Resin composition and catalyst masterbatch

Abstract

Provided is a resin material which imparts a finished product such as a motor vehicle or a cellular phone with lightness and high strength. Also provided is a catalyst masterbatch which catalyzes an epoxy reaction of a thermoplastic resin. The catalyst master batch contains (I) a thermoplastic resin not having an epoxy group and (II) at least one type of catalyst selected from among a transesterification catalyst and an epoxy ring-opening catalyst. The amount of the catalyst (II) is 0.1-30 wt% relative to the total amount of the thermoplastic resin (I) not having an epoxy group and the catalyst (II).

Description

Resin composition and catalyst masterbatch

[0001] The present invention relates to a catalyst masterbatch and a resin composition containing the masterbatch and a thermoplastic resin.

[0002] Condensation thermoplastic resins such as polycarbonate resin, polyamide resin, and polyester resin, as well as polyphenylene sulfide resin and liquid crystal resin, are known as engineering plastics due to their excellent physical properties, such as impact resistance and heat resistance. They are widely used in electrical and electronic components, mechanical components, and automotive parts. In recent years, the automotive materials field has been constantly exploring ways to improve fuel efficiency by reducing the weight of automobiles, with the aim of reducing the burden on the natural environment. Similarly, in the electronic materials field, such as in mobile phones and mobile personal computers, research into thinner and lighter housing materials is also progressing daily to improve portability. Methods such as replacing heavy metal parts with resin materials and thinning the walls of conventional resin materials are effective means of reducing the weight of automobiles and mobile phones.

[0003] However, resin materials containing large amounts of inorganic materials such as glass fiber and talc are lighter than metals, but because their specific gravity is higher than that of the resin itself, there is a limit to how light they can be made.

[0004] Methods using lightweight organic materials have been proposed, for example, by compounding acrylic or diene rubbers (Japanese Patent Laid-Open Publication No. 49-041442), polyetheresteramides (Japanese Patent Laid-Open Publication Nos. 61-64752 and 61-81456), and ethylene-glycidyl methacrylate copolymers (Japanese Patent Laid-Open Publication No. 52-032045). However, while these methods have improved impact resistance to some extent, they are still insufficient, and the balance between rigidity and impact resistance is not satisfactory. For example, compounding ethylene-glycidyl methacrylate copolymers can achieve a high impact strength improvement effect on polybutylene terephthalate resins, but no sufficient effect has been confirmed for other engineering plastics.

[0005] JP-A-49-041442 JP-A-61-64752 JP-A-61-81456 JP-A-52-032045

[0006] An object of the present invention is to provide a resin material that imparts light weight and high strength to final products such as automobiles and mobile phones.

[0007] The present invention includes the following inventions: [1] A catalyst masterbatch for catalyzing an epoxy reaction of a thermoplastic resin, the catalyst masterbatch comprising: (I) a thermoplastic resin having no epoxy groups, and (II) a catalyst which is at least one selected from a transesterification catalyst and an epoxy ring-opening catalyst, wherein the amount of catalyst (II) is 0.05 to 30% by weight based on the total weight of the thermoplastic resin having no epoxy groups (I) and the catalyst (II). [2] The catalyst masterbatch according to [1], wherein the thermoplastic resin having no epoxy groups (I) is a polyethylene and ethylene copolymer, or is compatible or miscible with the thermoplastic resin having epoxy groups (B) and has a structure similar to that of the thermoplastic resin (B). [3] The catalyst masterbatch according to [1] or [2], wherein the thermoplastic resin (I) having no epoxy groups is at least one resin selected from the group consisting of polyester, polycarbonate, polyphenylene sulfide, polyamide, polyimide, polyetherimide, polyacetal, polyether, polyether ketone, polyphenylene ether, liquid crystal polymer, polyarylate, polysulfone, polyethersulfone, etc. [4] The catalyst masterbatch according to any one of [1] to [3], wherein the catalyst (II) is at least one catalyst selected from the group consisting of alkali metal compounds, alkaline earth metal compounds, titanium compounds, antimony compounds, germanium compounds, manganese compounds, tin compounds, aluminum compounds, bismuth compounds, gallium compounds, indium compounds, zinc compounds, nitrogen-containing compounds, basic phosphorus compounds, phosphorous compounds, basic ammonium compounds, and amine compounds. [5] A resin composition comprising 100 parts by weight of a thermoplastic resin (A) having a site reactive with an epoxy group, 0.5 to 20 parts by weight of a thermoplastic resin (B) having an epoxy group, and 0.01 to 20 parts by weight of the catalyst masterbatch (C) according to any one of [1] to [4]. [6] The resin composition according to [5], wherein the thermoplastic resin (A) having a site reactive with an epoxy group has at least one epoxy-reactive group selected from the group consisting of a hydroxy group, a phenol group, a thiol group, a carboxy group, an amino group, and an ester group.[7] The resin composition according to [5] or [6], wherein the thermoplastic resin (A) having a site reactive with an epoxy group has an epoxy-reactive group at a molecular terminal. [8] The resin composition according to any one of [5] to [7], wherein the thermoplastic resin (A) having a site reactive with an epoxy group is at least one resin selected from the group consisting of polyester, polyamide, polycarbonate, polyethersulfone, polyphenylene ether, polyphenylene sulfide, polyethersulfone, polyacetal, polysulfone, polyetheretherketone, polyetherketone, polyetherimide, polyimide, polyether, liquid crystal polymer, and polyarylate. [9] The resin composition according to any one of [5] to [8], wherein the thermoplastic resin (B) having an epoxy group has at least one epoxy group in the polymer.

[10] The resin composition according to any one of [1] to [9], wherein the thermoplastic resin (A) having a site reactive with an epoxy group, the thermoplastic resin (B) having an epoxy group, and the catalyst masterbatch (C) are each in a particulate form.

[11] A method for producing the catalyst masterbatch according to any one of [1] to [4], which comprises mixing a thermoplastic resin (I) having no epoxy groups with a catalyst (II).

[12] A method for producing a resin composition, which comprises melt-kneading a thermoplastic resin (A) having a site reactive with an epoxy group, a thermoplastic resin (B) having an epoxy group, and the catalyst masterbatch according to any one of [1] to [4].

[0008] In a resin composition in which a masterbatch containing a thermoplastic resin having no epoxy groups and a catalyst is added to a thermoplastic resin having a site reactive with an epoxy group and a thermoplastic resin having an epoxy group, the masterbatch has good dispersibility, and a thermoplastic resin composition with dramatically high impact strength can be obtained.

