Resin composition, method for producing resin composition, pellets, molded body, injection molded body, and apparatus

Abstract

The present invention contains: a matrix 1 having a polar polymer as a main component; a plurality of filler particles 2 having an inorganic material as a main component and having a particle diameter of 0.1 μm or more; and a plurality of elastomer particles 3 having a particle diameter of 0.1 μm or more. The plurality of filler particles 2 and the plurality of elastomer particles 3 are dispersed in the matrix 1 in contact with the matrix 1. In a certain cross section of the resin composition: among the plurality of elastomer particles 3, first elastomer particles 3a and second elastomer particles 3b are present with spacings of 10 μm or less; among the plurality of filler particles 2, a first filler particle 2a that is closest to a first elastomer particle 3a in the cross section is separated from the first elastomer particle 3a with the matrix 1 therebetween; and among the plurality of filler particles 2, a second filler particle 2b that is closest to a second elastomer particle 3b in the cross section is separated from the second elastomer particle 3b with the matrix 1 therebetween.

Description

Resin composition, method for producing resin composition, pellets, molded body, injection molded body and equipment

[0001] The present invention relates to a resin composition.

[0002] Mechanical properties can be controlled by adding fillers and elastomers to thermoplastic resins. Patent Document 1 discloses a method in which melt-kneading is performed twice to unevenly distribute the fillers and elastomers in the thermoplastic resin in order to improve impact strength (toughness) and elastic modulus (rigidity).

[0003] Japanese Patent Application Laid-Open No. 2020-193284

[0004] The resin composition disclosed in Patent Document 1 has room for improvement in mechanical properties. Therefore, one aspect of the present embodiment is aimed at providing a resin composition having excellent mechanical properties.

[0005] The resin composition of the present invention is a resin composition containing a matrix primarily composed of a polar polymer, a plurality of filler particles primarily composed of an inorganic material and having a particle diameter of 0.1 μm or more, and a plurality of elastomer particles each having a particle diameter of 0.1 μm or more, wherein the plurality of filler particles and the plurality of elastomer particles are in contact with the matrix and dispersed in the matrix, and in a cross section of the resin composition, a first elastomer particle and a second elastomer particle among the plurality of elastomer particles are present at intervals of 10 μm or less, a first filler particle among the plurality of filler particles that is closest to the first elastomer particle in the cross section is separated from the first elastomer particle via the matrix, and a second filler particle among the plurality of filler particles that is closest to the second elastomer particle in the cross section is separated from the second elastomer particle via the matrix.

[0006] According to this embodiment, a resin composition having excellent mechanical properties can be provided.

[0007] FIG. 1 is a schematic diagram illustrating the morphology of a resin composition. FIG. 2 is a schematic diagram illustrating the morphology of a resin composition. FIG. 3 is a schematic diagram illustrating the morphology of a resin composition. FIG. 4 is a schematic diagram illustrating the morphology of a resin composition. FIG. 5 is a schematic diagram illustrating the morphology of a resin composition. FIG. 6 is a schematic diagram illustrating the morphology of a resin composition. FIG. 7 is a schematic diagram illustrating the state of cracks occurring in a molded body obtained by molding a resin composition. FIG. 8 is a schematic diagram illustrating the state of cracks occurring in a molded body obtained by molding a resin composition. FIG. 9 is a schematic diagram illustrating equipment. FIG. 10 is a cross-sectional SEM image of Example 1. FIG. 11 is a cross-sectional SEM image of Comparative Example 1. FIG. 12 is a cross-sectional SEM image of Example 3.

[0008] <Resin Composition> The resin composition according to this embodiment will be described in detail. FIGS. 1A and 1B are schematic diagrams illustrating the morphology of the resin composition according to this embodiment. FIG. 1A shows the morphology of a resin composition 10 according to this embodiment, and FIG. 1B shows the morphology of a comparative resin composition 20. In FIGS. 1A and 1B, 1 denotes a matrix, 2 denotes filler particles, 3 denotes elastomer particles, and 4 denotes an elastomer material.

[0009] As shown in FIG. 1A , a resin composition 10 of this embodiment contains a matrix 1 , a plurality of filler particles 2 , and a plurality of elastomer particles 3 .

[0010] The main component of the matrix 1 is a polar polymer. Therefore, a matrix 1 having a resin as its main component can be referred to as a matrix resin or a resin matrix. The main component of the plurality of filler particles 2 is an inorganic material. Filler particles 2 having an inorganic material as their main component can be referred to as inorganic filler particles. The main component of the plurality of elastomer particles 3 is typically an organic material, but may also be an inorganic material. Elastomer particles 3 having an organic material as their main component can be referred to as organic elastomer particles. In a matrix 1 having a polar polymer as its main component, the mass of the polar polymer as its main component is the largest, and the mass of the polar polymer as its main component in the matrix 1 is preferably 50 mass% or more, more preferably 75 mass% or more, and even more preferably 90 mass% or more. A matrix 1 having a polar polymer as its main component may contain a secondary component in addition to the polar polymer as its main component, and this secondary component does not have to be a polar polymer.

[0011] Since the particle diameter of the plurality of filler particles 2 of interest is 0.1 μm or more, the resin composition 10 contains a plurality of filler particles 2 having a particle diameter of 0.1 μm or more. The resin composition 10 may or may not contain a plurality of filler particles having a particle diameter of less than 0.1 μm. Since the particle diameter of the plurality of elastomer particles 3 of interest is 0.1 μm or more, the resin composition 10 contains a plurality of elastomer particles 3 having a particle diameter of 0.1 μm or more. The resin composition 10 may or may not contain a plurality of elastomer particles having a particle diameter of less than 0.1 μm. The particle diameter of the filler particles 2 or elastomer particles 3 of interest is 0.1 μm or more because particles having a particle diameter of 0.1 μm or more contribute significantly to the control of mechanical properties.

[0012] When the filler particles 2 have a minor axis and a major axis, the minor axis can be used as the particle diameter of the filler particles 2. The aspect ratio of the filler particles 2 is defined as the ratio of the major axis to the minor axis (major axis / minor axis). Filler particles 2 with an aspect ratio of less than 5 can be classified as having a low aspect ratio, and filler particles 2 with an aspect ratio of 5 or more can be classified as having a high aspect ratio.

[0013] A plurality of filler particles 2 and a plurality of elastomer particles 3 are dispersed in a matrix 1. It is preferable that the plurality of filler particles 2 and the plurality of elastomer particles 3 are dispersed independently in the matrix 1, and this dispersion structure is called an independent dispersion structure. In the independent dispersion structure, the plurality of filler particles 2 and the plurality of elastomer particles 3 are in contact with the matrix 1.

[0014] As shown in FIG. 1A , in the resin composition 10 of this embodiment, the filler particles 2 and the elastomer particles 3 have an independently dispersed structure in which they are independently dispersed in the matrix 1. In a cross-section of the resin composition 10, the first elastomer particles 3a and the second elastomer particles 3b of the plurality of elastomer particles 3 are spaced apart by an interval of less than 100 μm. That is, the distance between the first elastomer particles 3a and the second elastomer particles 3b is less than 100 μm. In a cross-section of the resin composition 10, the first elastomer particles 3a and the second elastomer particles 3b are spaced apart by an interval of 10 μm or less. That is, the distance between the first elastomer particles 3a and the second elastomer particles 3b is less than 10 μm. The first elastomer particles 3a and the second elastomer particles 3b referred to here can be selected as two elastomer particles 3 of interest from among the plurality of elastomer particles 3. That is, the condition for the two elastomer particles 3 of interest is that the distance between the two elastomer particles is less than 100 μm, or even 10 μm or less. In this embodiment, the first elastomer particles 3a and the second elastomer particles 3b, which are present in close proximity to each other, have an independently dispersed structure. The second elastomer particles 3b may be the elastomer particles present closest to the first elastomer particles 3a among the plurality of elastomer particles 3, or alternatively, there may be other elastomer particles present closer to the first elastomer particles 3a than the second elastomer particles 3b. It is not essential that other elastomer particles 3 be present within a 10 μm radius of any elastomer particle 3. It should be noted that focusing on two elastomer particles 3 that are spaced apart by, for example, 100 μm or more is not particularly suitable for evaluating the independent dispersion structure, and it is also not appropriate to focus on two elastomer particles that are extremely spaced apart by 1 mm or more.The plurality of elastomer particles 3 may include those in which the distance between the two closest elastomer particles 3 exceeds 10 μm, but such two elastomer particles 3 do not need to be selected as the pair of first elastomer particles 3 a and second elastomer particles 3 b that are of interest for evaluating the independently dispersed structure. The distance between the first elastomer particle 3 a and the second elastomer particle 3 b is preferably 0.1 μm or more, and more preferably 1 μm or more. This is because elastomer particles 3 a and 3 b that are extremely close to each other are not very suitable for evaluating dispersibility.

[0015] In resin composition 10 having an independently dispersed structure, of the plurality of filler particles 2, the first filler particle 2a that is closest to the first elastomer particle 3a in the observed cross section is separated from the first elastomer particle 3a via matrix 1. In resin composition 10 having an independently dispersed structure, the first elastomer particle 3a is separated from the first filler particle 2a that is closest to the first elastomer particle 3a in the observed cross section via matrix 1. In other words, the first filler particle 2a is not in contact with the first elastomer particle 3a, and matrix 1 is interposed between the first filler particle 2a and the first elastomer particle 3a. In other words, the first filler particle 2a and the first elastomer particle 3a are separated from each other by matrix 1.

[0016] Furthermore, in resin composition 10 having an independently dispersed structure, of the plurality of filler particles 2, the second filler particle 2b that is closest to the second elastomer particle 3b in the observed cross section is separated from the second elastomer particle 3b via matrix 1. In resin composition 10 having an independently dispersed structure, the second elastomer particle 3b is separated from the second filler particle 2b that is closest to the second elastomer particle 3b in the observed cross section via matrix 1. In other words, the second filler particle 2b is not in contact with the second elastomer particle 3b, and matrix 1 is interposed between the second filler particle 2b and the second elastomer particle 3b. In other words, the second filler particle 2b and the second elastomer particle 3b are separated from each other by matrix 1.

[0017] On the other hand, as shown in Fig. 1B, in the comparative resin composition 20, the filler particles 2 are incorporated into the elastomer material 4, forming a core-shell structure. In the resin composition 20 having a core-shell structure, the filler particles 2 are in contact with the elastomer material 4 and are not separated. In addition, in the resin composition 20 having a core-shell structure shown in Fig. 1B, the filler particles 2 are not in contact with the matrix 1.

[0018] The resin composition of this embodiment has an independent dispersion structure as shown in FIG. 1A, and thus can achieve excellent mechanical properties, such as flexural modulus and impact strength.

[0019] The distance between the first filler particles 2 a and the second filler particles 2 b can be less than 100 μm. The distance between the first filler particles 2 a and the second filler particles 2 b is preferably 10 μm or less. In this embodiment, it is preferable that the first filler particles 2 a and the second filler particles 2 b that are present in close proximity to each other in this manner have an independently dispersed structure.

[0020] The distance between the first filler particles 2a and the first elastomer particles 3a may be less than 100 μm. The distance between the first filler particles 2a and the first elastomer particles 3a is preferably 10 μm or less. The distance between the second filler particles 2b and the second elastomer particles 3b may also be less than 100 μm. It is also preferable that the distance between the second filler particles 2b and the second elastomer particles 3b is 10 μm or less. As described above, the short distance between the nearest filler particles 2 and elastomer particles 3 enables excellent mechanical properties to be obtained. The distance between the first filler particles 2a and the first elastomer particles 3a is, for example, 10 nm or more, and may be 0.1 μm or more. The distance between the second filler particles 2b and the second elastomer particles 3b is, for example, 10 nm or more, and may be 0.1 μm or more.

