Polymer, resin additive, resin composition, and molded body

Abstract

The purpose of the present invention is to provide a polymer with which compatibility is improved when a polyester resin such as a poly(butylene terephthalate) resin is compounded with another resin and with which the tensile elongation of a molded body can be improved. This polymer has a first polymer portion and a second polymer portion. The first polymer portion is a polyester-based polymer. The second polymer portion has a constituent unit that is different from a constituent unit that constitutes the first polymer portion. The proportion of the first polymer is more than 20 parts by mass and not more than 90 parts by mass relative to a total of 100 parts by mass of the first polymer portion and the second polymer portion. The second polymer portion has a constituent unit derived from a (meth)acrylate monomer.

Description

[Technical field]

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

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

[0003] Patent Document 1 discloses that polybutylene terephthalate resin, polystyrene resin, and carbon fiber have good low warpage properties and mechanical properties when polycarbonate is used as a compatibilizer. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 2020-176159 Summary of the Invention [Problem to be solved by the invention]

[0005] However, according to the study by the present inventors, it was found that the compatibilizer described in Patent Document 1 may not sufficiently improve the compatibility of polybutylene terephthalate resin and polystyrene resin. Therefore, an object of one aspect of the present invention is to provide a polymer or the like that can improve the compatibility when a polyester resin, such as polybutylene terephthalate resin, is composited with another resin, and further provides a molded product with excellent tensile elongation. [Means for solving the problem]

[0006] One aspect of the present invention is a polymer having a first polymer portion and a second polymer portion, the first polymer portion being a polyester-based polymer, the second polymer portion having a structural unit different from the structural unit constituting the first polymer portion, and the first polymer portion being a total of 100 parts by mass of the first polymer portion and the second polymer portion. portion is more than 20 parts by mass and not more than 90 parts by mass, and the second polymer portion has a constitutional unit derived from a (meth)acrylate monomer. Effect of the Invention

[0007] According to one embodiment of the present invention, it is possible to provide a polymer or the like which can improve the compatibility of resins and reduce phase separation when two or more resins are mixed, and which has excellent tensile elongation in a molded product. [Brief description of the drawings]

[0008] [Figure 1] 2 is a cross-sectional photograph of the molded body of Example 1 observed with a transmission electron microscope. [Diagram 2] 2 is a cross-sectional photograph of the molded body of Comparative Example 1 observed with a transmission electron microscope. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] The present embodiment will be described in detail below. Note that the following description is one embodiment of the present invention, and the present invention is not limited to the following configuration. The polymer according to the present embodiment is a polymer (hereinafter, sometimes referred to as polymer A) having a first polymer portion which is a polyester polymer, and a second polymer portion having a structural unit different from the structural unit constituting the first polymer portion. By using the polymer A as a resin additive for two or more types of matrix resins including a polyester resin, the first matrix resin can be easily formed. and The compatibility with the second matrix resin can be improved, and therefore phase separation between the first matrix resin and the second matrix resin can be reduced.

[0010] <1. Polymer A> The polymer A according to the present embodiment is a polymer having a first polymer portion and a second polymer portion, the first polymer portion being a polyester-based polymer, the second polymer portion having a structural unit different from the structural unit constituting the first polymer portion, and the first polymer portion being a total of 100 parts by mass of the first polymer portion and the second polymer portion. portion is more than 20 parts by mass and not more than 90 parts by mass, and the second polymer portion has a structural unit derived from a (meth)acrylate monomer. In one aspect of the present invention, the polymer having a first polymer portion and a second polymer portion may be a polymer in which the first polymer portion and the second polymer portion are covalently bonded to each other. In another aspect of the present invention, even if the first polymer portion and the second polymer portion are not covalently bonded to each other, portion is the second polymer portion The present invention also includes polymers that are encapsulated or enveloped by the above.

[0011] Examples of the polymer in which the first polymer portion and the second polymer portion are covalently bonded include block copolymers having the first polymer portion and the second polymer portion. portion is the second polymer portion Examples of the polymer encapsulated or enveloped by include polymers having a core-shell structure in which the core portion comprises one of the first polymer portion and the second polymer portion, and the shell portion comprises the other of the first polymer portion and the second polymer portion. The core-shell structure is a structure in which a portion called the core is encapsulated in a portion called the shell.

[0012] Among them, the polymer A is preferably a polymer having a core-shell structure, with the first polymer portion constituting the shell portion of the core-shell structure. That is, the polymer A is preferably a polymer in which the first polymer portion, which is a polyester polymer, constitutes the shell portion of the core-shell structure, and the second polymer portion, which has a constitutional unit different from the constitutional unit constituting the first polymer portion, constitutes the core portion. Below, a preferred embodiment of the polymer A having the core-shell structure will be described in detail as a representative example.