[0009] The resin composition comprises: (A) a thermoplastic resin having a site reactive with an epoxy group; (B) a thermoplastic resin having an epoxy group; and (C) a catalyst masterbatch.

[0010] The catalyst masterbatch comprises: (I) a thermoplastic resin having no epoxy groups; and (II) a catalyst which is at least one selected from a transesterification catalyst and an epoxy ring-opening catalyst.

[0011] <(A) Thermoplastic Resin Having a Site Reactive with Epoxy Groups> In the thermoplastic resin (A) having a site reactive with epoxy groups, the site reactive with the epoxy group is preferably a group having active hydrogen, i.e., an active hydrogen-containing group. The active hydrogen-containing group is present in a side chain or terminal of the thermoplastic resin. The active hydrogen-containing group is not particularly limited as long as it is a group that reacts with epoxy groups. Examples of the active hydrogen-containing group include a hydroxy group, a phenol group, a thiol group, a carboxy group, and an amino group. Thermoplastic resins capable of transesterification can also be used.

[0012] Examples of the thermoplastic resin (A) include polyester, polycarbonate, polyphenylene sulfide, polyamide, polyimide, polyetherimide, polyacetal, polyether, polyether ketone, polyphenylene ether, liquid crystal polymer, polyarylate, polysulfone, polyether sulfone, etc. These may be used alone or in combination of two or more. For example, two or more polyesters may be used, or a combination of polyester and polycarbonate may be used.

[0013] Examples of polyesters include aliphatic polyesters such as polylactic acid and polycaprolactone, and aromatic polyesters such as polyethylene terephthalate, polybutylene terephthalate and polyethylene naphthalate.

[0014] Examples of aliphatic polyesters include polyesters obtained by polymerizing hydroxycarboxylic acids and polyesters obtained by copolymerizing diols and dicarboxylic acids. These may be used alone or in combination of two or more.

[0015] The polyester obtained by polymerizing hydroxycarboxylic acid includes a polymer having a repeating unit derived from 3-hydroxyalkanoate, and may be a homopolymer or a multi-component copolymer containing two or more types of repeating units. The multi-component copolymer may be any of a random copolymer, an alternating copolymer, a block copolymer, a graft copolymer, etc.

[0016] Examples of the homopolymer include polylactic acid, polycaprolactone, poly-3-hydroxybutyrate ester, poly(4-hydroxybutyrate), poly(3-hydroxypropionate), etc. Examples of the multicomponent copolymer include 3-hydroxybutyrate-3-hydroxypropionate copolymer, 3-hydroxybutyrate-4-hydroxybutyrate copolymer, 3-hydroxybutyrate-3-hydroxyvalerate copolymer, 3-hydroxybutyrate-3-hydroxyhexanoate copolymer, 3-hydroxybutyrate-3-hydroxyoctanoate copolymer, 3-hydroxybutyrate-3-hydroxyvalerate-3-hydroxyhexanoate-4-hydroxybutyrate copolymer, 3-hydroxybutyrate-lactic acid copolymer, etc. Of these, it is preferable to use polylactic acid and mixtures thereof.

[0017] Aromatic polyesters include condensation polymers of diols and dicarboxylic acids having an aromatic moiety.

[0018] Examples of diols include linear or branched aliphatic diols having 2 to 20 carbon atoms, such as ethylene glycol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,10-decanediol, and neopentyl glycol, diols containing an alicyclic group, such as 1,4-cyclohexanediol and 1,4-cyclohexanediethanol, and long-chain glycols, such as polyethylene glycol, poly-1,3-propylene glycol, and polytetramethylene glycol, having a molecular weight of 400 to 6000. Two or more types of diols may be used.

[0019] Examples of aromatic dicarboxylic acids include terephthalic acid, isophthalic acid, phthalic acid, bis(4-carboxyphenyl)methane, 1,2-bis(4-carboxyphenyl)ethane, 4,4'-dicarboxybiphenyl ether, and naphthalenedicarboxylic acid.

[0020] As the aromatic dicarboxylic acids, two or more kinds of dicarboxylic acids may be used.

[0021] Polycarbonates can be classified into aromatic polycarbonates in which the carbon atoms directly bonded to the carbonate bonds are aromatic carbon atoms, and aliphatic polycarbonates in which the carbon atoms directly bonded to the carbonate bonds are aliphatic carbon atoms, and either can be used.

[0022] Among the monomers that serve as raw materials for aromatic polycarbonates, examples of aromatic dihydroxy compounds include hydroxybenzenes such as 1,2-dihydroxybenzene, 1,3-dihydroxybenzene (and resorcinol), and 1,4-dihydroxybenzene; dihydroxybiphenyls such as 2,5-dihydroxybiphenyl, 2,2'-dihydroxybiphenyl, and 4,4'-dihydroxybiphenyl; and dihydroxynaphthalenes such as 2,2'-dihydroxy-1,1'-binaphthyl, 1,2-dihydroxynaphthalene, 1,3-dihydroxynaphthalene, 2,3-dihydroxynaphthalene, 1,6-dihydroxynaphthalene, 2,6-dihydroxynaphthalene, 1,7-dihydroxynaphthalene, and 2,7-dihydroxynaphthalene.

[0023] Examples of dihydroxydiaryl ethers include 2,2'-dihydroxydiphenyl ether, 3,3'-dihydroxydiphenyl ether, 4,4'-dihydroxydiphenyl ether, 4,4'-dihydroxy-3,3'-dimethyldiphenyl ether, 1,4-bis(3-hydroxyphenoxy)benzene, 1,3-bis(4-hydroxyphenoxy)benzene, and the like. Examples of bis(hydroxyaryl)alkanes include 2,2-bis(4-hydroxyphenyl)propane (bisphenol A), 1,1-bis(4-hydroxyphenyl)propane, 2,2-bis(3-methyl-4-hydroxyphenyl)propane (bisphenol C), and 2,2-bis(3-methoxy-4-hydroxyphenyl)propane.