[0021] 10 of the observed cross section of the resin composition 10 ２ μm ２ X% by number of 10 or more filler particles 2 in the above area range are separated from the plurality of elastomer particles 3 via the matrix 1. ２ μm ２ Within the above area range, 10 or more filler particles 2 are present in the matrix phase 1 at a percentage of X by number. X (number %) is, for example, a majority of 50% by number or more, preferably 70% by number or more, more preferably 80% by number or more, and even more preferably 90% by number or more.

[0022] 10 of the observed cross section of the resin composition 10 ２ μm ２ Y% by number of 10 or more elastomer particles 3 in the above area range are separated from the plurality of filler particles 2 via the matrix 1. ２ μm ２ Within the above area range, 10 or more elastomer particles 3 are present in the matrix phase 1 at a number percentage of Y. Y (number percentage) is, for example, a majority of 50% or more, preferably 70% or more, more preferably 80% or more, and even more preferably 90% or more.

[0023] 10 of the observed cross section of the resin composition 10 described above ２ μm ２ The above area range preferably includes the first elastomer particles 3a, the second elastomer particles 3b, the first filler particles 2a, and the second filler particles 2b. ２ μm ２ The occupancy rate of the matrix 1 in the above area range is preferably 30 area % or more and 90 area % or less. ２ μm ２ The occupancy rate of the plurality of filler particles 2 in the above area range is preferably 1 area % or more and 50 area % or less. ２ μm ２ The occupancy rate of the plurality of elastomer particles 3 in the above area range is preferably 1 area % or more and 50 area % or less. ２ μm ２ However, the upper limit may be set to a range in which 10 or more filler particles 2 or 10 or more elastomer particles 3 are contained, and the number of these particles can be calculated within a reasonable time. For example, the area of ​​the observed cross section of the resin composition 10 is 1000 ２ μm ２ is less than or equal to 500 ２ μm ２ Preferably, it is 250 or less. ２ μm ２ More preferably, it is 130 ２ μm ２ In particular, if the filler particle 2 has a low aspect ratio, the area of ​​the observed cross section is 250 ２ μm ２ More preferably, it is 130 ２ μm ２ In particular, if the filler particle 2 has a high aspect ratio, the area of ​​the observed cross section is 130 ２ μm ２ More preferably, it is 250 or more. ２ μm ２It is also preferable that the area of ​​the observed cross section of the resin composition 10 is equal to or smaller than 2000 μm. The outline of the area range may be square, rectangular, or circular, for example, a 1000 μm x 1000 μm square, a 100 μm x 100 μm square, or a 10 μm x 10 μm square, but the maximum width of the area range is 2000 μm or smaller, preferably 500 μm or smaller, preferably 250 μm or smaller, and even preferably 200 μm or smaller. The maximum width of the area range of a 100 μm x 100 μm square is the diagonal (√2) x 100 μm. Furthermore, it is preferable that 30 area percent or more of the region 1 μm from the outer periphery of the filler particle 2 is occupied by the matrix 1.

[0024] 100 in resin composition 10 ３ μm ３ More than 1mm ３ In the composition in the following volume range, it is preferable that the matrix 1 is 30 mass % or more and 90 mass % or less. ３ μm ３ More than 1mm ３ In the composition in the following volume range, the plurality of filler particles 2 is preferably 1% by mass or more and 50% by mass or less. ３ μm ３ More than 1mm ３ In the composition within the following volume range, the elastomer material constituting the plurality of elastomer particles 3 is preferably 1% by mass or more and 50% by mass or less. This volume range preferably includes the first elastomer particles 3a, second elastomer particles 3b, first filler particles 2a, and second filler particles 2b. The contour of the volume range of the resin composition 10 may be a cube, rectangular parallelepiped, or sphere, for example, a 100 μm × 100 μm × 100 μm cube or a 1 mm × 1 mm × 1 mm cube. However, the maximum width of the volume range is preferably 2 mm or less, and more preferably 1 mm or less. The maximum width of the volume range of a 1 mm × 1 mm × 1 mm rectangular parallelepiped is the diagonal (√3) × 1 mm.

[0025] <Matrix 1> A polar polymer, among thermoplastic resins, is used as the matrix. A polar polymer is a polymer containing polar groups, such as amide groups, imide groups, carbonyl groups (ketone groups), and ester bonds, in the main chain. Polar polymers are generally resins known as general-purpose engineering plastics or super engineering plastics, and are used in applications requiring higher physical properties, such as heat resistance and strength, than general-purpose resins such as polyethylene and polypropylene. Furthermore, if it becomes possible to improve the mechanical properties, it will become possible to make molded products thinner and lighter, and therefore further improvements in the physical properties of polar polymers are expected.

[0026] Specific examples of polar polymers include polymers having an amide group, such as polyamide and polyamideimide. Polymers having an imide group, such as polyimide, polyamideimide, and polyetherimide. Polymers having a carbonyl group (ketone group), such as polyetherketone and polyetheretherketone. Polymers having an ester bond, such as polyarylate, polycarbonate, and polyester. Polyesters include polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, and polybutylene naphthalate.

[0027] Among thermoplastic resins, it is preferable to use a crystalline polymer as the matrix. Crystalline polymers are advantageous in that they are superior in hardness, elasticity, and rigidity compared to amorphous polymers. Among the polar polymers mentioned above, examples of crystalline polymers include polyamide, polyether ketone, polyether ether ketone, polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, and polybutylene naphthalate. Among polyesters, polyarylate and polycarbonate are amorphous polymers. As the polar polymer, polyester is preferable, and polyethylene terephthalate is more preferable. CO during the production of polyethylene terephthalate ２ CO emissions during polycarbonate production ２ The use of polyethylene terephthalate reduces CO emissions２ The degree of crystallinity of the matrix or crystalline polymer is, for example, 1 to 50%, preferably 1 to 40%. The degree of crystallinity can be controlled by the molding conditions (temperature and pressure).

[0028] The matrix may also be a polar polymer crosslinked using a crosslinking agent. Examples of crosslinking agents include compounds that undergo a crosslinking reaction when heated, such as carbodiimide crosslinking agents, oxazoline crosslinking agents, epoxy crosslinking agents, and isocyanate crosslinking agents. The polar polymer may also be a recycled polymer, for example, obtained by recovering used polymers with reduced molecular weights and re-crosslinking the used polymers with a crosslinking agent to increase their molecular weight. Polyethylene terephthalate, which is widely produced and used, is a suitable used polymer and recycled polymer.

[0029] The carbodiimide crosslinking agent in this embodiment is a compound having at least one carbodiimide group in the molecule, and can be produced, for example, by heating an organic isocyanate in the presence of a suitable catalyst and subjecting it to a decarboxylation reaction. The carbodiimide group is represented by (-N=C=N-). In a resin matrix using a carbodiimide crosslinking agent, the carbodiimide group derived from the carbodiimide crosslinking agent is present as part of the polymer.

[0030] Examples of the carbodiimide crosslinking agent include diphenylcarbodiimide, dicyclohexylcarbodiimide, di-2,6-dimethylphenylcarbodiimide, diisopropylcarbodiimide, dioctyldecylcarbodiimide, di-o-toluylcarbodiimide, di-p-toluylcarbodiimide, di-p-nitrophenylcarbodiimide, di-p-aminophenylcarbodiimide, di-p-hydroxyphenylcarbodiimide, di-p-chlorophenylcarbodiimide, di-o-chlorophenylcarbodiimide, di-3,4-dichlorophenylcarbodiimide, Nylcarbodiimide, di-2,5-dichlorophenylcarbodiimide, p-phenylene-bis-o-toluylcarbodiimide, p-phenylene-bis-dicyclohexylcarbodiimide, p-phenylene-bis-di-p-chlorophenylcarbodiimide, 2,6,2',6'-tetraisopropyldiphenylcarbodiimide, hexamethylene-bis-cyclohexylcarbodiimide, ethylene-bis-diphenylcarbodiimide, ethylene-bis-di-cyclohexylcarbodiimide, N,N'-di-o-tolylcarbodiimide, N,N'-di phenylcarbodiimide, N,N'-dioctyldecylcarbodiimide, N,N'-di-2,6-dimethylphenylcarbodiimide, N-triyl-N'-cyclohexylcarbodiimide, N,N'-di-2,6-diisopropylphenylcarbodiimide, N,N'-di-2,6-di-tert-butylphenylcarbodiimide, N-toluyl-N'-phenylcarbodiimide, N,N'-di-p-nitrophenylcarbodiimide, N,N'-di-p-aminophenylcarbodiimide, N,N'-di-p-hydroxyphenylcarbodiimide, N,N'-di-cyclohexylcarbodiimide, N,N'-di-p-toluylcarbodiimide, N,N'-benzylcarbodiimide, N-octadecyl-N'-phenylcarbodiimide, N-benzyl-N'-phenylcarbodiimide, N-octadecyl-N'-tolylcarbodiimide, N-cyclohexyl-N'-tolylcarbodiimide, N-phenyl-N'-tolylcarbodiimide, N-benzyl-N'-tolylcarbodiimide, N,N'-di-o-ethylphenylcarbodiimide, N,N'-di-p-ethylphenylcarbodiimide, N,Mono- or dicarbodiimide compounds such as N'-di-o-isopropylphenylcarbodiimide, N,N'-di-p-isopropylphenylcarbodiimide, N,N'-di-o-isobutylphenylcarbodiimide, N,N'-di-p-isobutylphenylcarbodiimide, N,N'-di-2,6-diethylphenylcarbodiimide, N,N'-di-2-ethyl-6-isopropylphenylcarbodiimide, N,N'-di-2-isobutyl-6-isopropylphenylcarbodiimide, N,N'-di-2,4,6-trimethylphenylcarbodiimide, N,N'-di-2,4,6-triisopropylphenylcarbodiimide, and N,N'-di-2,4,6-triisobutylphenylcarbodiimide; Examples of polycarbodiimides include poly(4,4'-methylenebiscyclohexylcarbodiimide), poly(1,3-cyclohexylenecarbodiimide), poly(1,4-cyclohexylenecarbodiimide), poly(4,4'-diphenylmethanecarbodiimide), poly(3,3'-dimethyl-4,4'-diphenylmethanecarbodiimide), poly(naphthylenecarbodiimide), poly(p-phenylenecarbodiimide), poly(m-phenylenecarbodiimide), poly(tolylcarbodiimide), poly(diisopropylcarbodiimide), poly(methyl-diisopropylphenylenecarbodiimide), poly(triethylphenylenecarbodiimide), and poly(triisopropylphenylenecarbodiimide).