[0013] <1-1. First polymer portion> As described above, the first polymer portion is composed of a polyester-based polymer. In one aspect of the present invention, the polyester-based polymer means a polymer composed of a structural unit containing an ester bond as a repeating unit, and the polyester is synthesized by a polycondensation reaction between a dicarboxylic acid component and a diol component. By making the first polymer portion composed of a polyester-based polymer, the affinity with the first matrix resin, which is a polyester resin, is improved, and as a result, the compatibility between the first matrix resin and the second matrix resin is improved.

[0014] The dicarboxylic acid is not particularly limited, and examples thereof include aromatic dicarboxylic acids, aliphatic dicarboxylic acids, and alicyclic dicarboxylic acids. Examples of such aromatic dicarboxylic acids include terephthalic acid, isophthalic acid, phthalic acid, 2,5-norbornane dicarboxylic acid, and the like. R 1,4-Naphthalic acid, 1,5-Naphthalic acid, 4,4-Hydroxybenzoic acid, Fumaric acid, Maleic anhydride, Succinic acid, Glutaric acid, Adipic acid, Sebacic acid, Dodecanedicarboxylic acid, Tetrahydrophthalic anhydride, Tetrahydroterephthalic acid, 5-Sodium sulfoisophthalic acid, 5-Lithium sulfoisophthalic acid, Trimellitic anhydride, Pi B Examples include mellitic acid.

[0015] The diol component is not particularly limited, and examples thereof include ethylene glycol, propylene glycol, 1,3-butylene glycol, 1,4-butanediol, 1,6-hexanediol, neopentyl glycol, triethylene glycol, dipropylene glycol, 2,2,4-trimethyl-1,3-pentanediol, cyclohexanedimethanol, an ethylene oxide adduct of bisphenol A, a propylene oxide adduct of bisphenol A, an ethylene oxide and propylene oxide adduct of bisphenyl A, an ethylene oxide adduct and propylene oxide adduct of hydrogenated bisphenol A, polytetramethylene glycol, polyethylene glycol, polypropylene glycol and modified products thereof, and sodium sulfobutanediol.

[0016] Two or more kinds of dicarboxylic acid components may be used, and similarly, two or more kinds of diol components may be used.

[0017] The first polymer portion may be composed of a plurality of polymers having a plurality of different structural units. In this case, the structural units are the first polymer portion The structural units exemplified above can be used.

[0018] The mass average molecular weight of the first polymer portion is not particularly limited, but is preferably 3000 or more, more preferably 5000 or more, and particularly preferably 7000 or more, in terms of powder handling properties. On the other hand, in order to suppress an increase in viscosity when a matrix resin is added, the mass average molecular weight is preferably 200,000 or less, more preferably 100,000 or less, and particularly preferably 50,000 or less. The mass average molecular weight can be measured by gel permeation chromatography (GPC).

[0019] The glass transition temperature of the first polymer portion is not particularly limited, but in order to ensure powder recoverability, it is preferably 40° C. or higher, more preferably 45° C. or higher, and particularly preferably 50° C. or higher. On the other hand, in order to avoid pulverization of the powder, the glass transition temperature is preferably 150° C. or lower, more preferably 130° C. or lower, and particularly preferably 100° C. or lower.

[0020] <1-2. Second polymer portion> The second polymer portion has a structural unit different from the structural unit constituting the first polymer portion. The second polymer portion has a structural unit derived from a (meth)acrylate monomer. By having a structural unit derived from a (meth)acrylate monomer, the tensile elongation of the molded body is improved. In addition, the second polymer portion preferably has a structural unit other than the structural unit derived from a (meth)acrylate monomer, and such a structural unit is preferably a component having excellent affinity with the second matrix resin. Specifically, it is preferable that at least a part of the structural units of the second polymer portion and at least a part of the structural units constituting the second matrix resin are the same.

[0021] Regarding the (meth)acrylate monomer-derived constituent unit constituting the second polymer portion, examples of the (meth)acrylate monomer include methyl methacrylate, ethyl methacrylate, methyl acrylate, ethyl acrylate, butyl acrylate, butyl methacrylate, propyl acrylate, 2-ethylhexyl acrylate, glycidyl acrylate, propyl methacrylate, 2-ethylhexyl methacrylate, glycidyl methacrylate, phenyl acrylate, phenyl methacrylate, hydroxyethyl acrylate, 4-hydroxybutyl acrylate, benzyl acrylate, benzyl methacrylate, polyalkylene glycol monoacrylate, and polyalkylene glycol monomethacrylate. Among these, methyl methacrylate, butyl acrylate, glycidyl methacrylate, and polyalkylene glycol monomethacrylate are preferred from the viewpoint of tensile elongation of the molded article.