[0024] Further, examples of bis(hydroxyaryl)cycloalkanes include 1,1-bis(4-hydroxyphenyl)cyclopentane, 1,1-bis(4-hydroxyphenyl)cyclohexane, 1,1-bis(4-hydroxyphenyl)-3,3-dimethylcyclohexane, 1,1-bis(4-hydroxyphenyl)-3,4-dimethylcyclohexane, and 1,1-bis(4-hydroxyphenyl)-3,5-dimethylcyclohexane. Examples of dihydroxydiaryl sulfides include 4,4'-dihydroxydiphenyl sulfide and 4,4'-dihydroxy-3,3'-dimethyldiphenyl sulfide. Examples of dihydroxydiaryl sulfoxides include 4,4'-dihydroxydiphenyl sulfoxide and 4,4'-dihydroxy-3,3'-dimethyldiphenyl sulfide. dimethyldiphenyl sulfoxide, etc.; dihydroxydiaryl sulfones such as 4,4'-dihydroxydiphenyl sulfone and 4,4'-dihydroxy-3,3'-dimethyldiphenyl sulfone; and cardo structure-containing bisphenols such as 9,9-bis(4-hydroxyphenyl)fluorene and 9,9-bis(4-hydroxy-3-methylphenyl)fluorene.

[0025] The aromatic dihydroxy compound may be used alone or in any combination of two or more in any ratio.

[0026] Among the monomers that serve as raw materials for polycarbonate, examples of carbonate precursors include carbonyl halides, carbonate esters, etc. The carbonate precursors may be used alone or in any combination and ratio of two or more.

[0027] Examples of carbonyl halides include phosgene; and haloformates such as bischloroformates of dihydroxy compounds and monochloroformates of dihydroxy compounds.

[0028] Examples of carbonate esters include diaryl carbonates such as diphenyl carbonate and ditolyl carbonate; dialkyl carbonates such as dimethyl carbonate and diethyl carbonate; biscarbonates of dihydroxy compounds, monocarbonates of dihydroxy compounds, and carbonates of dihydroxy compounds such as cyclic carbonates.

[0029] The method for producing polycarbonate is not particularly limited, and any method can be used, including, for example, interfacial polymerization, melt transesterification, pyridine method, ring-opening polymerization of a cyclic carbonate compound, and solid-phase transesterification of a prepolymer.

[0030] It is a polymer having p-phenylene sulfide as a main structural unit, and may contain phenylene sulfide sulfone units or phenylene sulfide ketone units in addition to p-phenylene units, and may be a random copolymer, a block copolymer, or a mixture thereof.

[0031] Examples of polyamides include polymers obtained by polycondensation of diamines and dicarboxylic acids, polymers obtained by polycondensation of diamine derivatives such as diformyl with dicarboxylic acids, polymers obtained by polycondensation of dicarboxylic acid derivatives such as dimethyl ester with diamines, polymers obtained by reaction of dinitriles or diamides with formaldehyde, polymers obtained by polyaddition of diisocyanates with dicarboxylic acids, polymers obtained by self-condensation of amino acids or their derivatives, and polymers obtained by ring-opening polymerization of lactams. Furthermore, polyamides may contain polyether blocks. One type of polyamide may be used alone, or two or more types may be used in combination.

[0032] Examples of polyamides include aliphatic polyamides such as nylon 4, nylon 6, nylon 66, nylon 7, nylon 9, nylon 11, nylon 12, nylon 46, nylon 56, nylon 410, nylon 412, nylon 610, and nylon 612; semi-aromatic polyamides such as nylon 6T, nylon 6I, nylon 9T, nylon 10T, nylon M5T, and nylon MXD6; and copolymer polyamides such as nylon 6 / 66, nylon 6 / 12, nylon 6 / 66 / 12, nylon 6 / 6T, nylon 66 / 6T, nylon 6 / 6I, nylon 6T / 6I, nylon 6T / 12, and nylon 66 / 6T / 6I.

[0033] The polyimide is not particularly limited as long as it is a resin having an imide bond in the repeating unit. Specifically, the polyimide can be an imidized product of a polyamic acid (also called a polyimide precursor), which is a polymer of a tetracarboxylic dianhydride and a diamine compound.

[0034] The tetracarboxylic dianhydride may be either an aromatic or aliphatic compound.

[0035] Examples of aromatic tetracarboxylic dianhydrides include pyromellitic dianhydride, 3,3',4,4'-benzophenonetetracarboxylic dianhydride, 3,3',4,4'-biphenylsulfonetetracarboxylic dianhydride, 1,4,5,8-naphthalenetetracarboxylic dianhydride, 2,3,6,7-naphthalenetetracarboxylic dianhydride, 3,3',4,4'-biphenylethertetracarboxylic dianhydride, 3,3',4,4'-dimethyldianhydride, Examples include phenylsilane tetracarboxylic dianhydride, 3,3',4,4'-tetraphenylsilane tetracarboxylic dianhydride, 1,2,3,4-furan tetracarboxylic dianhydride, 4,4'-bis(3,4-dicarboxyphenoxy)diphenyl sulfide dianhydride, 4,4'-bis(3,4-dicarboxyphenoxy)diphenyl sulfone dianhydride, and 4,4'-bis(3,4-dicarboxyphenoxy)diphenylpropane dianhydride.

[0036] Examples of aliphatic tetracarboxylic dianhydrides include butane tetracarboxylic dianhydride, 1,2,3,4-cyclobutane tetracarboxylic dianhydride, 1,3-dimethyl-1,2,3,4-cyclobutane tetracarboxylic dianhydride, 1,2,3,4-cyclopentane tetracarboxylic dianhydride, 2,3,5-tricarboxycyclopentyl acetic dianhydride, 3,5,6-tricarboxynorbonane-2-acetic dianhydride, 2,3,4,5-tetrahydrofuran tetracarboxylic dianhydride, 5-(2,5-dioxotetrahydrofuryl)-3-methyl-3-cyclohexene-1,2-dicarboxylic dianhydride, bicyclo[2,2 aliphatic or alicyclic tetracarboxylic acid dianhydrides such as 1,3,3a,4,5,9b-hexahydro-2,5-dioxo-3-furanyl)-naphtho[1,2-c]furan-1,3-dione, 1,3,3a,4,5,9b-hexahydro-5-methyl-5-(tetrahydro-2,5-dioxo-3-furanyl)-naphtho[1,2-c]furan-1,3-dione, and 1,3,3a,4,5,9b-hexahydro-8-methyl-5-(tetrahydro-2,5-dioxo-3-furanyl)-naphtho[1,2-c]furan-1,3-dione.

[0037] The tetracarboxylic acid dianhydrides may be used alone or in combination of two or more. When two or more types are used in combination, aromatic tetracarboxylic acid dianhydrides or aliphatic tetracarboxylic acids may be used in combination, or an aromatic tetracarboxylic acid dianhydride and an aliphatic tetracarboxylic acid dianhydride may be used in combination.