[0031] The oxazoline crosslinking agent in this embodiment is a compound having an oxazoline group in the molecule. In particular, a polymer synthesized using a monomer containing an oxazoline compound as at least one of the raw material monomers is preferred. Examples of oxazoline compounds include 2-oxazoline, 3-oxazoline, and 4-oxazoline compounds. Any of these may be used, but 2-oxazoline compounds are particularly highly reactive and have been industrially put into practical use. Examples of oxazoline compounds include 2-vinyl-2-oxazoline, 5-methyl-2-vinyl-2-oxazoline, 4,4-oxazoline, 4,4-dimethyl-2-vinyl-5,6-dihydro-4H-1,-oxazine, 4,4,6-trimethyl-2-vinyl-5,6-dihydro-4H-1,3-oxazine, 2-isopropenyl-2-oxazoline, 4,4-dimethyl-2-isopropenyl-2-oxazoline, and 4-acryloyl-oxymethyl-2,4-dimethyl. 4-(4-vinylphenyl)-2-oxazoline, 4-methacryloyl-oxymethyl-2,4-dimethyl-2-oxazoline, 4-methacryloyl-oxymethyl-2-phenyl-4-methyl-2-oxazoline, 2-(4-vinylphenyl)-4,4-dimethyl-2-oxazoline, 4-ethyl-4-hydroxymethyl-2-isopropenyl-2-oxazoline, 4-ethyl-4-carbethoxymethyl-2-isopropenyl-2-oxazoline, and the like, but are not limited thereto.

[0032] As the epoxy-based crosslinking agent in this embodiment, for example, a glycidyl ether compound, a glycidyl ester compound, a glycidyl amine compound, a glycidyl imide compound, an alicyclic epoxy compound, or the like can be preferably used.

[0033] Examples of the glycidyl ether compound include butyl glycidyl ether, stearyl glycidyl ether, allyl glycidyl ether, phenyl glycidyl ether, o-phenylphenyl glycidyl ether, ethylene oxide lauric alcohol glycidyl ether, ethylene oxide phenol glycidyl ether, ethylene glycol diglycidyl ether, polyethylene glycol diglycidyl ether, propylene glycol diglycidyl ether, polypropylene glycol diglycidyl ether, neopentyl glycol diglycidyl ether, and polytetramethylene glycol diglycidyl ether. Examples of suitable epoxy resins include bisphenol A diglycidyl ether epoxy resins, bisphenol F diglycidyl ether epoxy resins, and bisphenol S diglycidyl ether epoxy resins obtained by condensation reaction of epichlorohydrin with bisphenols such as cyclohexanedimethanol diglycidyl ether, glycerol triglycidyl ether, trimethylolpropane triglycidyl ether, pentaerythritol polyglycidyl ether, 2,2-bis-(4-hydroxyphenyl)propane, 2,2-bis-(4-hydroxyphenyl)methane, and bis(4-hydroxyphenyl)sulfone. Among these, bisphenol A diglycidyl ether epoxy resins are preferred.

[0034] Examples of the glycidyl ester compound include benzoic acid glycidyl ester, p-toluic acid glycidyl ester, cyclohexanecarboxylic acid glycidyl ester, stearic acid glycidyl ester, lauric acid glycidyl ester, palmitic acid glycidyl ester, versatic acid glycidyl ester, oleic acid glycidyl ester, linoleic acid glycidyl ester, linolenic acid glycidyl ester, terephthalic acid diglycidyl ester, isophthalic acid diglycidyl ester, phthalic acid diglycidyl ester, naphthalenedicarboxylic acid diglycidyl ester, and the like. Examples of suitable glycidyl esters include glycidyl esters of benzoic acid, diglycidyl esters of methyl terephthalic acid, diglycidyl esters of hexahydrophthalic acid, diglycidyl esters of tetrahydrophthalic acid, diglycidyl esters of cyclohexanedicarboxylic acid, diglycidyl esters of adipic acid, diglycidyl esters of succinic acid, diglycidyl esters of sebacic acid, diglycidyl esters of dodecanedioic acid, diglycidyl esters of octadecanedicarboxylic acid, triglycidyl esters of trimellitic acid, and tetraglycidyl esters of pyromellitic acid. Of these, glycidyl esters of benzoic acid and glycidyl esters of versatic acid are preferred.

[0035] Examples of the glycidyl amine compound include tetraglycidylaminodiphenylmethane, triglycidyl-paraaminophenol, triglycidyl-metaaminophenol, diglycidyl aniline, diglycidyl toluidine, tetraglycidyl meta-xylenediamine, diglycidyl tribromoaniline, tetraglycidyl bisaminomethylcyclohexane, triglycidyl cyanurate, and triglycidyl isocyanurate. Examples of the glycidyl imide compound include N-glycidyl phthalimide, N-glycidyl-4-methylphthalimide, N-glycidyl-4,5-dimethylphthalimide, N-glycidyl-3-methylphthalimide, N-glycidyl-3,6-dimethylphthalimide, N-glycidyl-4-ethoxyphthalimide, N-glycidyl-4-chlorophthalimide, N-glycidyl-4,5-dichlorophthalimide, N-glycidyl-3,4,5,6-tetrabromophthalimide, and N-glycidyl-4-n-butyl-5- Examples of such an alkyl ester include bromophthalimide, N-glycidyl succinimide, N-glycidyl hexahydrophthalimide, N-glycidyl-1,2,3,6-tetrahydrophthalimide, N-glycidyl maleinimide, N-glycidyl-α,β-dimethylsuccinimide, N-glycidyl-α-ethylsuccinimide, N-glycidyl-α-propylsuccinimide, N-glycidyl benzamide, N-glycidyl-p-methylbenzamide, N-glycidyl naphthamide, and N-glycidyl steramide. Of these, N-glycidyl phthalimide is preferred.

[0036] Examples of the alicyclic epoxy compound include 3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexylcarboxylate, bis(3,4-epoxycyclohexylmethyl)adipate, vinylcyclohexene diepoxide, N-methyl-4,5-epoxycyclohexane-1,2-dicarboxylic acid imide, N-ethyl-4,5-epoxycyclohexane-1,2-dicarboxylic acid imide, N-phenyl-4,5-epoxycyclohexane-1,2-dicarboxylic acid imide, N-naphthyl-4,5-epoxycyclohexane-1,2-dicarboxylic acid imide, and N-tolyl-3-methyl-4,5-epoxycyclohexane-1,2-dicarboxylic acid imide.

[0037] Other epoxy compounds that can be used include epoxy-modified fatty acid glycerides such as epoxidized soybean oil, epoxidized linseed oil, and epoxidized whale oil, phenol novolac epoxy resins, and cresol nosolac epoxy resins.

[0038] The isocyanate crosslinking agent used in this embodiment is not particularly limited as long as it has an isocyanate group as a functional group in the compound, and known polyisocyanate crosslinking agents can be used. Specifically, commonly used water-dispersible polyisocyanate crosslinking agents can be used. Water-dispersible polyisocyanate crosslinking agents are polyisocyanate polymers with hydrophilic groups introduced therein, and when added to water and stirred, they can be dispersed in water as fine particles.

[0039] Examples of polyisocyanates constituting the water-dispersible polyisocyanate include aliphatic isocyanates such as hexamethylene diisocyanate, trimethylhexamethylene diisocyanate, tetramethylene diisocyanate, pentamethylene diisocyanate, lysine diisocyanate, and dimer acid diisocyanate; tolylene diisocyanate, xylylene diisocyanate, diphenylmethane diisocyanate, tetramethylxylylene diisocyanate, 1,5-naphthalene diisocyanate, 1,4-naphthalene diisocyanate, 4,4'-toluidine diisocyanate, 4,4'-diphenyl ether isocyanate, and (m- or p-)phenylene diisocyanate. Examples of the isocyanate include aromatic polyisocyanates such as 4,4'-biphenylene diisocyanate, 3,3'-biphenylene diisocyanate, bis(4-isocyanatophenyl)sulfone, and isopropylidenebis(4-phenylisocyanate); and alicyclic diisocyanate compounds such as hydrogenated xylylene diisocyanate, isophorone diisocyanate, 4,4'-methylenebis(cyclohexylisocyanate), methylcyclohexane-2,4-(or -2,6-)diisocyanate, 1,3-(or 1,4-)di(isocyanatomethyl)cyclohexane, 1,4-cyclohexane diisocyanate, 1,3-cyclopentane diisocyanate, and 1,2-cyclohexane diisocyanate. As such a polyisocyanate compound, a polyisocyanate compound having an isocyanurate structure, a urethane structure, a biuret structure, an allophanate structure, a uretdione structure, a trimer structure, etc. A so-called blocked isocyanate in which an isocyanate group is blocked with an active hydrogen group may also be used.

[0040] The matrix is ​​preferably formed from one of these polar polymers or a mixture of these.

[0041] <Filler Particles 2> The filler particles improve the elastic modulus. The shape of the filler particles may be spherical (e.g., spherical or oblate spheroid), polyhedral, irregular, plate-like, scaly, needle-like, or fibrous. The length of the low-aspect-ratio needle-like or fibrous filler particles is, for example, 100 μm or less, preferably 30 μm or less, and more preferably 10 μm or less.

[0042] The length of the fibrous filler particles can be referred to as the fiber length. The length of the fibrous filler particles with a high aspect ratio may be 100 μm or more. The fiber length of the fibrous filler particles is less than 10 mm, and may be 6 mm or less, 3 mm or less, or 1 mm or less. It is preferably 500 μm or less, and more preferably 300 μm or less. The particle diameter of the fibrous filler particles can be referred to as the fiber diameter. The suitable range of the fiber diameter of the fibrous filler particles may be the same as the particle diameter of the filler particles. The fiber diameter of the fibrous filler particles is preferably 100 μm or less, more preferably 50 μm or less, and even more preferably 30 μm or less. The fiber diameter of the fibrous filler particles may be 10 μm or less, but is preferably 1 μm or more, and more preferably 3 μm or more. The aspect ratio of the fibrous filler particles is defined as the ratio of the fiber length to the fiber diameter (fiber length / fiber diameter). The aspect ratio of the fibrous filler particles is 3 or more, for example 5 or more, and for example 1000 or less. The aspect ratio is more preferably 300 or less, and even more preferably 100 or less. The aspect ratio may be 10 or more, or less than 10, or 30 or more, or less than 30.

[0043] 2A and 2B show the morphology of a resin composition 10 according to an embodiment when high aspect ratio filler particles 2 are used. FIG. 2C shows the morphology of a comparative resin composition 30 when high aspect ratio filler particles 2 are used. In the configurations of FIGS. 2A and 2B, the filler particles 2 have an independent dispersion structure in which they are separated from the elastomer particles 3 via the matrix 1. In the configuration of FIG. 2C, an attached dispersion structure is formed in which the high aspect ratio filler particles 2 are attached to the elastomer material 4 and dispersed integrally. In the resin composition 30 having an attached dispersion structure, the filler particles 2 are in contact with the elastomer material 4 and are not separated. The resin composition 10 according to an embodiment has an independent dispersion structure of the high aspect ratio filler particles 2 as shown in FIGS. 2A and 2B, thereby achieving excellent mechanical properties, such as flexural modulus and impact strength, as well as excellent flame retardancy. FIG. 2(b) shows a state in which additive particles 8 are dispersed in elastomer particles 3, which will be described later.

[0044] Filler particles primarily composed of inorganic materials are not particularly limited, but examples include mica, glass fiber, glass spheres, zinc oxide, titanium oxide (titania), zirconium oxide (zirconia), hafnium oxide (hafnia), zinc titanate, magnesium titanate, strontium titanate, calcium titanate, calcium zirconate, calcium carbonate, clay, talc, silicon oxide (silica), wollastonite, forsterite, zeolite, diatomaceous earth, silica sand, fly ash, pumice powder, slate powder, aluminum oxide (alumina), alumina white, aluminum sulfate, carbon fiber, carbon nanotubes, metal fiber, barium sulfate, calcium sulfate, molybdenum disulfide, shirasu balloons, and fly ash balloons. The first filler particles 2a and the second filler particles 2b preferably contain silica or calcium carbonate. It is also preferable that the first filler particles 2a and the second filler particles 2b contain glass fiber or carbon fiber.