[0022] All structural units constituting the second polymer portion Total of 100 parts by mass In the above, the proportion of the constitutional unit derived from the (meth)acrylate monomer is not particularly limited, but in order to further improve the compatibility between the first matrix resin and the second matrix resin and to further improve the tensile elongation of the molded article, it is preferably 5 parts by mass or more, and 80 parts by mass or less, and more preferably 8 parts by mass or more and 60 parts by mass or less.

[0023] The structural units constituting the second polymer portion other than the structural units derived from the (meth)acrylate monomer are preferably selected in accordance with the structure of the second matrix resin to be used, and examples of such units include structural units derived from aromatic vinyl monomers. Vinyl Monomer In the case where the second matrix resin contains a structural unit derived from styrene, for example, when a polystyrene-containing resin is used as the second matrix resin, the affinity between the second polymer portion and the polystyrene-containing resin is improved, and as a result, it is expected that the compatibility between the first matrix resin and the second matrix resin will be improved. In particular, the structural unit constituting the second polymer portion is more preferably a structural unit derived from an aromatic vinyl monomer having a six-membered monocyclic structure, and even more preferably a structural unit derived from styrene which may have a substituent. Examples of the structural unit derived from styrene which may have a substituent include a structural unit derived from styrene or a structural unit derived from α-methylstyrene, and among these, a structural unit derived from styrene is particularly preferred.

[0024] All units of the second polymer portion Total of 100 parts by mass The proportion of the aromatic vinyl monomer-derived structural unit in is not particularly limited, but in order to further improve the compatibility between the first matrix resin and the second matrix resin, it is preferably 30 parts by mass or more, more preferably 50 parts by mass or more, even more preferably 60 parts by mass or more, and particularly preferably 70 parts by mass or more, while it is preferably 95 parts by mass or less and less than 100 parts by mass. It is okay .

[0025] The second polymer portion ,So All of the structural units of the second polymer portion may further include other structural units. Total of 100 parts by mass There are no particular limitations on the proportion of the other structural units in, but in order to further improve the compatibility between the first matrix resin and the second matrix resin, it is preferably 50 parts by mass or less, more preferably 30 parts by mass or less, and particularly preferably 20 parts by mass or less, while it is 0 parts by mass or more.

[0026] The second polymer portion may be composed of a plurality of polymers having a plurality of different structural units. In this case, the structural units are the second polymer portion The structural units exemplified above can be used.

[0027] The first polymer in a total of 100 parts by mass of the first polymer portion and the second polymer portion portion The ratio of is preferably more than 20 parts by mass and not more than 90 parts by mass, more preferably more than 20 parts by mass and not more than 80 parts by mass, even more preferably more than 20 parts by mass and not more than 70 parts by mass, even more preferably more than 20 parts by mass and not more than 60 parts by mass, even more preferably more than 20 parts by mass and not more than 50 parts by mass, even more preferably more than 20 parts by mass and not more than 45 parts by mass, and particularly preferably more than 20 parts by mass and not more than 40 parts by mass.

[0028] <1-3. Method for producing polymer A> The method for producing polymer A when it has a core-shell structure is not particularly limited, and it can be produced by a known method such as suspension polymerization, solution polymerization, or emulsion polymerization. Among them, from the viewpoint of ease of production, it is preferable to produce it by emulsion polymerization. That is, it is preferable that polymer A is a polymer obtained by emulsion polymerization of a monomer component constituting the second polymer portion in the presence of a polymer constituting the first polymer portion to be finally obtained. In addition, when carrying out emulsion polymerization, the monomer component may be added and polymerized all at once by batch polymerization, or may be added stepwise by dropwise polymerization.

[0029] More specifically, a polymer that will constitute the first polymer portion is dispersed in a solvent, and a second polymer is added to the dispersion. portion The monomer components constituting the above are added, emulsified using a mixer, and then a polymerization initiator is added to polymerize.

[0030] First Polymer Polymer that will make up the part The solution in which the first polymer portion is dispersed in an arbitrary solvent can be obtained, for example, by adding the polymer constituting the first polymer portion to one or more solvents such as water, various alcohols such as isopropyl alcohol, ethanol, and methanol, acetone, methyl ethyl ketone, and diethyl ether, and stirring the mixture while applying shear. Polymer that will make up the part The proportion is preferably 10% by mass or more because of excellent dispersibility, and is preferably 50% by mass or less from the viewpoint of handleability taking into account the viscosity of the dispersion solution.

[0031] When the monomer component constituting the second polymer portion is added to a solution in which the polymer constituting the first polymer portion is dispersed in an arbitrary solvent, a surfactant may be further added. Examples of the surfactant include anionic surfactants, cationic surfactants, and neutral surfactants. These surfactants may be used alone or in combination.

