps and achieving the objective of monomaterialization to a higher degree.

[0082] On the other hand, it is also possible to form a design layer and a back layer as a skin layer of the intermediate layer 12 while foaming the intermediate layer 12 (however, in this case, both the design layer and the back layer will be formed from the second resin composition). However, in this method, a pre-formed design layer 11 and back layer 13 are used, and foaming occurs in the interlayer (gap 2) between the design layer 11 and the back layer 13. As a result, surface irregularities such as swirl marks and foaming unevenness, and other appearance defects do not occur on the design surface of the molded body 1. In other words, when manufacturing the intermediate layer 12, it is not necessary to take measures against surface irregularities and appearance defects of the foamed layer.

[0083] Core back foaming can be carried out in any way, but for example, it can be done as follows: that is, a first support layer 11 is placed in a mold 3 equipped with a core-back movable wall 31. F and the third support layer 13 F By positioning them opposite each other while keeping them separated, and fixing them inside the mold 3, the first support layer 11 F and the third support layer 13 F A gap 2 can be formed between them. This step is the arrangement step described above. Subsequently, a second resin composition with foaming properties is injected into the gap 2 (for example, into the mold 3 via the injection port 32) to interpose the second resin composition in a foamable state within the gap 2. This step is the interposition step described above. Next, the movable wall 31 is retracted so that the volume of the gap 2 is expanded, and the pressure inside the gap 2 is reduced, thereby causing the second resin composition to be core-back foamed. This step is the intermediate layer formation step described above.

[0084] Thus, the first support layer 11 F and the third support layer 13 F By core-back foaming the second resin composition between the layers, an intermediate layer 12 is formed, while the intermediate layer 12 is supported by the first support layer 11 F and third support layer 13 F The layers are then welded together. Therefore, no additional adhesive or other materials are required to join these three layers. Furthermore, no additional processing steps are needed for that purpose.

[0085] Furthermore, of the above, the intermediary process and the intermediate layering process may be performed after the completion of the intermediary process, or after the start of the intermediary process but before its completion, or the intermediary process and the intermediate layering process may be performed substantially simultaneously. Furthermore, naturally, the movable wall 31 is supported by the first support layer 11 F and / or third support layer 13 F The wall may be one on which these are placed, or it may be a wall without them. Furthermore, the method for imparting foaming properties to the second resin composition is as described above.

[0086] Also, support layer 11 F and support layer 13 F The molding method is not limited, and any known molding method can be used. Specifically, examples include injection molding, extrusion molding (sheet extrusion), die molding, vacuum forming, compression molding, press molding, stamping mold molding, and transfer molding. These may be used individually or in combination of two or more.

[0087] [4] Method for recycling polyolefin resin compositions The present invention provides a method for recycling polyolefin-based resin compositions, comprising a first support layer 11 formed from a first resin composition containing polyolefin, polyamide, and polyolefin-based modified elastomer. F And a third support layer 13 formed from a third resin composition mainly composed of polyolefin. F The arrangement process involves arranging the two objects opposite each other with a gap between them, 1st support layer 11 F and the third support layer 13 F An interposition step is to interpose a polyolefin-based recycled resin composition that has been given foaming properties into the gap between the two, While foaming the polyolefin-based recycled resin composition, the first support layer 11 F and the third support layer 13 F The process involves widening the gap 2 to form an intermediate layer, and then proceeding through the intermediate layer formation process, 1st support layer 11 F A non-foamed design layer 11, a foamed intermediate layer 12, and a third support layer 13 F The present invention is characterized by obtaining a molded body 1 comprising a non-foamed back layer 13 made of the above, and the above, laminated in this order (see Figures 4-5).

[0088] This recycling method differs from the aforementioned method for manufacturing molded articles in that it specifies the second resin composition in the aforementioned method for manufacturing molded articles to be a polyolefin-based recycled resin composition. Furthermore, the polyolefin-based recycled resin composition is as described above in [1](3). According to this recycling method, the same effects as those in the molded article manufacturing method described above can be obtained using a polyolefin-based recycled resin composition. That is, the intermediate layer formation step is the first support layer 11 F and the third support layer 13 F This process involves expanding the gap 2 formed by the process to core-back foam the polyolefin-based recycled resin composition. By forming the intermediate layer 12 by core-back foaming in this way, it is not necessary to separately obtain each layer and then bond them together. That is, although it is also possible to obtain the molded body 1 by separately forming the design layer 11, the intermediate layer 12, and the back layer 13 and then bonding them together, this bonding process is not required. Furthermore, the adhesive used in that process is not required. As a result, it is possible to obtain a molded body while reducing the number of steps and achieving the objective of monomaterialization to a higher degree.

[0089] On the other hand, it is also possible to form a design layer and a back layer as a skin layer of the intermediate layer 12 while foaming the intermediate layer 12 (however, in this case, both the design layer and the back layer will be formed from the second resin composition). However, in this recycling method, a pre-formed design layer 11 and back layer 13 are used, and foaming occurs in the interlayer (gap 2) between the design layer 11 and the back layer 13. As a result, surface irregularities such as swirl marks and foaming unevenness, and other appearance defects do not occur on the design surface of the molded body 1. In other words, when manufacturing the intermediate layer 12, it is not necessary to take measures against surface irregularities and appearance defects of the foamed layer.

[0090] The examples described herein are for illustrative purposes only and should not be construed as limiting the invention. Although the invention has been described with examples of typical embodiments, the language used in the description and illustrations of the invention should be understood as descriptive and illustrative, not limiting. As detailed herein, modifications are possible within the scope or spirit of the invention without departing in any way. While specific structures, materials, and examples have been referenced in this detailed description of the invention, the invention is not intended to be limited to the disclosures herein, but rather to encompass all functionally equivalent structures, methods, and uses within the scope of the claims. [Explanation of symbols]

[0091] 1; Molded body, 11; Design layer, 11 F ;1st support layer, 12; Middle layer, 12 M ; second resin composition; 13; back layer, 13 F ;Third support layer; 2; gap, 3; mold, 31; movable wall, 32; injection port.