[0045] The filler particles may have a base made of an inorganic material that is the main component of the filler particles, and a surface layer made of an organic or inorganic material that covers the base. The thickness of the surface layer is, for example, 100 nm or less, preferably 10 nm or less. In filler particles whose main component is an inorganic material, the volume occupied by the inorganic material is larger than the volume occupied by the organic material, preferably 90 volume % or more.

[0046] 3A to 3C are schematic diagrams illustrating the occurrence of cracks in a molded article obtained by molding the resin composition of this embodiment. As shown in FIGS. 3A to 3C, when an impact is applied to the resin molded article so as to cause deformation in the direction of arrow 7, matrix 1 orients around elastomer particle 3, forming crazes 5, thereby more efficiently absorbing the impact. In this case, to avoid a decrease in impact strength due to material defects in filler particles 2, it is preferable that the filler particles have a small particle size. As shown in FIG. 3A, if filler particles 2 are large, coarse particles, they may act as stress concentration points, reducing impact strength and potentially propagating cracks 6. On the other hand, in order to thoroughly disintegrate and disperse the particles in the resin composition production process, it is preferable to avoid poor dispersion due to particle aggregation caused by small particle sizes. As shown in FIG. 3B, if filler particles 2 are fine particles with a small particle size, particle aggregation may make it difficult to disperse the filler particles in the resin composition production process. As a result, material defects occur due to particle aggregation, which may lead to a decrease in impact strength and cause cracks 6 to grow.

[0047] For this reason, the particle diameter of the independently dispersed filler particles 2 is, for example, 10 μm or less, preferably 5 μm or less, and more preferably 2 μm or less. When the particle diameter of the filler particles 2 is 10 μm or less, the decrease in impact strength due to the addition of the filler particles 2 can be effectively suppressed. Furthermore, when the particle diameter is 0.2 μm or more, the filler particles 2 can be effectively finely dispersed in the matrix 1, thereby suppressing the decrease in impact strength. For this reason, the particle diameter of the filler particles 2 is preferably 0.2 μm or more and 10 μm or less, more preferably 0.2 μm or more and 5 μm or less, and even more preferably 0.2 μm or more and 2 μm or less. It is preferable that filler particles having a particle diameter of 2 μm or more that can be contained in the plurality of filler particles 2 are separated from the elastomer particles 3 that are closest to the filler particles having a particle diameter of 2 μm or more via the matrix 1. Therefore, at least one of the first filler particles 2a and the second filler particles 2b described above may have a particle diameter of 2 μm or more. The resin composition 10 may contain filler particles 2 having a particle diameter exceeding 10 μm. The particle diameter of the filler particles 2 having a particle diameter exceeding 10 μm is preferably 100 μm or less, more preferably 50 μm or less, and even more preferably 30 μm or less.

[0048] When the filler particles 2 are fibrous or otherwise have an aspect ratio of 5 or more (high aspect ratio), the interface between the matrix 1 and the filler particles 2 has a large area, as shown in FIG. 3C , and impact is absorbed while the crack 6 propagates along the interface. Therefore, a large aspect ratio is preferable. Therefore, the aspect ratio of the independently dispersed filler particles 2 is preferably 5 or more, for example. When the aspect ratio of the filler particles 2 is 5 or more, the decrease in impact strength due to the addition of the filler particles 2 can be effectively suppressed. The aspect ratio of the filler particles 2 is preferably 10 or more, and more preferably 15 or more. On the other hand, in order to sufficiently disperse the filler particles 2 in the resin composition production process, it is preferable to avoid poor dispersion due to aggregation of the filler particles 2 caused by a high aspect ratio. If the aspect ratio of the filler particles 2 is too high, the filler particles 2 may become entangled, making it difficult to disperse the filler particles 2 in the resin composition production process. As a result, material defects due to aggregation may occur, leading to a decrease in impact strength and the development of cracks 6. When the aspect ratio of the filler particles 2 is 100 or less, the filler particles 2 can be well dispersed in the matrix 1, and a decrease in impact strength can be suppressed. The first filler particles 2a and the second filler particles 2b may have an aspect ratio of 5 or more and 100 or less.

[0049] Examples of methods for measuring particle size include the following. Specifically, a transverse cross-sectional sample of a molded article obtained by molding the resin composition of this embodiment is prepared by pretreatment such as cross-sectional polishing, microtome processing, or ion milling. Ion milling is preferred because it provides a high level of cross-sectional smoothness and prevents particles from falling off. If the temperature of the resin composition increases due to processing, cooling such as cryo-treatment may be performed. The sample is then observed using a scanning electron microscope (SEM) under the conditions shown below to obtain an SEM image of the cross section. It is preferable to use different magnifications for observation depending on the particle size of the filler particles. For example, when the particle size is 5 μm or less, observation is preferably performed at a magnification of 10,000x, and when the particle size is greater than 5 μm, observation is preferably performed at a magnification of 1,000x. From the obtained SEM image, binarization and image analysis are performed to determine the median diameter (50% particle diameter) of the filler particles in an arbitrary region of the cross section of the molded article as the particle size of the filler particles. Any range of the cross section of the molded body can be, for example, a quadrilateral region with two adjacent sides having lengths L and M. Length L and length M are, for example, 5 μm or more, preferably 10 μm or more, and for example, 500 μm or less, for example, 100 μm or less. Length L and length M may be the same or different, and the ratio of length L to length M may be 0.5 to 2. Note that the binarization and image analysis of SEM images can be performed using the image processing software ImageJ (available from https: / / imagej.nih.gov / ij / ) of the National Institutes of Health. The particle diameter of the filler particles can be determined by the average diameter of the particles measured so as to pass through the center of gravity of the filler particles in the cross section of the molded body.

[0050] Examples of methods for measuring the aspect ratio include the following. That is, a molded product obtained by molding the resin composition of this embodiment is subjected to thermal decomposition treatment or solvent dissolution treatment to remove organic components, and only the filler particles are extracted to prepare an aspect ratio measurement sample. Then, observation is performed using a scanning electron microscope (SEM) under the conditions shown below to obtain a cross-sectional SEM image. It is preferable to use different observation magnifications depending on the length of the filler particles. For example, when the length is 5 μm or less, observation is performed at a magnification of 10,000x, and when the length is greater than 5 μm, observation is performed at a magnification of 1,000x. Furthermore, when the length of the filler particles exceeds 100 μm, the filler particles are divided into multiple SEM images to obtain SIM images of the entire filler particles. The average aspect ratio within any range of the SEM image obtained from the obtained SEM image by binarization and image analysis under the conditions shown below is used as the aspect ratio of the filler particles. Any range of the cross section of the molded body can be, for example, a quadrilateral region in which the lengths of two adjacent sides are length L and length M. Length L and length M are, for example, 5 μm or more, preferably 10 μm or more, for example, 500 μm or less, for example, 100 μm or less. Length L and length M may be the same or different, and the ratio of length L to length M may be 0.5 to 2. Note that the binarization and image analysis of SEM images can be performed using the image processing software ImageJ of the National Institutes of Health (available from https: / / imagej.nih.gov / ij / ). The maximum diameter of the filler particle measured so as to pass through the center of gravity of the filler particle in the cross section of the molded body is defined as the filler particle length, and the diameter measured from the center of gravity in a direction perpendicular to the maximum diameter is defined as the filler particle diameter. The aspect ratio of each filler particle can be calculated by dividing the filler particle length by the filler particle diameter.

[0051] The filler particles preferably have a substrate surface-treated with a surface treatment agent such as a coupling agent or fatty acid. Surface-treated filler particles may be commercially available products that have already been surface-treated, or a separate surface treatment process may be performed during the production of the resin composition. The amount of surface treatment agent used can be calculated from the specific surface area of ​​the filler particles to be treated and the minimum coverage area of ​​the surface treatment agent. When using filler particles with small particle sizes, the specific surface area of ​​the filler particles increases, inevitably resulting in a larger amount of surface treatment agent used. For this reason, the amount of surface treatment agent used varies, with approximately 0.5 wt% to 5 wt% added to the filler particles being the norm. Treatment methods include known methods such as dry treatment methods such as integral blending and wet treatment methods using an aqueous solution of the surface treatment agent. The surface layer formed by the surface treatment constitutes part of the filler particles.

[0052] Examples of surface treatment agents include silane coupling agents such as vinyltrimethoxysilane, vinyltriethoxysilane, 3-glycidoxypropyltrimethoxysilane, 3-glycidoxypropyltriethoxysilane, 3-methacryloxypropyltrimethoxysilane, 3-methacryloxypropyltriethoxysilane, 3-acryloxypropyltrimethoxysilane, 3-aminopropyltrimethoxysilane, tris-(trimethoxysilylpropyl)isocyanurate, and 3-trimethoxysilylpropylsuccinic anhydride. Titanate-based and aluminate-based coupling agents may also be used. Fatty acids include lauric acid, stearic acid, and oleic acid. Among these, silane coupling agents are preferred. These surface treatment agents may be used alone or in combination.

[0053] <Elastomer Particles 3, Elastomer Material> The elastomer material constituting the elastomer particles 3 improves impact strength. The elastomer material is a copolymer formed by combining hard segments that act as crosslinking points and soft segments that exhibit rubber elasticity, and is preferably a thermoplastic elastomer that has both the properties of plastic and rubber.

[0054] Examples of the elastomer material include urethane elastomers, ester elastomers, amide elastomers, acrylic elastomers, olefin elastomers, styrene elastomers, etc. The elastomer material is preferably an acrylic elastomer or an ester elastomer.

[0055] Examples of urethane elastomers include elastomers in which the hard segment is polyurethane containing urethane groups and the soft segment is polyester containing ester bonds or polyether containing ether bonds. Note that the urethane groups and ester bonds have polarity.

[0056] Examples of ester-based elastomers include elastomers in which the hard segment is a polyester containing an ester bond and the soft segment is a polyester containing an ester bond or a polyether containing an ether bond. Note that the ester bond has polarity.

[0057] Examples of amide elastomers include elastomers in which the hard segment is a polyamide containing an amide group and the soft segment is a polyester containing an ester bond or a polyether containing an ether bond. Note that the amide group and the ester bond have polarity.

[0058] Examples of acrylic elastomers include elastomers in which the hard segment is polymethyl methacrylate, a polymer of methyl methacrylate having an ester bond, and the soft segment is a copolymer of butyl acrylate, 2-ethylhexyl acrylate, or the like, having an ester bond. Also included are elastomers in which the hard segment is a polyolefin such as polyethylene, and the soft segment is polymethyl methacrylate, a polymer of methyl methacrylate having an ester bond. The ester bond has polarity.

[0059] Examples of olefin-based elastomers include elastomers in which the hard segment is a polyolefin such as polypropylene or polyethylene, and the soft segment is an ethylene propylene rubber or ethylene propylene diene rubber.

[0060] Examples of styrene-based elastomers include elastomers in which the hard segment is polystyrene and the soft segment is butadiene, isoprene, ethylene, or the like.

[0061] From the viewpoint of affinity with the matrix, which is a polar polymer, the elastomer material preferably has a polar group. Examples of the polar group that the elastomer material has include a urethane group, an amide group, and an ester bond. In particular, the elastomer material preferably has an ester bond in either or both of the hard segment and the soft segment.