[0038] Examples of the diamine compound include p-phenylenediamine, m-phenylenediamine, 4,4'-diaminodiphenylmethane, 4,4'-diaminodiphenylethane, 4,4'-diaminodiphenyl ether, 4,4'-diaminodiphenyl sulfide, 4,4'-diaminodiphenyl sulfone, 1,5-diaminonaphthalene, 3,3-dimethyl-4,4'-diaminobiphenyl, 5-amino-1-(4'-aminophenyl)-1,3,3- trimethylindan, 6-amino-1-(4'-aminophenyl)-1,3,3-trimethylindan, 4,4'-diaminobenzanilide, 3,5-diamino-3'-trifluoromethylbenzanilide, 3,5-diamino-4'-trifluoromethylbenzanilide, 3,4'-diaminodiphenyl ether, 2,7-diaminofluorene, 2,2-bis(4-aminophenyl)hexafluoropropane, 4,4'-methylene-bis(2-chloroaniline), 2,2',5,5'-tetrachloro-4,4'-diaminobiphenyl, 2,2'-dichloro-4,4'-diamino-5,5'-dimethoxybiphenyl, 3,3'-dimethoxy-4,4'-diaminobiphenyl, 4,4'-diamino-2,2'-bis(trifluoromethyl)biphenyl, 2,2-bis[4-(4-aminophenoxy)phenyl]propane, 2,2-bis[4-(4-aminophenoxy)phenyl]hexafluoropropane, 1,4-bis(4-aminophenoxy)benzene, 4,4'-bis(4-aminophenoxy)-biphenyl, 1,3'-bis(4-aminophenoxy)benzene, 9,9-bis(4- aromatic diamines such as 4,4'-(4-amino-2-trifluoromethylphenoxy)phenyl]hexafluoropropane, 4,4'-bis[4-(4-amino-2-trifluoromethyl)phenoxy]-octafluorobiphenyl, etc.; aromatic diamines having two amino groups bonded to an aromatic ring and a heteroatom other than the nitrogen atom of the amino group, such as diaminotetraphenylthiophene;1,1-meta-xylylenediamine, 1,3-propanediamine, tetramethylenediamine, pentamethylenediamine, octamethylenediamine, nonamethylenediamine, 4,4-diaminoheptamethylenediamine, 1,4-diaminocyclohexane, isophoronediamine, tetrahydrodicyclopentadienylenediamine, hexahydro-4,7-methanoindanylenediamine, tricyclo[6,2,1,0; ２，７ ]-undecylenedimethyldiamine, 4,4'-methylenebis(cyclohexylamine), and other aliphatic diamines and alicyclic diamines.

[0039] The diamine compounds may be used alone or in combination of two or more. When two or more diamine compounds are used in combination, aromatic diamine compounds or aliphatic diamine compounds may be used in combination, or an aromatic diamine compound and an aliphatic diamine compound may be used in combination.

[0040] Polyetherimides are resins containing a cyclic imide structure, and are preferably polyetherimide resins containing aliphatic or aromatic ether units and cyclic imide groups as repeating units. The main chain of the polyimide may contain structural units other than the cyclic imide and ether units, such as aromatic or aliphatic ester units, or oxycarbonyl units.

[0041] Polyacetal is a polymer having a repeating acetal structure, and its main structural unit is usually an oxymethylene group, which is a hydrogen atom. Polyacetal includes not only acetal homopolymers consisting of this repeating structure, but also copolymers and terpolymers containing one or more repeating structural units other than oxymethylene groups, and may have not only a linear structure but also a branched or crosslinked structure.

[0042] Examples of the structural units other than the oxymethylene group include oxyalkylene groups having from 2 to 10 carbon atoms, which may be branched, such as an oxyethylene group, an oxypropylene group, or an oxybutylene group.

[0043] Examples of polyethers include polymers obtained by polymerizing a compound selected from alkylene oxides such as ethylene oxide, propylene oxide, and n-butylene oxide; glycidyls such as methyl glycidyl ether, ethyl glycidyl ether, 1-butoxy-2,3-epoxypropane (n-butyl glycidyl ether), allyl glycidyl ether, and 1,2-epoxy-3-phenoxypropane (phenyl glycidyl ether); epihalohydrins such as epichlorohydrin and epibromohydrin; and styrene oxide.

[0044] Polyetherketone is a resin containing a repeating unit composed of an arylene group, an ether group, and a carbonyl group. Examples of the polyetherketone include polyetherketone, polyetheretherketone, polyetherketoneketone, polyetheretherketoneketone, and polyetherketone ester. The polyetherketones may be used alone or in combination of two or more.

[0045] Examples of polyphenylene ethers include poly(2,6-dimethyl-1,4-phenylene) ether, poly(2,6-diethyl-1,4-phenylene) ether, poly(2,6-dipropyl-1,4-phenylene) ether, poly(2-methyl-6-ethyl-1,4-phenylene) ether, poly(2-methyl-6-propyl-1,4-phenylene) ether, and poly(2,6-dichloro-1,4-phenylene ether). Further examples include copolymers of 2,6-dimethylphenol with other phenols.

[0046] The liquid crystal polymer is a liquid crystal polyester or liquid crystal polyester amide that forms an anisotropic melt phase, called a thermotropic liquid crystal polymer.

[0047] Examples of repeating units constituting the liquid crystal polymer include aromatic oxycarbonyl repeating units, aromatic dicarbonyl repeating units, aromatic dioxy repeating units, aromatic aminooxy repeating units, aromatic diamino repeating units, aromatic aminocarbonyl repeating units, and combinations thereof.

[0048] Examples of monomers that provide aromatic oxycarbonyl repeating units include aromatic hydroxycarboxylic acids such as 4-hydroxybenzoic acid, 3-hydroxybenzoic acid, 2-hydroxybenzoic acid, 6-hydroxy-2-naphthoic acid, 5-hydroxy-2-naphthoic acid, 3-hydroxy-2-naphthoic acid, 4'-hydroxyphenyl-4-benzoic acid, 3'-hydroxyphenyl-4-benzoic acid, 4'-hydroxyphenyl-3-benzoic acid, and the like, as well as alkyl-, alkoxy-, or halogen-substituted products thereof, and ester-forming derivatives thereof such as acylated products, ester derivatives, and acid halides.

[0049] Examples of monomers that provide aromatic dicarbonyl repeating units include aromatic dicarboxylic acids such as terephthalic acid, isophthalic acid, 2,6-naphthalenedicarboxylic acid, 1,6-naphthalenedicarboxylic acid, 2,7-naphthalenedicarboxylic acid, 1,4-naphthalenedicarboxylic acid, and 4,4'-dicarboxybiphenyl, as well as alkyl-, alkoxy-, or halogen-substituted derivatives thereof, and ester-forming derivatives thereof such as ester derivatives and acid halides.