Claims

1. A molded body comprising a non-foamed design layer, a foamed intermediate layer, and a non-foamed back layer, laminated in this order, The design layer, the intermediate layer, and the back layer are each formed from a first resin composition, a second resin composition, and a third resin composition, respectively, which mainly consist of polyolefin. The intermediate layer is a core-back foamed layer in which the second resin composition is core-back foamed between the design layer and the back layer. The first resin composition is a newly produced impact-resistant resin composition comprising a polyolefin, a polyamide, and a polyolefin-based modified elastomer having a reactive group for the polyamide, wherein the proportions of the polyamide and the polyolefin-based modified elastomer are 5 to 65% by mass when the total of these is 100% by mass. The second resin composition is a polyolefin-based recycled resin composition containing 80 to 99% by mass of polyolefin when the entire second resin composition is considered to be 100% by mass. The molded article is characterized in that the third resin composition contains 80 to 99% by mass of polyolefin when the entire third resin composition is considered to be 100% by mass, and is the same as or different from the second resin composition, a polyolefin-based recycled resin composition.

2. A molded body comprising a non-foamed design layer, a foamed intermediate layer, and a non-foamed back layer, laminated in this order, The design layer, the intermediate layer, and the back layer are each formed from a first resin composition, a second resin composition, and a third resin composition, respectively, which mainly consist of polyolefin. The intermediate layer is a core-back foamed layer in which the second resin composition is core-back foamed between the design layer and the back layer. The first resin composition is a newly produced impact-resistant resin composition comprising a polyolefin, a polyamide, and a polyolefin-based modified elastomer having a reactive group for the polyamide, wherein the proportions of the polyamide and the polyolefin-based modified elastomer are 5 to 65% by mass when the total of these is 100% by mass. The second resin composition is a polyolefin-based recycled resin composition containing 80 to 99% by mass of polyolefin when the entire second resin composition is considered to be 100% by mass. The third resin composition is an impact-resistant resin composition comprising a polyolefin, a polyamide, and a polyolefin-based modified elastomer having a reactive group for the polyamide, wherein the proportions of the polyamide and the polyolefin-based modified elastomer are 5 to 65% by mass when the total of these is 100% by mass. A molded article characterized in that the first resin composition and the third resin composition are the same or different impact-resistant resin compositions.

3. A method for manufacturing a molded article according to claim 1 or 2, Arrangement step of arranging the first support layer which will be the design layer and the third support layer which will be the back surface layer at a distance from each other and facing each other, An interposition step is to interpose the second resin composition, which has been imparted with foaming properties, in the gap between the first support layer and the third support layer, A method for manufacturing a molded article, comprising: an intermediate layer forming step of expanding the gap while foaming the second resin composition to form the intermediate layer.

4. A method for recycling polyolefin resin compositions, A placement step of arranging, spaced apart and facing each other, a first support layer formed from a first resin composition which is a newly produced impact-resistant resin composition comprising polyolefin, polyamide, and a polyolefin-based modified elastomer having a reactive group for the polyamide, wherein the proportions of the polyamide and the polyolefin-based modified elastomer are 5 to 65% by mass when the total of these is 100% by mass, and a third support layer formed from a third resin composition which contains 80 to 99% by mass of polyolefin when the total is 100% by mass, An interposition step is to interpose the same or different polyolefin-based recycled resin composition as the third resin composition in the gap between the first support layer and the third support layer, the polyolefin-based recycled resin composition containing 80 to 99% by mass of polyolefin when the total mass is 100%, and which is provided with foaming properties, The process involves an intermediate layer formation step, in which the polyolefin-based recycled resin composition is foamed while the gap is expanded to form an intermediate layer, A method for recycling a polyolefin resin composition, characterized by obtaining a molded article comprising a non-foamed design layer consisting of the first support layer, a foamed intermediate layer, and a non-foamed back layer consisting of the third support layer, laminated in this order.

5. A method for recycling polyolefin resin compositions, A placement step of arranging, spaced apart and facing each other, a first support layer formed from a first resin composition which is a newly produced impact-resistant resin composition comprising a polyolefin, a polyamide, and a polyolefin-based modified elastomer having a reactive group for the polyamide, wherein the proportions of the polyamide and the polyolefin-based modified elastomer are 5 to 65% by mass when the total of these is 100% by mass, and a third support layer formed from a third resin composition which is the same as or different from the first resin composition, comprising a polyolefin, a polyamide, and a polyolefin-based modified elastomer having a reactive group for the polyamide, wherein the proportions of the polyamide and the polyolefin-based modified elastomer are 5 to 65% by mass when the total of these is 100% by mass, and the same as or different from the first resin composition, An interposition step is to interpose a polyolefin-based recycled resin composition, which contains 80 to 99% by mass of polyolefin when the total mass is 100%, and which is imparted with foaming properties, in the gap between the first support layer and the third support layer. The process involves an intermediate layer formation step, in which the polyolefin-based recycled resin composition is foamed while the gap is expanded to form an intermediate layer, A method for recycling a polyolefin resin composition, characterized by obtaining a molded article comprising a non-foamed design layer consisting of the first support layer, a foamed intermediate layer, and a non-foamed back layer consisting of the third support layer, laminated in this order.

6. A method for recycling a molded article according to claim 1 or 2, A method for recycling a molded article, characterized by comprising a subdivision step of subdividing the molded article to obtain a polyolefin-based recycled resin.

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