[0062] The polar group such as an ester bond in the elastomer material provides the elastomer material with heat resistance, making it possible to melt-knead it with polar polymers, particularly polar polymers with high heat resistance. Furthermore, the mechanical properties of the elastomer material with an ester bond are relatively high, contributing to the improvement of physical properties, which is the objective of the present invention.

[0063] The elastomer material has a glass transition temperature lower than room temperature, so that it functions as an elastomer at room temperature. The glass transition temperature of the elastomer material is preferably lower than 0°C, and more preferably -20°C or lower.

[0064] Impact strength is improved by melt-kneading the elastomer material in a molten state with a thermoplastic resin matrix to finely disperse the elastomer particles 3 in the matrix 1. Therefore, to enable melt-kneading with the matrix, the melting point of the elastomer material is preferably lower than the heating temperature (molding temperature) of the resin composition. The heating temperature of the resin composition is the temperature at which the thermoplastic polymer matrix melts, and is higher than the glass transition point of the matrix. If the matrix is ​​a crystalline polymer, it is preferably higher than the melting point of the matrix. Therefore, the melting point of the elastomer material is preferably lower than the melting point of the matrix. Although the melting point of the elastomer material may be higher than the melting point of the matrix, this may cause thermal degradation, such as a decrease in the molecular weight of the matrix due to heating the matrix to melt the elastomer material. When the matrix is ​​a crystalline polymer, the melting point of the elastomer material may be higher than the glass transition point of the matrix. When the matrix is ​​an amorphous polymer, the melting point of the matrix is ​​not defined, so the melting point of the elastomer material is preferably lower than the glass transition point of the matrix.

[0065] The glass transition point of the matrix is ​​preferably 50°C or higher to ensure strength during use, and also preferably 200°C or lower in consideration of processability. The melting point of the matrix is ​​preferably 100°C or higher, and preferably 200°C or higher in consideration of heat resistance, and preferably 300°C or lower in consideration of processability. The melting point of the elastomer material is preferably 50°C or higher to ensure strength during use, and preferably 300°C or lower, and preferably 200°C or lower in consideration of processability.

[0066] The elastomer material has rubber elasticity, i.e., flexibility, and therefore contributes to improving the impact strength of the matrix. As shown in Figures 3A to 3C, when an impact is applied to a molded article obtained by molding the resin composition of this embodiment, the matrix 1 orients around the elastomer particles 3, forming crazes 5, thereby more efficiently absorbing the impact. On the other hand, because of its flexibility, the elastic modulus of the resin composition may decrease depending on the amount of elastomer material added. Therefore, to achieve both improved impact strength and elastic modulus of the matrix, it is preferable to use an elastomer material with high hardness. The rubber hardness of the elastomer material is preferably 70 degrees or more in Shore A hardness, more preferably 80 degrees or more, and even more preferably 90 degrees or more.

[0067] Furthermore, as described above, it is preferable that a large number of elastomer particles 3 are dispersed in a fine manner, since the generation of crazes 5 centered around the elastomer particles 3 can absorb impact energy and thus impact strength. Therefore, the particle diameter of the elastomer particles 3 is preferably 10 μm or less, more preferably 5 μm or less. To ensure that the elastomer particles 3 function efficiently mechanically, the particle diameter of the elastomer particles 3 is preferably 0.1 μm or more, more preferably 0.5 μm or more. The elastomer particles 3 are typically particles formed by dispersing and mixing them through melt-kneading, as described below, and the particle diameter of such elastomer particles 3 can be referred to as the dispersed particle diameter or dispersed particle size.

[0068] The particle diameter of the elastomer particles 3 dispersed in the matrix 1 can be calculated from cross-sectional observation of the resin molded product using a method similar to that used to measure the particle diameter of the filler particles 2. Specifically, a horizontal cross-sectional sample of the molded product is prepared using the same method as used to measure the particle diameter of the filler particles 2. Then, an SEM observation is performed under the same conditions as used to measure the particle diameter of the filler particles 2, and an SEM image of the cross section is obtained. Similarly to the method used to measure the particle diameter of the filler particles 2, the SEM image is binarized and image analyzed to determine the median diameter of the elastomer particles 3 in an arbitrary area range of the cross section of the molded product as the particle diameter of the elastomer particles 3. The arbitrary area range of the cross section of the molded product can be, for example, a quadrilateral region with the lengths L and M of two adjacent sides. The lengths L and M are, for example, 5 μm or more, preferably 10 μm or more, and for example, 500 μm or less, for example, 100 μm or less. The length L and the length M may be the same or different, and the ratio of the length L to the length M may be 0.5 to 2.

[0069] <Composition Ratio of Each Component> Matrix 1 acts as a matrix that independently disperses filler particles 2 and elastomer particles 3. Resin composition 10 of this embodiment can achieve mechanical properties superior to those of Matrix 1 by independently dispersing filler particles 2 and elastomer particles 3. Therefore, the content of Matrix 1 is, for example, 30% by mass or more, preferably 40% by mass or more, and more preferably 50% by mass or more, relative to the total amount of the resin composition. Furthermore, the content of Matrix 1 is, for example, 90% by mass or less, preferably 80% by mass or less, and more preferably 70% by mass or less, relative to the total amount of the resin composition. The composition ratio in the resin composition can be obtained by thermogravimetric analysis (TGA).

[0070] The composition ratio of the filler particles 2 to the elastomer material can be adjusted appropriately depending on the required mechanical properties, as long as it does not deviate from the preferred composition ratio range of the matrix 1. A higher content of the filler particles 2 increases the modulus of elasticity, while a higher content of the elastomer material increases the impact strength. Therefore, the content of the filler particles 2 is, for example, 1% by mass or more, preferably 5% by mass or more, and preferably 10% by mass or more, relative to the total amount of the composition. The content of the filler particles 2 is, for example, 50% by mass or less, preferably 40% by mass or less, and more preferably 30% by mass or less, relative to the total amount of the composition. The content of the elastomer material is, for example, 1% by mass or more, preferably 5% by mass or more, and preferably 10% by mass or more, relative to the total amount of the composition. The content of the elastomer material is, for example, 50% by mass or less, preferably 40% by mass or less, and more preferably 30% by mass or less, relative to the total amount of the composition. The content of the matrix 1 is preferably greater than the content of the filler particles 2 and the content of the elastomer material. The content of the filler particles 2 is, for example, 1 / 5 or more and 5 times or less, or 1 / 4 or more and 4 times or less, the content of the elastomer material. The content of the filler particles 2 can be 1 time or more the content of the elastomer material.

[0071] In the resin composition 10 of this embodiment, it is preferable that a structure in which the filler particles 2 and the elastomer particles 3 are independently dispersed in the matrix 1 is ubiquitous over a wide volume range of the entire resin composition 10. In such a case, the composition ratio of the matrix, the filler particles, and the elastomer material in the entire resin composition 10 and the ratio of the elastomer particles in the resin composition 10 to the total weight of the matrix 2 are ubiquitous over a wide volume range of the entire resin composition 10. ３ μm ３ More than 1mm ３ The compositions in the following moderately wide volume ranges are generally consistent. ３ μm ３ More than 1mm ３ The composition in the following volume ranges can be approximated by the composition ratio relative to the total amount of the resin composition described above. ３If it is confirmed that the independently dispersed structures are ubiquitous over a wide volume range exceeding 1 mm ３ A wide volume range (e.g., 10 to 100 mm ３ Thermogravimetric analysis (TGA) can be performed on the resin composition 10 in the volume range of 100 ３ μm ３ More than 1mm ３ The composition can be in the following volume ranges:

[0072] In addition, 100 ３ μm ３ More than 1mm ３ The volume ratios within the following moderately broad volume ranges vary depending on the density of each component, but the following ranges are preferred: the volume ratio of matrix 1 is, for example, 35 vol% or more and, for example, 92 vol% or less; the volume ratio of filler particles 2 is, for example, 2 vol% or more and, for example, 33 vol% or less; and the volume ratio of elastomer material is, for example, 7 vol% or more and, for example, 58 vol% or less.

[0073] <ΔHSP value> The affinity between two components correlates with the solubility parameter. Specifically, the affinity between two components can be controlled by the difference in HSP value (ΔHSP value) between the two components, calculated from the Hansen solubility parameter (HSP value). When the ΔHSP value between two components is small, the affinity between the two components is high and they tend to be attracted to each other. On the other hand, when the ΔHSP value between two components is large, the affinity between the two components is low and they tend to be independent.

[0074] The HSP value is the energy δd (MPa) due to the dispersion force between molecules. １／２ ), the energy due to intermolecular dipole interaction δp (MPa １／２ ), and the energy due to intermolecular hydrogen bonds δh (MPa １／２ ) and the HSP value is obtained as the vector sum of these three energies. The vector difference of the HSP value between two components is ΔHSP, which can be calculated using the following formula (1). ΔHSP value = {4(δdA - δdB) ２ + (δpA-δpB) ２ + (δhA-δhB)２} １／２ ...(1)

[0075] The HSP values ​​of many substances have been determined by Hansen and his successors and are described in the Polymer Handbook (fourth edition), VII-698-711, and Wesley L. Archer's Industrial Solvents Handbook. Furthermore, HSP values ​​can be calculated using software such as Hansen Solubility Parameter in Practice (HSPiP, Charles M. Hansen, URL: http: / / www.hansen-solubility.com / ).

[0076] The ΔHSP values ​​described in this embodiment were calculated by inputting the chemical structural formula of the compound using the 5th Edition 5.4.01 of the database-attached calculation software "HSPiP" developed and sold by the Hansen Group.

[0077] In order to independently disperse the filler particles and elastomer particles in the matrix, it is preferable to control the affinity between the surface of the filler particles and the elastomer material. If the ΔHSP values ​​of the two are small, they are easily attracted to each other, forming a core-shell structure as shown in Figure 1B. On the other hand, if the ΔHSP values ​​of the two are large, they are easily independent in the matrix, forming an independent particle dispersion structure as shown in Figure 1A, which makes it possible to obtain excellent mechanical properties.

[0078] The inventors calculated the ΔHSP values ​​of the filler particle surface and the elastomer material and found that the affinity differs depending on the combination. That is, by appropriately selecting the combination of the filler particle surface (or the surface treatment agent if the filler particles are surface-treated) and the elastomer material, the elastomer material can be dispersed in a particulate form in the matrix. This makes it possible to form an independent particle dispersion structure of the filler particles and elastomer particles in the matrix, thereby achieving excellent mechanical properties.