[0032] As the polymerization initiator, those generally used for radical polymerization can be used. Specific examples thereof include persulfates such as potassium persulfate, sodium persulfate, and ammonium persulfate, oil-soluble azo compounds such as azobisisobutyronitrile, 2,2'-azobis(2-methylbutyronitrile), 2,2'-azobis(2,4-dimethylvaleronitrile), 2,2'-azobis(4-methoxy-2,4-dimethylvaleronitrile), and 2-phenylazo-4-methoxy-2,4-dimethylvaleronitrile, and 2,2'-azobis{2-methyl-N-[1,1-bis(hydroxymethyl)-2-hydroxyphenyl]phenylazo-4-methoxy-2,4-dimethylvaleronitrile. 2,2'-azobis{2-methyl-N-[2-(1-hydroxyethyl)]propionamide}, 2,2'-azobis{2-methyl-N-[2-(1-hydroxybutyl)]propionamide}2,2'-azobis[2-(5-methyl-2-imidazolin-2-yl)propane] and its salts, 2,2'-azobis[2-(2-imidazolin-2-yl)propane] and its salts, 2,2'-azobis{2-[1-(2-hydroxyethyl)-2-imidazolin-2-yl]propane} and its salts, 2,2'-azobis(2-methylpropionamide) O Examples of the polymerization initiator include water-soluble azo compounds such as 2,2'-azobis[N-(2-carboxyethyl)-2-methylpropionamidine] and salts thereof, benzoyl peroxide, cumene hydroperoxide, t-butyl hydroperoxide, t-butyl peroxy-2-ethylhexanoate, t-butyl peroxyisobutyrate, etc. The polymerization initiator may be used alone or in combination of two or more kinds.

[0033] Preferred radical polymerization methods in one embodiment of the present invention include, for example, a method in which polymerization is carried out using a water-soluble polymerization initiator, and a method in which polymerization is carried out by a redox reaction using an organic peroxide and a reducing agent such as ferrous sulfate or isoascorbic acid.

[0034] The amount of the polymerization initiator used is portionThe amount of the peroxide-based polymerization initiator is preferably 0.05 to 1.0 parts by mass relative to 100 parts by mass of the total of the monomers constituting the second polymer, and the lower limit is more preferably 0.1 parts by mass or more and the upper limit is more preferably 0.3 parts by mass or less. When a peroxide-based polymerization initiator is used, it can be used as a redox-based polymerization initiator in combination with a reducing agent. The amount of the reducing agent used is determined based on the amount of the second polymer. portion The content is preferably 0.0001 to 1 part by mass relative to 100 parts by mass of the total of the constituent monomers.

[0035] Furthermore, as a molecular weight regulator, a known chain transfer agent such as n-dodecyl mercaptan, t-dodecyl mercaptan, α-methylstyrene dimer, etc. may be used to polymerize the monomers.

[0036] The reaction temperature is not particularly limited, but is usually from 45° C. to 80° C. The reaction time is not particularly limited, but is usually from 30 minutes to 300 minutes.

[0037] The latex of polymer A obtained by emulsion polymerization can be dried by spray drying or freeze drying, or coagulated, to recover the polymer powder. Among these, drying or coagulation by spray drying is preferred.

[0038] In the case of drying by spray drying, it is preferable to spray the latex of polymer A onto fine droplets and dry them by applying hot air to them. Any device such as a rotating disk type, a pressure nozzle type, or a two-fluid nozzle type may be used as a device for generating droplets.

[0039] Polymer A latex is blown with hot air of When drying is performed by blowing hot air over the latex, the hot air temperature is preferably 100° C. or higher and 200° C. or lower. When the hot air temperature is 100° C. or higher, the latex can be sufficiently dried, and when the hot air temperature is 200° C. or lower, thermal decomposition of the obtained powder can be suppressed.

[0040] When coagulation is performed, the latex of polymer A is put into hot water in which a coagulant is dissolved, and polymer A is salted out, separated, purified, coagulated, and made wet, which is then dehydrated and dried. Examples of the coagulant include inorganic salts such as aluminum chloride, aluminum sulfate, sodium sulfate, magnesium sulfate, sodium nitrate, and calcium acetate, and acids such as sulfuric acid, with calcium acetate being particularly preferred. These coagulants may be used alone or in combination of two or more, but when used in combination, it is preferable to select a combination that does not form a water-insoluble salt. For example, the combination of calcium acetate with sulfuric acid or its sodium salt is not preferable because it forms a water-insoluble calcium salt.