[0050] Examples of monomers that provide aromatic dioxy repeating units include aromatic diols such as hydroquinone, resorcinol, 2,6-dihydroxynaphthalene, 2,7-dihydroxynaphthalene, 1,6-dihydroxynaphthalene, 1,4-dihydroxynaphthalene, 4,4'-dihydroxybiphenyl, 3,3'-dihydroxybiphenyl, 3,4'-dihydroxybiphenyl, 4,4'-dihydroxybiphenyl ether, and ester-forming derivatives thereof such as alkyl, alkoxy, or halogen-substituted products, and acylated products thereof.

[0051] Examples of monomers that provide aromatic aminooxy repeating units, aromatic diamino repeating units and aromatic aminocarbonyl repeating units include aromatic hydroxyamines, aromatic diamines and aromatic aminocarboxylic acids.

[0052] The liquid crystal polymer used in the present invention may contain an aromatic oxydicarbonyl repeating unit, a fatty acid dihydroxy repeating unit, a fatty acid dicarbonyl repeating unit, or a thioester bond. Examples of monomers that provide a thioester bond include mercaptoaromatic carboxylic acids, aromatic dithiols, and hydroxyaromatic thiols.

[0053] The liquid crystal polymer used in the present invention may be a blend of two or more liquid crystal polymers.

[0054] The polyarylate resin used as component B of the present invention may be obtained by a conventional method from a dihydric phenol or a derivative thereof and an aromatic dicarboxylic acid or a derivative thereof. Examples of the dihydric phenol used here include 2,2-bis(4-hydroxyphenyl)propane, 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, 4,4-dihydroxy-biphenyl, bis(4-hydroxyphenyl)methane, 2,2-bis(4-hydroxy-3,5-dimethylphenyl)propane, 2,2-bis(4-hydroxy-3,5-dibromophenyl)propane, 2,2-(4-hydroxy-3-methylphenyl)propane, 4,4'-dihydroxydiphenyl sulfone, 4,4'-dihydroxydiphenyl ether, and 4,4'-dihydroxydiphenyl sulfide, and two or more of them may be used in combination.

[0055] The aromatic dicarboxylic acid may be terephthalic acid or isophthalic acid, and any of them may be used as long as they react with a dihydric phenol to give a satisfactory polymer, and may be used alone or in combination of two or more.

[0056] Polysulfones and polyethersulfones typically have repeating units containing divalent aromatic and sulfonyl groups and ether linkages.

[0057] The aromatic group may be a phenylene group, a bisphenol group, a condensed aromatic ring, or the like, and is preferably a phenylene group. The phenylene group may be a p-phenylene group, an m-phenylene group, or an o-phenylene group.

[0058] The aromatic group may have a substituent, and examples of the substituent include an alkyl group, an alkenyl group, an aryl group, a halogen atom, and an alkoxy group.

[0059] The thermoplastic resin (A) having a site reactive with an epoxy group is preferably polyester, polylactic acid, polycarbonate, polyphenylene sulfide, or a liquid crystal polymer, and more preferably polyethylene terephthalate, polylactic acid, polycarbonate, or polyphenylene sulfide.

[0060] The thermoplastic resin (A) having a site reactive with an epoxy group may be a single resin or a combination of at least two types. The amount of the thermoplastic resin (A) having a site reactive with an epoxy group in the resin composition is 100 parts by weight.

[0061] Alternatively, the amount of thermoplastic resin (A) having a site reactive with an epoxy group may be 60% by weight or more, 65% by weight or more, 70% by weight or more, 75% by weight or more, 80% by weight or more, 85% by weight or more, 90% by weight or more, or 95% by weight or more, and may be 99% by weight or less, 98% by weight or less, 97% by weight or less, 95% by weight or less, 92% by weight or less, 90% by weight or less, 88% by weight or less, or 85% by weight or less, based on the resin composition.

[0062] <(B) Thermoplastic Resin Having Epoxy Group> The epoxy group in the thermoplastic resin (B) having an epoxy group reacts with a site in the thermoplastic resin (A) that reacts with the epoxy group.

[0063] The thermoplastic resin (B) having an epoxy group is a copolymer (e.g., a graft polymer) having a monomer unit derived from a monomer having an epoxy group and a monomer unit derived from ethylene. Examples of the monomer having an epoxy group include α,β-unsaturated glycidyl esters such as glycidyl methacrylate and glycidyl acrylate, and α,β-unsaturated glycidyl ethers such as allyl glycidyl ether and 2-methylallyl glycidyl ether, with glycidyl methacrylate being preferred. Polymers modified with a modifier (e.g., an acrylic modifier) ​​are also included.

[0064] The thermoplastic resin (B) having an epoxy group may have, in addition to the monomer units derived from a monomer having an epoxy group and the monomer units derived from ethylene, monomer units derived from other monomers, and examples of the other monomers include unsaturated carboxylic acid esters such as methyl acrylate, ethyl acrylate, methyl methacrylate, and butyl acrylate, and unsaturated vinyl esters such as vinyl acetate and vinyl propionate.

[0065] The thermoplastic resin (B) having an epoxy group may contain a rubber component in addition to the monomer units derived from the epoxy group-containing monomer and the monomer units derived from ethylene. The type of rubber component is not particularly limited, as long as it is composed of a polymer component having rubber elasticity. Examples of polymer components having rubber elasticity include rubbers composed of polymerized acrylic components, silicone components, styrene components, nitrile components, conjugated diene components, urethane components, or ethylene-propylene components. For example, rubbers composed of polymerized acrylic components such as ethyl acrylate units or butyl acrylate units, silicone components such as dimethylsiloxane units or phenylmethylsiloxane units, styrene components such as styrene units or α-methylstyrene units, nitrile components such as acrylonitrile units or methacrylonitrile units, or conjugated diene components such as butadiene units or isoprene units. Rubbers formed by copolymerizing two or more of these components may also be used, including rubbers formed by copolymerizing an acrylic component such as ethyl acrylate units or butyl acrylate units with a silicone component such as dimethylsiloxane units or phenylmethylsiloxane units, rubbers formed by copolymerizing an acrylic component such as ethyl acrylate units or butyl acrylate units with a styrene component such as styrene units or α-methylstyrene units, rubbers formed by copolymerizing an acrylic component such as ethyl acrylate units or butyl acrylate units with a conjugated diene component such as butadiene units or isoprene units, and rubbers formed by copolymerizing an acrylic component such as ethyl acrylate units or butyl acrylate units with a silicone component such as dimethylsiloxane units or phenylmethylsiloxane units with a styrene component such as styrene units or α-methylstyrene units. Furthermore, rubbers formed by copolymerizing a crosslinkable component such as divinylbenzene units, allyl acrylate units, or butylene glycol diacrylate units and crosslinking the copolymerized components may also be used.