[0079] To form an independent particle dispersion structure, the ΔHSP value of the surface of the filler particle and the elastomer material is, for example, 6.5 MPa. １／２ Larger, 7.0 MPa １／２ It is preferable that the pressure is 7.6 MPa or more. １／２ The ΔHSP value between the surface of the filler particle and the elastomer material is more preferably 15.0 MPa or more. １／２ It may be 10.0 MPa or less, １／２ The ΔHSP value of the matrix and the elastomer material may be, for example, 6.0 MPa or less. １／２ Larger, 6.7 MPa １／２ It is preferable that the pressure is 7.0 MPa or more. １／２ The ΔHSP value of the matrix and the elastomer material is more preferably 15.0 MPa or more. １／２ It may be 10.0 MPa or less, １／２ The ΔHSP value of the matrix and the surface of the filler particle may be, for example, 7.0 MPa or less. １／２ or more, 9.0 MPa １／２ It is preferable that the pressure is 11.0 MPa or more. １／２ It is more preferable that the ΔHSP value of the matrix and the surface of the filler particle is 20.0 MPa or more. １／２ It may be 15.0 MPa or less, １／２ It may be the following:

[0080] <Other Components> The resin composition of this embodiment may contain various other additives as needed. The type of additive is not particularly limited as long as it is one commonly used in compounding thermoplastic resins and thermoplastic elastomer materials. Examples of additives that improve functionality include flame retardants, waxes, lubricants and release agents such as various fatty acids, fatty acid amides, fatty acid esters, and metal salts of fatty acids, various antistatic agents, fatty acid esters, sliding property improvers such as polyolefins, olefin copolymer elastomers, and polysiloxanes, decomposition inhibitors such as polyamide resins and acrylamide polymers, amide compounds, amino-substituted triazine compounds and their derivatives, urea and its derivatives, hydrazine derivatives, imidazole compounds, imide compounds, and epoxy compounds, formic acid scavengers such as melamine and alkali metal hydroxides and carbonates, and flame retardants such as organophosphorus compounds. Examples of additives that improve long-term stability include ultraviolet absorbers such as benzotriazole compounds, benzophenone compounds, and phenyl salicylate compounds, hindered amine light stabilizers, and hindered phenol antioxidants. The above additives may be used in combination of one or more.

[0081] The resin composition of the present embodiment may contain at least one of a metal material containing a transition metal element, a compound material containing a transition metal element, a metal material containing a typical metal element, and a compound material containing a typical metal element, which are different from the inorganic material that is the main component of the first filler particles 2a described above.

[0082] Examples of transition metal elements include titanium (Ti), chromium (Cr), manganese (Mn), iron (Fe), cobalt (Co), nickel (Ni), copper (Cu), zirconium (Zr), niobium (Nb), molybdenum (Mo), hafnium (Hf), tantalum (Ta), tungsten (W), palladium (Pd), platinum (Pt), silver (Ag), and gold (Au). Examples of typical metal elements include sodium (Na), magnesium (Mg), calcium (Ca), strontium (Sr), barium (Ba), zinc (Zn), aluminum (Al), gallium (Ga), germanium (Ge), indium (In), tin (Sn), and antimony (Sb). Silicon (Si) and arsenic (As) can be classified as semimetals along with germanium (Ge) and antimony (Sb), but here, silicon (Si) and arsenic (As) are treated as nonmetallic elements. Metal materials are simple metals or alloys, and metal compounds, which are compounds containing metal elements, are, for example, oxides, nitrides, carbides, inorganic acid salts, and organic acid salts of metal elements. Metal compounds may be composite compounds containing multiple transition metal elements, multiple typical metal elements, or transition metal elements and typical metal elements. Compounds are classified into inorganic compounds and organic compounds, and organic compounds, which are metal compounds, i.e., organometallic compounds, are compounds having a bond between carbon and a metal element. Among these, inorganic compounds can also be used as the inorganic material that is the main component of the first filler particles 2a. Titanium oxide (titania), zirconium oxide (zirconia), hafnium oxide (hafnia), zinc titanate, magnesium titanate, strontium titanate, calcium titanate, calcium zirconate, and the like, which were also listed as inorganic materials used as the main component of filler particles, contain transition metal elements, and some of these are composite compounds containing transition metal elements and typical metal elements. Many transition metal compounds are high-dielectric-constant materials with a high dielectric constant (relative dielectric constant of 10 or more). By including such a high-dielectric-constant material in a resin composition, the dielectric constant of resin composition 10 containing matrix 1, which typically has a low dielectric constant (relative dielectric constant less than 10), can be increased, thereby improving radio wave shielding properties by utilizing dielectric loss.Even when the resin composition 10 contains a metal material, the radio wave shielding properties can be improved due to the electrical conductivity of the metal material.

[0083] The material containing the transition metal element or typical metal element listed here may be the main component of the second filler particles 2b, but it is preferable that the inorganic material that is the main component of the first filler particles 2a and the inorganic material that is the main component of the second filler particles 2b are the same.

[0084] The materials containing a transition metal element or a typical metal element listed here may be filler particles (part of the plurality of filler particles 2) having a particle diameter of 0.1 μm or more dispersed in the matrix 1, or may be particles having a particle diameter of less than 0.1 μm. Furthermore, the materials containing a transition metal element or a typical metal element listed here may be particles smaller than the elastomer particles 3, or may be particles dispersed in the elastomer particles 3. Alternatively, the materials containing a transition metal element or a typical metal element listed here may be dissolved in the matrix 1 or the elastomer particles 3.

[0085] FIG. 2B shows a morphology in which additive particles 8 are dispersed in elastomer particles 3. The additive particles 8 and elastomer particles 3 have a core-shell structure, with the additive particles 8 as the core and the elastomer particles 3 as the shell. As long as there are a plurality of filler particles 2 independently dispersed among a plurality of elastomer particles 3, the additive particles 8 do not have to be independently dispersed among the elastomer particles 3. The additive particles 8 may be attached to and in contact with the elastomer particles 3. The additive particles 8 may also be attached to and in contact with the filler particles 2. The additive particles 8 attached to the elastomer particles 3 may or may not be in contact with the matrix 1.

[0086] The content of the material containing the transition metal element or typical metal element listed here is preferably less than the content of the polar polymer that is the main component of the matrix 1, the content of the inorganic material that is the main component of the first filler particles 2a, and the content of the elastomer material that is the main component of the elastomer particles 3.

[0087] When the content of a specific metal element differs between the matrix 1 and the elastomer material, obtaining a distribution image (mapping image) of the metal element makes it easy to distinguish between the matrix 1 and the elastomer material in the observation image. For example, aluminum (Al), germanium (Ge), antimony (Sb), or titanium (Ti) may be contained in a compound that serves as a polymerization catalyst when polymerizing a polar polymer, and may be dissolved or dispersed in the matrix 1. Alternatively, a material containing a transition metal element or a typical metal element may be contained in a compound that serves as a pigment for coloring a resin composition, and may be dispersed in the matrix 1. Alternatively, the plurality of filler particles 2 may include, for example, filler particles primarily composed of calcium carbonate and filler particles primarily composed of titanium oxide, with both of these particles being independently dispersed.

[0088] The additives may include bromine compounds, phosphorus compounds, chlorine compounds, antimony compounds, nitrogen compounds, boron compounds, etc. These compounds may be used as flame retardants. For example, many organic acid salts containing phosphorus are flame retardants, such as aluminum phosphates, aluminum phosphinates, and their derivatives. The inclusion of such flame retardants in a resin composition can enhance the flame retardancy of the resin composition. If the flame retardant is dispersed or dissolved in the elastomer particles 3, the flame retardancy can be efficiently improved. This is because the elastomer particles 3 are flammable. The additive particles 8 dispersed in the filler particles 3 shown in FIG. 2B may also be the flame retardant.

[0089] <Proportion of Independently Dispersed Filler Particles 2> The proportion of the independently dispersed filler particles 2 can be calculated from a cross-sectional observation of the resin molded body. ２ μm ２From the above area range, A filler particles 2 are extracted. The number of extracted filler particles 2 (A) may be 10 or more, but may be 100 or less. Among the extracted A filler particles 2, the number of filler particles 2 (B) that are separated from the nearest elastomer particle 3 via the matrix 1 is counted. The proportion of independently dispersed filler particles can be determined from the ratio of the number of particles (B) to the number of extracted filler particles 2 (A).

[0090] Specifically, a cross-sectional sample of the molded article is prepared in the same manner as in the method for measuring the particle diameter of the filler particles 2. Then, an SEM observation is performed under the same conditions as in the method for measuring the particle diameter of the filler particles 2, and an SEM image of the cross section is obtained. From the obtained SEM image, A (10 or more) filler particles 2 are counted by binarization and image analysis in the same manner as in the method for measuring the particle diameter of the filler particles 2, and among them, the number (B) of filler particles 2 that are separated from the nearest elastomer particle 3 is counted. Then, the abundance ratio of independently dispersed filler particles 2 is calculated using the following formula (2):

[0091] Proportion X (number %) of independently dispersed filler particles 2 = (B / A) × 100 (number %) (2) X (number %) is, for example, a majority of 50% by number or more, preferably 70% by number or more, more preferably 80% by number or more, and even more preferably 90% by number or more.

[0092] <Proportion of Independently Dispersed Elastomer Particles 3> The proportion of the independently dispersed elastomer particles 3 can be calculated from a cross-sectional observation of the resin molded product. ２ μm ２ From the above area range, C elastomer particles 3 are extracted. The number of extracted elastomer particles 3 (C) may be 10 or more, but may be 100 or less. Among the extracted C elastomer particles 3, the number (D) of elastomer particles 3 that are separated from the nearest filler particle 2 via the matrix 1 is counted. The proportion of independently dispersed elastomer particles 3 can be determined from the ratio of the number (D) of particles to the number (C) of extracted elastomer particles 3.

[0093] Specifically, a cross-sectional sample of the molded article is prepared in the same manner as in the method for measuring the particle size of the elastomer particles 3. Then, an SEM observation is performed under the same conditions as in the method for measuring the particle size of the elastomer particles 3, and an SEM image of the cross section is obtained. From the obtained SEM image, C (10 or more) elastomer particles 3 are counted by binarization and image analysis in the same manner as in the method for measuring the particle size of the elastomer particles 3, and the number (D) of elastomer particles 3 separated from the filler particles 2 is counted. Then, the proportion of independently dispersed elastomer particles 3 is calculated using the following formula (3):

[0094] Proportion Y (number %) of independently dispersed elastomer particles 3 = (D / C) × 100 (number %) (3) Y (number %) is, for example, a majority of 50% or more, preferably 70% or more, more preferably 80% or more, and even more preferably 90% or more.

[0095] <Area Occupancy Ratio> 10 of the observed cross section of the resin composition 10 ２ μm ２ Within the above area range, the matrix 1 occupies, for example, 30 area% or more, for example, 90 area% or less, and preferably 70 area% or less. Within this area range, the elastomer material occupies, for example, 1 area% or more, preferably 5 area% or more, for example, 50 mass% or less, and preferably 30 area% or less. Within this area range, the filler particles 2 occupy, for example, 1 area% or more, preferably 5 area% or more, for example, 50 mass% or less, and preferably 30 area% or less. This area range preferably includes the first elastomer particles 3a, second elastomer particles 3b, first filler particles 2a, and second filler particles 2b.