[0041] It is common technical knowledge that the polymerization mode of the first polymer portion and the second polymer portion of the polymer A changes depending on the production method thereof, but it is difficult to specify what the polymerization mode is. For example, it is considered that the polymerization mode of the polymer A obtained by emulsion polymerization of the monomer component constituting the second polymer portion in the presence of the polymer constituting the first polymer portion changes from that of the polymer A obtained by other methods, resulting in a difference in structure or properties. However, it is technically impossible or almost impractical to specify the structure or properties so as to clearly show such differences.

[0042] [Resin additives] The polymer A can be used as a resin additive such as a compatibilizer. The resin additive may be the polymer A itself, or may be mixed with any auxiliary. Examples of the auxiliary include known ones, such as flame retardants, anti-dripping agents, antioxidants, ultraviolet absorbers, light stabilizers, release agents, lubricants, sliding agents, colorants, fluorescent brighteners, phosphorescent pigments, fluorescent dyes, and antistatic agents.

[0043] <2.Resin composition> The resin composition according to the present embodiment includes a polymer A and a first matrix resin. The resin composition may further include a second matrix resin that is a resin different from the first matrix resin. The ratio of the polymer A to a total of 100 parts by mass of the first matrix resin and the second matrix resin is not particularly limited, but is preferably 0.1 to 30 parts by mass, more preferably 5 to 20 parts by mass. When the ratio of the resin additive is 0.1 parts by mass or more, the compatibility of the first matrix resin and the second matrix resin is further improved, and when it is 30 parts by mass or less, the processability during production of the resin composition is excellent.

[0044] The resin composition according to the present embodiment may further contain other components. For example, known auxiliary agents may be blended as necessary to impart functionality or improve properties. Examples of such auxiliary agents include flame retardants, anti-dripping agents, antioxidants, ultraviolet absorbers, light stabilizers, release agents, lubricants, sliding agents, colorants, fluorescent brighteners, phosphorescent pigments, fluorescent dyes, and antistatic agents.

[0045] <2-1. First matrix resin> The first matrix resin is not particularly limited, but is preferably a polyester resin, and may be, for example, at least one resin selected from the group consisting of polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polyethylene naphthalate (PEN), polybutylene naphthalate (PBN), polybutylene succinate (PBS), polyhydroxyalkanoic acid (PHA), and polylactic acid (PLA). Recycled materials may also be used for these.

[0046] <2-2. Second matrix resin> The second matrix resin is not particularly limited as long as it is a resin different from the first matrix resin, but for example, a polystyrene-containing resin such as polystyrene, high impact polystyrene (HIPS) and acrylonitrile-butadiene-styrene copolymer (ABS) can be used. Recycled materials may also be used for these. From the viewpoint of improving compatibility, it is preferable that at least a part of the constituent units constituting the second matrix resin is the same as at least a part of the constituent units of the second polymer portion in polymer A.

[0047] The proportion of the first matrix resin in a total of 100 parts by mass of the first matrix resin and the second matrix resin is not particularly limited, but is preferably 5 parts by mass or more, more preferably 10 parts by mass or more, even more preferably 20 parts by mass or more, and particularly preferably 25 parts by mass or more, while the proportion of the first matrix resin is preferably 95 parts by mass or less, more preferably 90 parts by mass or less, even more preferably 80 parts by mass or less, and particularly preferably 75 parts by mass or less.

[0048] <2-3. Method for producing resin composition> The method for producing the resin composition is not particularly limited, but the resin composition can be produced by mixing or melt-kneading the polymer A, the first matrix resin, and the second matrix resin in the form of powder. For mixing or melt-kneading, a Henschel mixer, a Banbury mixer, a single-screw extruder, a twin-screw extruder, a two-roll mixer, a kneader, or a Brabender mixer can be used. mixer etc. are used.

[0049] <3. Molded body> The resin composition according to the present embodiment can be molded into a molded body. The resin composition according to the present embodiment may be mixed with other materials and then molded into a molded body. That is, the molded body may contain the resin composition. As a molding method, a known method can be used, for example, compression molding, transfer molding, injection molding, blow molding, vacuum molding, extrusion molding, lamination molding, and calendar molding.

[0050] <4. Summary> As described above, the present invention has the following aspects.

[0051] [1] A polymer having a first polymer portion and a second polymer portion, wherein the first polymer portion is a polyester-based polymer, the second polymer portion has a structural unit different from the structural unit constituting the first polymer portion, and the first polymer portion is a polyester-based polymer in a total of 100 parts by mass of the first polymer portion and the second polymer portion. portion is more than 20 parts by mass and not more than 90 parts by mass, and the second polymer portion has a structural unit derived from a (meth)acrylate monomer.

[0052] [2] All structural units constituting the second polymer portion Total of 100 parts by mass The polymer according to [1], wherein the proportion of the structural units derived from the (meth)acrylate monomer is 5 parts by mass or more.