[0066] The thermoplastic resin (B) having an epoxy group may be a single resin or a combination of at least two types. The content of monomer units derived from a monomer having an epoxy group is preferably 0.01 to 30% by weight, more preferably 0.1 to 20% by weight, where the content of all monomer units in the ethylene polymer having an epoxy group is taken as 100% by weight.

[0067] Alternatively, the amount of the thermoplastic resin (B) having an epoxy group may be 0.3% by weight or more, 0.5% by weight or more, 1% by weight or more, 2% by weight or more, 3% by weight or more, 5% by weight or more, 8% by weight or more, or 10% by weight or more, and may be 30% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 3% by weight or less, 2% by weight or less, or 1% by weight or less, based on the resin composition.

[0068] <(C) Catalyst Masterbatch> The catalyst masterbatch (C) comprises: (I) a thermoplastic resin having no epoxy groups; and (II) a catalyst which is at least one selected from a transesterification catalyst and an epoxy ring-opening catalyst.

[0069] The catalyst masterbatch (C) may be used alone or in combination of at least two types. The amount of the catalyst masterbatch (C) may be 0.01 to 20 parts by weight, 0.1 to 15 parts by weight, or 1 to 10 parts by weight, relative to 100 parts by weight of the thermoplastic resin (A) having a site reactive with an epoxy group in the resin composition. Alternatively, the amount of the catalyst masterbatch (C) may be 0.01% by weight or more, 0.05% by weight or more, 0.1% by weight or more, 0.5% by weight or more, 1% by weight or more, 2% by weight or more, 3% by weight or more, or 5% by weight or more, and may be 30% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 3% by weight or less, 2% by weight or less, or 1% by weight or less, relative to the resin composition.

[0070] <(I) Thermoplastic Resin Having No Epoxy Group> The thermoplastic resin (I) having no epoxy group may or may not have a site reactive with an epoxy group. Generally, the thermoplastic resin (I) having no epoxy group does not have a site reactive with an epoxy group.

[0071] The thermoplastic resin (I) having no epoxy group may be a copolymer having a repeating unit derived from ethylene and a unit derived from vinyl acetate or a methacrylate ester.

[0072] In the olefin copolymer, examples of the monomer other than the olefin include unsaturated carboxylic acid esters such as methyl acrylate, ethyl acrylate, methyl methacrylate, and butyl acrylate, and unsaturated vinyl esters such as vinyl acetate and vinyl propionate.

[0073] The thermoplastic resin (I) having no epoxy group may contain units derived from vinyl acetate, methacrylic acid ester, etc. The amount of the units derived from vinyl acetate, methacrylic acid ester, etc. is 0.01% by weight to 50% by weight, preferably 0.1% by weight to 30% by weight, based on the thermoplastic resin (I) having no epoxy group.

[0074] The thermoplastic resin (I) having no epoxy groups is preferably compatible or miscible with the thermoplastic resin (B) having epoxy groups. Furthermore, the thermoplastic resin (I) having no epoxy groups preferably has a similar structure to the thermoplastic resin (B) having epoxy groups. "Similar structure" means a resin having the same monomer unit. For example, the thermoplastic resin (I) having no epoxy groups and the thermoplastic resin (B) having epoxy groups correspond to a homopolymer, copolymer, blend, or graft product having the same monomer unit.

[0075] As the thermoplastic resin (I) having no epoxy group, ethylene / methyl methacrylate copolymer is particularly preferred. In addition, as the thermoplastic resin (I) having no epoxy group, polyester, polycarbonate, polyphenylene sulfide, polyamide, polyimide, polyetherimide, polyacetal, polyether, polyether ketone, polyphenylene ether, liquid crystal polymer, polyarylate, polysulfone, polyethersulfone, etc. can also be used. Examples of polyester, polycarbonate, etc. are as described above (as described for the thermoplastic resin (A)).

[0076] The thermoplastic resin (I) having no epoxy group may be a single resin or a combination of at least two types. The amount of the thermoplastic resin (I) having no epoxy group in the catalyst masterbatch (C) is 100 parts by weight.

[0077] <Catalyst (II)> The catalyst (II) is at least one selected from a transesterification catalyst and an epoxy ring-opening catalyst. The catalyst (II) may be either a transesterification catalyst or an epoxy ring-opening catalyst, or may be both a transesterification catalyst and an epoxy ring-opening catalyst. The catalyst (II) promotes the reaction between the polyester and the epoxy. Examples of the catalyst (II) include alkali metal (e.g., sodium, potassium) compounds, alkaline earth metal (e.g., magnesium, calcium, barium) compounds, titanium compounds, antimony compounds, germanium compounds, manganese compounds, tin compounds, aluminum compounds, bismuth compounds, gallium compounds, indium compounds, zinc compounds, nitrogen-containing compounds (e.g., imidazole), basic phosphorus compounds, phosphorous compounds, basic ammonium compounds, and amine compounds.

[0078] The catalyst (II) may be an organic or inorganic compound.

[0079] The catalyst (II) is preferably a metal compound. The metal compound may be, for example, an alkoxide, an organic acid salt (e.g., an acetate), an inorganic acid salt (e.g., a borate), a metal oxide, or a hydrate thereof. The metal compound may be a titanium compound (e.g., tetra-n-propyl titanate), an antimony compound (e.g., antimony trioxide, antimony acetate), a germanium compound (e.g., germanium dioxide), a tin compound (e.g., tin dioxide), or the like. Antimony trioxide, antimony acetate, and germanium dioxide are particularly preferred.

[0080] The catalyst (II) may be an organic compound, and the organic compound is a nitrogen-containing compound (e.g., imidazole), an amine compound, etc. The amine compound is not particularly limited, but may be an aliphatic amine, an aromatic amine, an amino alcohol, an amino acid, or a combination of two or more of these.