[0096] 10 of the observed cross section of the resin composition 10 ２ μm ２The occupancy rates of various materials within the above area ranges can be calculated by observing the cross section of a molded product of the resin composition 10. Specifically, a transverse cross-sectional sample of the molded product is prepared using the same method as for measuring the particle diameter of the filler particles 2. Then, SEM observation is performed under the same conditions as for measuring the particle diameter of the filler particles 2, and an SEM image of the cross section is obtained. In the SEM image taken with a scanning electron microscope, the filler particles 2, matrix 1, and elastomer material can be identified based on their shape, size, and contrast in the obtained image. It is desirable to distinguish the filler particles 2, matrix 1, and elastomer material by mapping the elements contained in each material. Energy dispersive X-ray spectroscopy (EDS) can be used for elemental mapping. SEM-EDS, which combines the above-mentioned SEM and elemental analysis, is preferred. The obtained image is then analyzed using a small, general-purpose image processing and analysis system (LUZEX; Nicole Co., Ltd.). The obtained image is binarized using a predetermined threshold, and the area ratio in the processed image is used to calculate the 10 ２ μm ２ The occupancy rate of each material in the above area range is calculated. The area of ​​the observed cross section of the resin composition 10 is, for example, 1000 ２ μm ２ is less than or equal to 500 ２ μm ２ Preferably, it is 250 or less. ２ μm ２ More preferably, it is 130 ２ μm ２ It is even more preferable that:

[0097] The method for producing a resin composition according to the present embodiment includes a step of melt-kneading a matrix, filler particles, and an elastomer raw material containing an elastomer material constituting the elastomer particles. Examples of the kneading device include a twin-screw extruder and a twin-roll extruder. Specific examples include a TEM extruder (manufactured by Toshiba Machine Co., Ltd.), a TEX twin-screw extruder (manufactured by the Japan Steel Works, Ltd.), a PCM extruder (manufactured by Ikegai Iron Works), and a Kneadex (manufactured by Nippon Coke Company).

[0098] <<Molded Article>> The molded article of this embodiment is obtained by molding the resin composition of this embodiment. Typical molding methods include extrusion molding from a mold or injection molding into a mold. Injection molding may also be performed using pellets produced by extrusion molding from a mold. A resin composition molded by injection molding may be referred to as an injection-molded article. Furthermore, a molded article formed by injection molding may be further processed by blow molding or the like.

[0099] The Charpy impact value of the compact is 3 kJ / m ２ More than 6 kJ / m is preferable. ２ More preferably, 3 kJ / m or more. ２ If it is less than this, cracks may occur during a drop test or the like.

[0100] The flexural modulus of the molded body is preferably 2300 MPa or more, more preferably 2600 MPa or more. This is because when the flexural modulus is in this range, deformation due to expected external forces is in the elastic deformation region and the shape does not deform. On the other hand, when the flexural modulus is less than 2300 MPa, there is a possibility that plastic deformation occurs due to expected external forces, and therefore, there is a possibility that a thicker wall than before is required.

[0101] <Device> As shown in Fig. 4, the device 100 of this embodiment has members 10a and 10b molded from the resin composition 10 of this embodiment. Examples of the device 100 include office equipment such as printers and copiers, medical equipment such as CT scanners, and imaging equipment such as projectors and displays. These various devices have at least one of an electrical component 13, an optical component 12, and a metal component 11 in addition to the members 10a and 10b molded from the resin composition 10 of this embodiment. The electrical component 13, the optical component 12, or the metal component 11 realizes the function of the device 100. The metal component 11 can also be used as a housing for ensuring the mechanical strength of the device 100.

[0102] The members 10a and 10b formed from the resin composition 10 can be used as members that ensure the mechanical strength of the device 100 or mechanically protect the device 100. The member 10a formed from the resin composition 10 may be an exterior body of the device 100, for example, an exterior cover. This exterior body may be fixed to a metal housing (metal part 11). The member 10a formed from the resin composition 10 of the present embodiment may be an interior body of the device 100, for example, a mechanical part. This interior body may be fixed to a metal housing (metal part 11). It is preferable that the members 10a and 10b formed from the resin composition 10 have radio wave shielding properties in terms of stable operation of the device 100 and suppression of radio wave radiation from the device 100.

[0103] Examples 1 to 15, Comparative Examples 1 to 3 The materials used in the examples (including comparative examples) are as follows.

[0104] (A) Matrix material

[0105]

[0106] (B) Filler Particles The average particle diameter [μm] of the filler particles shown in Table 2 is the catalog value of the product.

[0107]

[0108] (C) Surface treatment agent

[0109]

[0110] (D) Elastomer material

[0111]

[0112] <Production of resin composition pellets> The matrix materials shown in Tables 5 and 6 were pre-dried to a moisture content of 100 ppm. This was to suppress hydrolysis during kneading, and the temperature and time conditions differ depending on the type of resin. The moisture content was measured using a polymer moisture meter "Aquatrac V (product name) manufactured by ITS Japan Co., Ltd."

[0113] Next, the filler particles were subjected to the surface treatment shown in Tables 5 and 6. The filler particles were placed in a mixer "SMV-20Ba (product name) manufactured by Kawata Corporation," and the surface treatment agents shown in Tables 5 and 6 were added dropwise from above while stirring. The amount of surface treatment agent added was calculated using the following model formula (4) from the specific surface area of ​​the filler particles (B) and the minimum coverage area of ​​the surface treatment agent. The minimum coverage area was calculated by referring to manufacturer catalogs and literature values. Amount of surface treatment agent added (g) = Filler particle mass (g) × Specific surface area of ​​filler particles (m ２ / g) / minimum coverage area of ​​surface treatment agent (g) (4)

[0114] Thereafter, a blend of raw materials was prepared by adding the matrix material, filler particles, and elastomer material so that the mass percentage of each component in the final resin composition would be the blending amounts shown in Tables 5 and 6. When the filler particles were surface-treated, the mass percentage of the filler particles included the surface treatment agent.

[0115] In Examples 1 to 10 and Comparative Examples 1 to 3, the matrix material A-1, filler particles B-1 to B-6, and elastomer materials D-1 to D-10 were each fed by a weight feeder to a predetermined mass ratio. Prior to this feeding, the filler particles B-1 to B-6 were treated with the surface treatment agents C-1 and C-2 by the above-described surface treatment method.

[0116] In Examples 11 to 15, matrix materials A-2 and A-3, filler particles B-2 to B-6, and elastomer materials D-1 to D-3 and D-6 were each fed by a weight feeder to a predetermined mass ratio. Prior to this feeding, filler particles B-2 to B-6 were treated with surface treatment agents C-2 and C-3 by the above-described surface treatment method.

[0117] The blend was melt-kneaded in a twin-screw extruder "PCM30 (product name) manufactured by Ikegai Corporation" at a cylinder temperature of 260°C and a screw rotation speed of 250 rpm to produce strands, which were then cut and processed using a pelletizer to obtain pellets of the resin composition.

[0118] <Molding of resin molded article> Pellets of the obtained resin composition were dried in advance so that the moisture content was 100 ppm. The moisture content was measured in the same manner as for the moisture content of the matrix material. Subsequently, the resin composition was injection molded using an injection molding machine "SE-180D (product name) manufactured by Sumitomo Heavy Industries, Ltd." at a cylinder temperature of 280°C and a mold temperature of 30°C to mold strip-shaped test specimens Type B1 (length 80 mm × width 10 mm × thickness 4 mm) specified in JIS K7152-1.

[0119] <Charpy Impact Value> The molded rectangular test specimens were notched (shape A) using a notching machine "No. 189-PN (product name) manufactured by Yasuda Seiki Seisakusho Co., Ltd." in accordance with JIS K7111, to form a 45° notch with a depth of 2 mm and a notch tip radius of 0.25 mm in the center. The test specimens were then broken with an energy of 1 J from the backside of the notch in the test specimen using a Charpy impact tester "No. 258 (product name) manufactured by Yasuda Seiki Seisakusho Co., Ltd." in accordance with JIS K7111-1. The energy required for fracture was calculated from the angle at which the hammer, which had been swung up to 150°, swung up after the test specimen was broken, and the average value of the measured values ​​for five test specimens was taken as the Charpy impact value.

[0120] The results of the Charpy impact tests measured were evaluated according to the following indices. The results are shown in Tables 5 and 6. The higher the Charpy impact strength, the better the evaluation. A: Charpy impact strength is 6 kJ / m ２ B: Charpy impact strength is 3 kJ / m or more ２ 6kJ / m or more ２ C: Charpy impact strength is less than 3 kJ / m ２ less than.

[0121] <Flexural modulus> The molded rectangular test specimens were subjected to measurement in accordance with JIS K 7171 using a three-point bending jig attached to a universal testing machine "Instron 5581 (product name)" with a support distance of 64 mm and an indenter descending speed of 2 mm / min, and the flexural modulus was calculated from the stress gradient in a specified strain range (0.05% to 0.25%). The average value of the measurements for five test specimens was taken as the flexural modulus.

[0122] The flexural modulus was evaluated according to the following criteria. The results are shown in Table 5. The higher the flexural modulus, the better the evaluation. A: Flexural modulus is 2,600 MPa or more. B: Flexural modulus is 2,300 MPa or more and less than 2,600 MPa. C: Flexural modulus is less than 2,300 MPa.

[0123] <ΔHSP Value> The ΔHSP value was calculated by inputting the chemical structural formula of the compound using the 5th Edition 5.4.01 of "HSPiP," a calculation software with a database developed and sold by the Hansen Group. The ΔHSP value between the surface of the filler particle and the elastomer material is "ΔHSP Value 1," the ΔHSP value between the matrix material and the elastomer material is "ΔHSP Value 2," and the ΔHSP value between the matrix material and the surface of the filler particle is "ΔHSP Value 3," as shown in Tables 5 and 6.

[0124] <Confirmation of dispersion structure> The central part of the molded strip test piece is observed in the cross-sectional direction to confirm the dispersion structure of the filler particles and elastomer particles in the matrix. The observation cross section is polished using abrasive paper with particle sizes #400 to #2500 in order, and then buffed with a diamond slurry with a particle size of 0.5 μm to prepare a cross section for observation. The dispersion structure is observed using a scanning electron microscope "JEOL Ltd., JSM-F100 (product name)" at an acceleration voltage of 3 kV and a magnification of 10,000 times.

[0125] The results of the observation are shown in Tables 5 and 6, where the state shown in Figure 1A was "independent dispersion" and the state shown in Figure 1B was "core-shell." Figure 5A shows a cross-sectional SEM image of Example 1, and Figure 5B shows a cross-sectional SEM image of Comparative Example 1. Figure 6 shows a cross-sectional SEM image of Example 3.

[0126] <Proportion of Independently Dispersed Filler Particles> A cross section to be observed was prepared in the same manner as in the confirmation of the dispersion structure. Then, observation was performed using a scanning electron microscope (SEM) under the conditions shown below to obtain an SEM image of the cross section. The observation magnification was changed depending on the particle diameter of the filler particles. When the particle diameter was 5 μm or less, observation was performed at a magnification of 10,000 times, and when the particle diameter was more than 5 μm, observation was performed at a magnification of 1,000 times. The field area of ​​the SEM image was 10２ μm ２ Greater than or equal to 130 ２ μm ２ The total number of filler particles (A) (10 or more) was counted from the obtained SEM image by binarization and image analysis under the following conditions, and the number of filler particles (B) that were separated from the nearest elastomer particle via the matrix was counted. Then, the proportion X (number %) of independently dispersed filler particles was calculated using the above formula (2).

[0127] [Conditions] {Name of apparatus} Schottky field emission scanning electron microscope JSM-F100 (manufactured by JEOL Ltd.) {Accelerating voltage} 3 kV {Magnification} 10,000x or 1,000x {Measurement range} 12.8 μm × 9.6 μm (10,000x) or 128 μm × 96 μm (1,000x) {Number of evaluations} 10 areas / sample {Binarization and image analysis} ImageJ {Binarization method} MaxEntropy (The threshold is adjusted appropriately so that only the filler particles can be separated by binarization. If binarization is not possible using the image processing software, an image in which only the filler particles are visually filled in is prepared using paint software or the like.)

[0128] The results of Examples 1 to 15 and Comparative Examples 1 to 3 are shown in Tables 5 and 6.