[0053] [3] The second polymer portion further has a structural unit derived from an aromatic vinyl monomer. 、[ The polymer according to [1] or [2].

[0054] [4] All structural units constituting the second polymer portion Total of 100 parts by mass The polymer according to [3], wherein a ratio of the structural units derived from the aromatic vinyl monomer is 30 parts by mass or more and 95 parts by mass or less.

[0055] [5] The polymer according to any one of [1] to [4], having a core-shell structure, the first polymer portion constituting a shell portion of the core-shell structure, and the second polymer portion constituting a core portion of the core-shell structure.

[0056] [6] The polymer according to any one of [1] to [5], obtained by emulsion polymerization of a monomer component constituting the second polymer portion in the presence of a polymer constituting the first polymer portion.

[0057] [7] A resin additive comprising the polymer according to any one of [1] to [6].

[0058] [8] A resin composition comprising the polymer according to any one of [1] to [6] and a polyester resin as a first matrix resin.

[0059] [9] The resin composition according to [8], further comprising a second matrix resin, the second matrix resin being different from the first matrix resin.

[0060]

[10] The resin composition according to [9], wherein the second matrix resin is a polystyrene-containing resin.

[0061]

[11] A resin composition comprising the polymer according to [1], [5] or [6], a polyester resin as a first matrix resin, and a second matrix resin which is a resin different from the first matrix resin, wherein at least a portion of the structural units of the second polymer portion are identical to at least a portion of the structural units constituting the second matrix resin.

[0062]

[12] A molded article comprising the resin composition according to any one of [8] to

[11] . EXAMPLES

[0063] An embodiment of the present invention will now be described with reference to the following examples. In the examples, "parts" refers to "parts by mass."

[0064] <Tensile modulus, tensile elongation> A tensile test was carried out using a Tensilon universal testing machine (model name "RTC-1250A-PL", manufactured by Orientec Co., Ltd.) in accordance with JIS K7139 to measure the tensile modulus and tensile elongation of the molded body.

[0065] <Phase size> A transmission electron microscope (TEM) (model name "H-7600", Hitachi) was used to observe the phase size of some of the molded bodies. The test pieces were stained with osmium tetroxide for 12 hours, then stained with ruthenium tetroxide for 5 hours, and observation sections were prepared. The average diameter of the major axis of 30 randomly selected dispersed phases in the TEM photograph was calculated and used as the phase size.

[0066] (Production Example 1) As an aqueous dispersion solution of the polymer constituting the first polymer portion, 240 parts of Nichigo Polyester WR-905 (manufactured by Mitsubishi Chemical Corporation: solid content 20%), and as radical polymerizable monomers, 90 parts of styrene (St) and 10 parts of glycidyl methacrylate (GMA) were added, and emulsified using a homomixer to obtain a pre-emulsion liquid of the radical polymerizable monomer.

[0067] 222 parts of the pre-emulsion liquid and deionized water were added to a flask equipped with a stirrer, a reflux condenser, and a temperature controller, and the temperature was raised to 50°C while nitrogen bubbling was performed at a flow rate of 200 ml per minute, and the temperature was maintained for 1 hour. 0.7 parts of Percumyl P (manufactured by NOF Corp.) as a polymerization initiator, 0.002 parts of ferrous sulfate as reducing agents, 0.006 parts of sodium ethylenediaminetetraacetate (EDTA), 0.3 parts of sodium formaldehyde sulfoxylate, and 10 parts of deionized water were added, and the nitrogen flow was switched to initiate polymerization. After 1 hour, the temperature was raised to 60°C, the temperature was maintained for 2 hours, and the mixture was cooled to obtain a latex of polymer A1 according to one embodiment of the present invention. The obtained polymer A1 of The latex was added to 460 parts of deionized water containing 5 parts by mass of calcium acetate to cause coagulation, followed by washing with water, dehydration and drying to obtain polymer A1 in the form of powder.

[0068] (Examples 2 to 9) Polymers A2 to A6 according to an embodiment of the present invention and polymers B1 to B3 according to comparative examples were obtained by the same production method as in Production Example 1, except that the amount of the first polymer portion used, the type of radical polymerizable monomer, and the amount of copolymerization were changed as shown in Table 1 below. One or two types of (meth)acrylate were used as the radical polymerizable monomer. In Table 1, two types of (meth)acrylate are represented as "a1" and "a2", respectively. In Production Examples 2 to 7, at least one of glycidyl methacrylate (GMA), butyl acrylate (BA), methyl methacrylate (MMA), and polypropylene glycol monomethacrylate (BLEMMER PP-800 manufactured by NOF Corporation) was used as the radical polymerizable monomer.