[0081] The catalyst (II) may be used alone or in combination of at least two types. The amount of the catalyst (II) in the catalyst masterbatch (C) may be 0.01 to 50 parts by weight, 0.1 to 30 parts by weight, 0.2 to 20 parts by weight, 0.3 to 15 parts by weight, 0.5 to 10 parts by weight, 0.5 to 8 parts by weight, or 1 to 5 parts by weight, relative to 100 parts by weight of the thermoplastic resin (I) having no epoxy groups. Alternatively, the amount of the catalyst (II) may be 0.01 to 50% by weight, 0.1 to 30% by weight, 0.2 to 20% by weight, 0.3 to 15% by weight, 0.5 to 10 parts by weight, 0.5 to 8 parts by weight, or 1 to 5% by weight, relative to the total of the thermoplastic resin (I) having no epoxy groups and the catalyst (II).

[0082] The amount of catalyst (II) may be 1 to 100,000 ppm, 2 to 50,000 ppm, 5 to 10,000 ppm, 10 to 5,000 ppm, or 50 to 1,000 ppm, based on the resin composition.

[0083] <Other Components> The resin composition and masterbatch may contain other components. Examples of other components, such as additives, include neutralizing agents, antioxidants, UV absorbers, lubricants, antistatic agents, antiblocking agents, processing aids, colorants (inorganic pigments, organic pigments, pigment dispersants, etc.), foaming agents, nucleating agents, plasticizers, flame retardants, brightness enhancers, antibacterial agents, and light diffusing agents. These additives may be used alone or in combination of two or more. The additives may be present in an amount of 50% by weight or less, 0.1 to 30% by weight, or 1 to 20% by weight relative to the resin composition or masterbatch.

[0084] <Method for Producing Masterbatch> The masterbatch can be produced by melt-mixing a thermoplastic resin (A) reactive with an epoxy group or a thermoplastic resin (I) not having an epoxy group with a catalyst (II).

[0085] The components constituting the masterbatch (epoxy-free thermoplastic resin (I), catalyst (II), and other components as needed) are blended in a predetermined blending ratio in various forms such as bulk, pellets, or chips, and then premixed as needed. The blend is then placed in a melt kneader and heated to or above the melting point of the epoxy-free thermoplastic resin (I) to melt-knead. The blend is then extruded into a strand and cut into granules (pellets or chips) to obtain the masterbatch. The size (maximum length) may generally be 0.1 to 100 mm or 0.5 to 50 mm.

[0086] The premixing may be dry blending using a premixer such as a ribbon blender, a Henschel mixer, or a V blender. The melt-kneading may be performed using a melt-kneader equipped with a heating mechanism, such as a Banbury mixer, a mixing roll, a single-screw or twin-screw extruder, or a kneader. The melt-kneader may be equipped with a filter having an opening of 1 mm or less, for example, 0.01 to 0.5 mm, particularly 0.05 to 0.3 mm.

[0087] <Method for producing resin composition> The resin composition can be produced by premixing the catalyst masterbatch (C), the thermoplastic resin (A) having a site reactive with an epoxy group, and the thermoplastic resin (B) having an epoxy group, as needed, followed by melt-kneading.

[0088] The melt-kneading temperature is equal to or higher than the melting points of the thermoplastic resin (I) having no epoxy groups, the thermoplastic resin (A) having a site reactive with an epoxy group, and the thermoplastic resin (B) having an epoxy group (I) so that these resins are melted (a temperature higher than the highest melting point of these resins). The melt-kneading temperature depends on the melting point of the resin, but may generally be 180 to 350°C, or 230 to 320°C. In the premixing and melt-kneading, a premixer and melt-kneader similar to those used in the method for producing a masterbatch may be used.

[0089] EXAMPLES The present invention will be specifically explained below with reference to examples and comparative examples, but the present invention is not limited to these examples.

[0090] The test methods, raw materials and manufacturing methods used below are as follows:

[0091] [Raw materials] Thermoplastic resin (A) having a site reactive with an epoxy group A-1: ​​Mitsui PET J125 manufactured by Mitsui Chemicals, Inc. A-2: Luminy (registered trademark) LX-575 manufactured by Total Corbion A-3: Iupilon (registered trademark) S-2000 manufactured by Mitsubishi Chemical Corporation A-4: Polyphenylene sulfide melting point 280 ° C, MFR 74 g / 10 min Thermoplastic resin (B) having an epoxy group B-1: Bondfast (registered trademark) BF-E manufactured by Sumitomo Chemical Co., Ltd. Catalyst masterbatch (C) C-1: Masterbatch containing 0.5 wt% of antimony trioxide C-2: Masterbatch containing 2.0 wt% of antimony trioxide C-3: Masterbatch containing 5.0 wt% of antimony trioxide C-4: Masterbatch containing 5.0 wt% of germanium dioxide C-5: Masterbatch containing 10.0% triphenylphosphine C-6: Masterbatch containing 5.0% by weight of antimony acetate Thermoplastic resin (I) having no epoxy group I-1: Acryft (registered trademark) WD201-F manufactured by Sumitomo Chemical Co., Ltd. Catalyst (II) II-1: Antimony trioxide II-2: Antimony trioxide II-3: Antimony trioxide II-4: Germanium dioxide II-5: Triphenylphosphine II-6: Antimony acetate

[0092] [Charpy Impact Test] Test pieces for evaluating physical properties were prepared under the following injection molding conditions. Pellets of the resin composition obtained above were injection molded using an IS80EPN-2A injection molding machine manufactured by Shibaura Machine Co., Ltd., at a molding temperature of 240 to 260 ° C, a mold cooling temperature of 40 ° C, an injection time of 20 seconds, and a cooling time of 20 seconds. The obtained injection molded body was aged in a hot air circulation thermostatic oven at 150 ° C for 4 hours or more (120 ° C when A-2 is used as the raw material) to prepare a molded body. The prepared molded body was then notched to a width of 10 mm, a thickness of 4 mm, and a notch height of 8 mm. The prepared test piece was evaluated in accordance with ISO 179 using an IT-type impact tester manufactured by Toyo Seiki Seisakusho Co., Ltd.

[0093] [Intrinsic viscosity (when A-1 is used as raw material)] 25 mL of o-chlorophenol and 0.125 g of the resin composition were placed in a measuring flask and dissolved at 150°C, and the viscosity of the solution at 25°C was measured using an Ostwald viscometer. The viscosity of the solvent was also measured in the same manner. Using the obtained solution viscosity and solvent viscosity, [η] was calculated from the following formula (α), and the obtained value was taken as the intrinsic viscosity. [η] = (-1 + (1 + 4K'η ｓｐ ) １／２ ) / 2K'C (α) where η ｓｐ = (solution viscosity / solvent viscosity)-1, K' is Huggins' constant (PET = 0.343), C = polymer weight per 100 mL.