[0069] <Polymerization stability> The polymerization stability of each polymer was evaluated as "good" if the radical polymerizable monomer was kept in an emulsified state by the first polymer throughout the polymerization process, and as "bad" if it separated.

[0070] Example 1 70 parts of polybutylene terephthalate (PBT, manufactured by Mitsubishi Engineering Plastics Corporation: Novaduran 5010R) as the first matrix resin, 30 parts of polystyrene (PS, manufactured by Toyo Styrene Corporation: Toyo Styrol GP200) as the second matrix resin, and 10 parts of the polymer A1 manufactured in Manufacturing Example 1 were placed in a polyethylene bag. The polyethylene bag was shaken well by hand to perform hand blending, and then melt-kneaded at 250°C using a twin-screw extruder (manufactured by Toshiba Machine Co., Ltd., product name: TEM35B), and the extruded strand was cut to obtain pellets. The obtained pellets were molded using an injection molding machine (manufactured by Toshiba Machine Co., Ltd., product name: IS100EN) at a molding temperature of 250°C and a mold temperature of 60°C to produce a dumbbell-shaped molded body in accordance with JIS K7139, and a molded body according to Example 1 was obtained. The molded body was subjected to cross-sectional observation and tensile testing using a transmission electron microscope (TEM). A TEM photograph of the cross section of the molded body is shown in FIG. 1. The average diameter of the major axis of 30 randomly selected dispersed phases in the TEM photograph was 0.58 μm. Furthermore, the tensile modulus of the molded body in a tensile test was 2.2 GPa, and the tensile elongation was 3.1%.

[0071] (Examples 2 to 8) Molded bodies were obtained and evaluated in the same manner as in Example 1, except that the second matrix resin was changed to high impact polystyrene (HIPS, manufactured by Toyo Styrene: Toyo Styrol H350), or the ratio of the first matrix resin and the second matrix resin, the type of polymer used, and the amount added were changed as shown in Table 2 below.

[0072] Comparative Example 1 A resin composition and a molded body were produced in the same manner as in Example 1, except that the polymer A1 obtained in Production Example 1 was not added, and a molded body according to Comparative Example 1 was obtained. The molded body was subjected to cross-sectional observation by TEM and a tensile test. A TEM photograph of the cross section of the molded body is shown in FIG. 2. The average diameter of the major axis portion of 30 randomly selected dispersed phases in the TEM photograph was 1.01 μm. Furthermore, the tensile modulus of the molded body in the tensile test was 2.1 GPa, and the tensile elongation was 2.9%.

[0073] (Comparative Examples 2 to 7) Molded bodies were obtained and evaluated in the same manner as in Example 1, except that the second matrix resin was changed to high impact polystyrene (HIPS, manufactured by Toyo Styrene: Toyo Styrol H350), or the presence or absence of addition of a polymer, and the type and amount of polymer used were changed as shown in Table 2 below.

[0074] [Table 1]

[0075] [Table 2]

[0076] From the above results, it can be seen that, in a ratio of the first matrix resin to the second matrix resin of 70 / 30 (first matrix resin / second matrix resin), in Example 1 in which the polymer according to one embodiment of the present invention is used, the average diameter of the dispersed phase is significantly smaller than in Comparative Example 1 in which the polymer according to one embodiment of the present invention is not used, and the tensile elongation of the molded body is improved by 7% when Comparative Example 1 is taken as 100%. Similarly, it can be seen that, in Examples 4 and 6 in which the polymer according to one embodiment of the present invention is used, the average diameter of the dispersed phase and the tensile elongation of the molded body are improved compared to Comparative Example 1. From the above results, it can be seen that the compatibility between the first matrix resin and the second matrix resin and the tensile elongation of the molded body are improved by using the polymer according to one embodiment of the present invention as a resin additive. The improved tensile elongation improves the toughness of the molded body, and therefore has high industrial utility value.

[0077] In addition, it was confirmed that, compared to Comparative Example 5, in which a polymer having a small proportion of the first polymer portion was used, Example 2, in which the proportion of the first polymer portion was sufficient, had a smaller average diameter of the dispersed phase, and the tensile elongation of the molded body was also improved by 3% when Comparative Example 5 was taken as 100%. Similarly, in Comparative Example 4, in which a polymer having a small proportion of the first polymer portion was used, and Example 7, in which the proportion of the first polymer portion was sufficient, it was found that the average diameter of the dispersed phase and the tensile elongation of the molded body were improved. From the above results, it can be seen that the compatibility between the first matrix resin and the second matrix resin and the tensile elongation of the molded body are improved by using the polymer according to one embodiment of the present invention as a resin additive. The improved tensile elongation improves the toughness of the molded body, and therefore has high industrial utility value.

[0078] Furthermore, it was confirmed that, compared to Comparative Example 6 in which a polymer not containing a (meth)acrylate monomer was used in the second polymer portion, Examples 2, 5, and 7 in which a (meth)acrylate monomer was contained in the second polymer portion had a small average diameter of the dispersed phase and the tensile elongation of the molded article was improved. It was confirmed that, when the tensile elongation of Comparative Example 6 was taken as 100%, the tensile elongation of Examples 2, 5, and 7 was improved by 20%, 44%, and 96%, respectively. From the above results, it can be seen that the compatibility between the first matrix resin and the second matrix resin and the tensile elongation of the molded article are improved by using the polymer according to one aspect of the present invention as a resin additive. The improved tensile elongation increases the toughness of the molded article, and therefore the industrial value of the polymer is high.

[0079] It can be seen that Example 3, in which the ratio of the first matrix resin to the second matrix resin is 90 / 10 (first matrix resin / second matrix resin), has a significantly smaller average diameter of the dispersed phase than Comparative Example 2, in which the polymer according to an embodiment of the present invention is not used, and the tensile elongation of the molded body is improved by 29% when the tensile elongation of Comparative Example 2 is taken as 100%. From the above results, it can be seen that the use of the polymer according to an embodiment of the present invention as a resin additive improves the compatibility between the first matrix resin and the second matrix resin and the tensile elongation of the molded body. The improved tensile elongation increases the toughness of the molded body, making it highly valuable for industrial use.

[0080] It can be seen that in Example 8, in which HIPS was used as the second matrix resin, the average diameter of the dispersed phase was significantly smaller than in Comparative Example 3, in which the polymer according to an embodiment of the present invention was not used, and the tensile elongation of the molded article was improved by 14% when the tensile elongation of Comparative Example 3 was taken as 100%. From the above results, it can be seen that the use of the polymer according to an embodiment of the present invention as a resin additive improves the compatibility between the first matrix resin and the second matrix resin and the tensile elongation of the molded article. The improved tensile elongation increases the toughness of the molded article, making it highly valuable for industrial use.

[0081] In Comparative Example 7, in which a polymer not having a second polymer portion was used, the polymerization of the polymer Goan The quality was poor, and the tensile elongation of the molded article was inferior to that of Comparative Example 1 which did not contain a polymer, and therefore the industrial applicability was poor. [Industrial Applicability]

[0082] The polymer according to one embodiment of the present invention can be suitably used as a compatibilizer that can reduce phase separation of resins when two or more types of resins are mixed, and that has excellent tensile elongation when a resin composition containing the polymer is molded into a molded article.

Claims

1. A polymer having a first polymer portion and a second polymer portion, the first polymer portion is a polyester-based polymer, the second polymer portion has a structural unit different from the structural unit constituting the first polymer portion, a ratio of the first polymer portion to a total of 100 parts by mass of the first polymer portion and the second polymer portion is more than 20 parts by mass and 90 parts by mass or less; The second polymer portion has a structural unit derived from a (meth)acrylate monomer.

2. The polymer according to claim 1 , wherein the proportion of the structural units derived from the (meth)acrylate monomer in a total of 100 parts by mass of all structural units constituting the second polymer portion is 5 parts by mass or more.

3. The polymer of claim 1 , wherein the second polymer portion further comprises a constitutional unit derived from an aromatic vinyl monomer.

4. The polymer according to claim 3, wherein the proportion of the structural units derived from the aromatic vinyl monomer in a total of 100 parts by mass of all structural units constituting the second polymer portion is 30 parts by mass or more and 95 parts by mass or less.

5. It has a core-shell structure, the first polymer portion constitutes a shell portion of the core-shell structure; The polymer of claim 1 , wherein the second polymer portion constitutes a core portion of the core-shell structure.

6. 2. The polymer according to claim 1, obtained by emulsion polymerization of a monomer component constituting said second polymer portion in the presence of a polymer constituting said first polymer portion.

7. A resin additive comprising the polymer according to any one of claims 1 to 6.

8. A resin composition comprising the polymer according to claim 1 and a polyester resin as a first matrix resin.

9. The resin composition according to claim 8 , further comprising a second matrix resin, the second matrix resin being different from the first matrix resin.

10. The resin composition of claim 9 , wherein the second matrix resin is a polystyrene-containing resin.

11. The polymer of claim 1 ; A polyester resin as a first matrix resin; A resin composition comprising: a second matrix resin which is a resin different from the first matrix resin; A resin composition, wherein at least a portion of the structural units of the second polymer portion are identical to at least a portion of the structural units constituting the second matrix resin.

12. A molded article comprising the resin composition according to any one of claims 8 to 11.

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