[0094] [Intrinsic viscosity (when A-2 is used as raw material)] 25 mL of chloroform and 0.125 g of resin composition were placed in a measuring flask and dissolved. The viscosity of the prepared solution at 25°C was measured using an Ostwald viscometer. The viscosity of the solvent was also measured in the same manner. Using the obtained solution viscosity and solvent viscosity, [η] was calculated from the following formula (α), and the obtained value was taken as the intrinsic viscosity. [η] = (-1 + (1 + 4K'η ｓｐ ) １／２ ) / 2K'C where η ｓｐ = (solution viscosity / solvent viscosity)-1, K' is Huggins' constant (PLA = 0.636), C = polymer weight per 100 mL.

[0095] [Example 1] (Masterbatch Production Example) A twin-screw kneading extruder was used to produce a masterbatch by supplying 70% by weight of a thermoplastic resin (I-1) having no epoxy groups and 30% by weight of a catalyst (II-1) and melt-kneading them. The produced masterbatch was then diluted with the thermoplastic resin (I-1) having no epoxy groups to produce a masterbatch (C-1) containing 0.5% by weight of antimony trioxide.

[0096] (Resin Composition Production Example) Using a twin-screw kneading extruder, raw materials were supplied in the mixing ratios shown in Table 1, and melt-kneaded. The cylinder temperature was set to 50 to 260°C, and the extrusion rate was 30 kg / h and the screw rotation speed was 300 rpm to produce a resin composition.

[0097] [Examples 2 to 8 and Comparative Examples 1 to 7] Masterbatches (C-2 to C-6) and resin compositions were produced using the same procedures as in Example 1, except that the type and amount of catalyst were changed as shown in Tables 1 and 2. The cylinder temperature, extrusion rate, and screw rotation speed were changed and adjusted according to the raw materials used. Charpy impact tests and intrinsic viscosity measurements were performed on the resin compositions. The injection molding conditions for test pieces for evaluating physical properties were changed and adjusted according to the resin compositions. The results are shown in Tables 1 and 2.

[0098] Examples 1 to 8 and Comparative Examples 1 to 7 are shown in Tables 1 and 2 below.

[0099]

[0100]

[0101] The masterbatch and resin composition of the present invention can be used in the fields of automobiles and mobile phones. According to the present invention, excellent effects can be obtained in engineering plastics, such as light weight and high improvement in impact strength.

Claims

1. A catalyst masterbatch for catalyzing an epoxy reaction of a thermoplastic resin, comprising: The catalyst masterbatch (I) a thermoplastic resin having no epoxy groups, and (II) a catalyst which is at least one selected from a transesterification catalyst and an epoxy ring-opening catalyst; Including, the catalyst (II) is at least one catalyst selected from the group consisting of alkaline earth metal compounds, titanium compounds, antimony compounds, germanium compounds, manganese compounds, tin compounds, aluminum compounds, bismuth compounds, gallium compounds, indium compounds, zinc compounds, nitrogen-containing compounds, basic phosphorus compounds, phosphorous compounds, basic ammonium compounds, and amine compounds; The catalyst masterbatch contains the catalyst (II) in an amount of 0.05 to 30% by weight based on the total weight of the thermoplastic resin (I) having no epoxy group and the catalyst (II).

2. 2. The catalyst masterbatch according to claim 1, wherein the thermoplastic resin (I) having no epoxy groups is a polyethylene or ethylene copolymer, or is compatible or soluble with the thermoplastic resin (B) having epoxy groups and has a structure similar to that of the thermoplastic resin (B).

3. 2. The catalyst masterbatch according to claim 1, wherein the thermoplastic resin (I) having no epoxy group is at least one resin selected from the group consisting of polyester, polycarbonate, polyphenylene sulfide, polyamide, polyimide, polyetherimide, polyacetal, polyether, polyether ketone, polyphenylene ether, liquid crystal polymer, polyarylate, polysulfone, and polyethersulfone.

4. 2. The catalyst masterbatch according to claim 1, wherein the catalyst (II) is at least one catalyst selected from the group consisting of alkoxides, organic acid salts, inorganic acid salts, metal oxides, basic phosphorus compounds, and hydrates thereof.

5. A resin composition comprising: 100 parts by weight of a thermoplastic resin (A) having a site reactive with an epoxy group; 0.5 to 20 parts by weight of a thermoplastic resin (B) having an epoxy group; and 0.01 to 20 parts by weight of the catalyst masterbatch (C) according to claim 1.

6. 6. The resin composition according to claim 5, wherein the thermoplastic resin (A) having a site reactive with an epoxy group has at least one epoxy-reactive group selected from the group consisting of a hydroxy group, a phenol group, a thiol group, a carboxy group, an amino group, and an ester group.

7. 6. The resin composition according to claim 5, wherein the thermoplastic resin (A) having a site reactive with an epoxy group has an epoxy-reactive group at a molecular terminal.

8. 6. The resin composition according to claim 5, wherein the thermoplastic resin (A) having a site reactive with an epoxy group is at least one resin selected from the group consisting of polyester, polyamide, polycarbonate, polyethersulfone, polyphenylene ether, polyphenylene sulfide, polyethersulfone, polyacetal, polysulfone, polyetheretherketone, polyetherketone, polyetherimide, polyimide, polyether, liquid crystal polymer, and polyarylate.

9. 6. The resin composition according to claim 5, wherein the thermoplastic resin (B) having an epoxy group has at least one epoxy group in the polymer.

10. 6. The resin composition according to claim 5, wherein the thermoplastic resin (A) having a site reactive with an epoxy group, the thermoplastic resin (B) having an epoxy group, and the catalyst masterbatch (C) are each in a particulate form.

11. 2. A method for producing the catalyst masterbatch according to claim 1, comprising mixing a thermoplastic resin (I) having no epoxy groups with a catalyst (II).

12. 6. The method for producing a resin composition according to claim 5, wherein the thermoplastic resin (A) having a site reactive with an epoxy group, the thermoplastic resin (B) having an epoxy group, and the catalyst masterbatch (C) are melt-kneaded.

13. 6. The resin composition according to claim 5, wherein the thermoplastic resin (B) having an epoxy group is a copolymer having a monomer unit derived from a monomer having an epoxy group and a monomer unit derived from ethylene.

14. 2. The catalyst masterbatch according to claim 1, wherein the thermoplastic resin (I) having no epoxy groups has no sites reactive with epoxy groups.

15. 2. The catalyst masterbatch according to claim 1, wherein the thermoplastic resin (I) having no epoxy group is a copolymer having a repeating unit derived from ethylene and a repeating unit derived from at least one selected from vinyl acetate and methacrylic acid ester.