[0129]

[0130]

[0131] The particle sizes of the filler particles and elastomer particles in Tables 5 and 6 were measured from cross-sectional SEM images. The discrepancies with the catalog values ​​shown in Table 2 were within ±50%, indicating that the measurement methods are appropriate based on the cross-sectional SEM images. In the examples, SEM images at 10,000x magnification confirmed that two elastomer particles (3a, 3b) spaced 10 μm or less were dispersed apart from the filler particles. In the examples, the proportion of independently dispersed elastomer particles (Y number %) is not significantly different from the proportion of independently dispersed filler particles (X number %), and can be 50 number % or more, and even 70 number % or more. In a typical injection-molded article, a surface portion (skin layer) and a central portion (core layer) may be formed on the test specimen. In the examples, the independent dispersion structure is ubiquitous over a wide area in the central portion (core layer) of the test piece, so the ratios of the area occupancy of the matrix, the area occupancy of the filler particles, and the area occupancy of the elastomer particles are not significantly different from the composition ratios.

[0132] The resin compositions of Examples 1 to 15 were independently dispersed and exhibited a flexural modulus superior to that of the matrix alone shown in Table 1. In contrast, the resin compositions of Comparative Examples 1 to 3 had a core-shell structure and exhibited a lower flexural modulus than that of the matrix alone shown in Table 1.

[0133] Examples 1 to 3 and 11 received an A rating for Charpy impact strength and flexural modulus, demonstrating particularly excellent mechanical properties. Because Examples 1 and 2 use D-1, which contains an ester bond as a polar group, as the elastomer material, it is presumed that the Charpy impact strength is higher than that of Example 7, which uses D-7, which contains no ester bond. Because Examples 1 and 2 have a filler particle diameter of 0.5 μm, which is smaller than that of Example 9, which has a filler particle diameter of 15.0 μm, it is presumed that the phenomenon described using FIG. 3A is suppressed, resulting in a higher Charpy impact strength than that of Example 9. Because Example 7 has a filler particle diameter of 0.5 μm, which is larger than that of Example 10, which has a filler particle diameter of 0.2 μm, it is presumed that the phenomenon described using FIG. 3B is suppressed, resulting in a higher Charpy impact strength than that of Example 10.

[0134] Examples 16 to 20, Comparative Example 4 Materials used in the present examples (including comparative examples) other than those shown in Tables 1 to 4 are as shown in Table 7. The fiber diameter and fiber length of the filler (glass fiber) shown in Table 7 are the values ​​in the product catalog.

[0135]

[0136] The pellet production and molding in Examples 16 to 20 and Comparative Example 4 were the same as in Examples 1 to 15 except for the differences in components.

[0137] In Examples 16 to 19, the matrix material A-1, the glass fiber filler particles B-7 to B-9, and the elastomer material D-1 were each fed by a weight feeder to a predetermined mass ratio. Prior to this feeding, the glass fiber filler particles B-7 to B-9 were treated with the surface treatment agent C-1 in the same manner as in the surface treatment described above.

[0138] In Example 20, matrix material A-1, glass fiber filler particles B-7, elastomer material D-10, and additive (flame retardant) E-1 were each fed by weight feeder in a predetermined mass ratio. Prior to this feeding, the glass fiber filler particles B-7 were treated with surface treatment agent C-4 in the same manner as in the surface treatment described above. Prior to this feeding, particles of additive (flame retardant) E-1 were treated with surface treatment agent C-1 in the same manner as in the surface treatment described above.

[0139] In Comparative Example 4, the matrix material A-1, the glass fiber of the filler particle B-7, and the elastomer material D-9 were each fed by a weight feeder to a predetermined mass ratio. Prior to this feeding, the glass fiber of the filler particle B-7 was treated with the surface treatment agent C-1 in the same manner as in the surface treatment described above.

[0140] <Measurement of aspect ratio> The center of the molded strip test piece was cut out and heat-treated at 450°C in a nitrogen atmosphere for 10 hours to remove components other than the filler particles. Then, observation was performed using a scanning electron microscope (SEM) under the conditions shown below to obtain a cross-sectional SEM image. Depending on the length of the filler particles, observation was performed at a magnification of 10,000x when the length was 5 μm or less, and at a magnification of 1,000x when the length exceeded 5 μm. Furthermore, when the length of the filler particles exceeded 100 μm, the filler particles were divided into multiple SEM images to obtain SIM images of the entire filler particles. The average aspect ratio within any range of the SEM image obtained from the obtained SEM image by binarization and image analysis under the conditions shown below was taken as the aspect ratio of the filler particles. The binarization and image analysis of the SEM images are carried out using the image processing software ImageJ (available from https: / / imagej.nih.gov / ij / ) from the National Institutes of Health.

[0141] [Conditions] {Device name} Schottky field emission scanning electron microscope JSM-F100 (manufactured by JEOL Ltd.) {Accelerating voltage} 3 kV {Magnification} 10,000x or 1,000x {Measurement range} 12.8 μm × 9.6 μm (10,000x) or 128 μm × 96 μm (1,000x) {Number of evaluations} 10 areas / sample {Binarization and image analysis} ImageJ {Binarization method} MaxEntropy (The threshold is adjusted appropriately so that the filler particles can be separated by binarization. If binarization cannot be performed using image processing software, an image in which only the filler particles are visually filled in is prepared using paint software or the like.) {Method of calculating aspect ratio} The maximum diameter of the filler particle measured so as to pass through the center of gravity of the filler particle is defined as the filler particle length, and the diameter measured so as to pass through the center of gravity of the filler particle in a direction perpendicular to the maximum diameter is defined as the filler particle diameter.The aspect ratio of each filler particle is defined as the filler particle length divided by the filler particle diameter, and the average value is calculated.

[0142] The results of Examples 16 to 20 and Comparative Example 4 are shown in Table 8.

[0143]

[0144] The ΔHSP value of the flame retardant and the elastomer material is shown in Table 8 as "ΔHSP value 4," and the ΔHSP value of the matrix material and the flame retardant is shown as "ΔHSP value 5."

[0145] By kneading the resin composition, the glass fibers are cut, and the fiber length of filler particles 2 in the resin composition becomes shorter than the value shown in Table 7. The fiber lengths and aspect ratios of the glass fibers as filler particles in the resin compositions of Examples 16 to 20 and Comparative Example 4 are shown in Table 8. The fiber diameter of the glass fibers as filler particles does not change before and after kneading, and remains the fiber diameter shown in Table 7.

[0146] The resin compositions of Examples 16 to 20 have an independently dispersed filler particle and elastomer particle dispersion structure, and exhibit a flexural modulus superior to that of matrix material A-1 alone, as shown in Table 1. In contrast, the resin composition of Comparative Example 4 has an adhered dispersion structure of filler particles and elastomer particles, as shown in Figure 2C, and Comparative Example 4 has a lower flexural modulus than the other Examples. The resin composition of Example 20 has flame retardant particles corresponding to additive particle 8 dispersed in elastomer particles, as shown in Figure 2B, and additive particle 8 and the elastomer particles have a core-shell structure, resulting in excellent flame retardancy.

[0147] The present invention is not limited to the above-described embodiments and examples, and many modifications are possible within the technical concept of the present invention. Furthermore, the effects described in the embodiments and examples of the present invention are merely a list of the most preferable effects resulting from the present invention, and the effects of the present invention are not limited to those described in the embodiments and examples.

[0148] Furthermore, new matters may be added to at least one embodiment. The disclosure of this specification includes not only what is explicitly described in this specification, but also all matters that can be understood from this specification and the drawings attached hereto.

[0149] In addition, with regard to the specific numerical ranges exemplified in this specification, the notation "e to f" (e and f are numbers) means e or more and / or f or less. Furthermore, when a range of i to j and a range of m to n are both listed for the specific numerical ranges exemplified (i, j, m, and n are numbers), the set of lower and upper limits is not limited to the set of i and j or the set of m and n. For example, it is also possible to consider a combination of multiple sets of lower and upper limits. In other words, when a range of i to j and a range of m to n are both listed, it is also possible to consider the range of i to n or the range of m to j, as long as there is no contradiction. Furthermore, "e or more" means either e or greater than e (exceeding e), and it is also possible to adopt a value greater than e without adopting e. Furthermore, "f or less" means either f or smaller than f (less than f), and it is also possible to adopt a value smaller than f without adopting f.

[0150] Furthermore, the disclosure of this specification includes the complement of each individual concept described in this specification. In other words, if this specification contains a statement that "A is B," it can be said that this specification discloses "A is not B," even if it omits a statement that "A is not B." This is because a statement that "A is B" presupposes that the case in which "A is not B" is taken into consideration.

[0151] <<Configurations Included>> The disclosure of this embodiment includes the following configurations: (Configuration 1) A resin composition containing a matrix primarily composed of a polar polymer, a plurality of filler particles primarily composed of an inorganic material and having a particle diameter of 0.1 μm or greater, and a plurality of elastomer particles each having a particle diameter of 0.1 μm or greater, wherein the plurality of filler particles and the plurality of elastomer particles are in contact with and dispersed within the matrix, a first elastomer particle and a second elastomer particle among the plurality of elastomer particles are present at an interval of 10 μm or less in a cross section of the resin composition, a first filler particle among the plurality of filler particles that is closest to the first elastomer particle in the cross section is separated from the first elastomer particle via the matrix, and a second filler particle among the plurality of filler particles that is closest to the second elastomer particle in the cross section is separated from the second elastomer particle via the matrix.

[0152] (Configuration 2) The resin composition according to Configuration 1, wherein the distance between the first filler particles and the second filler particles is 100 μm or less, the distance between the first filler particles and the first elastomer particles is 10 μm or less, and the distance between the second filler particles and the second elastomer particles is 10 μm or less.

[0153] (Configuration 3) 10 of the cross section ２ μm ２ Greater than or equal to 1000 ２ μm ２ 50% by number or more of the 10 or more filler particles in the following area range are separated from the plurality of elastomer particles via the matrix; and ２ μm ２ Greater than or equal to 1000 ２ μm ２and 50% or more by number of the 10 or more elastomer particles in the following area range are separated from the plurality of filler particles via the matrix.

[0154] (Configuration 4) The cross section of 10 particles including the first elastomer particles, the second elastomer particles, the first filler particles, and the second filler particles. ２ μm ２ Greater than or equal to 1000 ２ μm ２ 4. The resin composition according to any one of configurations 1 to 3, wherein the occupancy in the following area ranges is 30 area % or more and 90 area % or less of the matrix, 1 area % or more and 50 area % or less of the plurality of filler particles, and 1 area % or more and 50 area % or less of the plurality of elastomer particles.

[0155] (Configuration 5) The resin composition contains 100% elastomer particles, 100% elastomer particles, 100% elastomer particles, 100% filler particles, and 100% filler particles. ３ μm ３ More than 1mm ３ The resin composition according to any one of Structures 1 to 4, characterized in that the composition in the following volume ranges is: the matrix is ​​30% by mass or more and 90% by mass or less; the plurality of filler particles is 1% by mass or more and 50% by mass or less; and the elastomer material constituting the plurality of elastomer particles is 1% by mass or more and 50% by mass or less.

[0156] (Configuration 6) The resin composition according to any one of Configurations 1 to 5, wherein the elastomer material constituting the plurality of elastomer particles has a polar group.

[0157] (Configuration 7) The resin composition according to any one of Configurations 1 to 6, wherein the elastomer material constituting the plurality of elastomer particles has an ester bond.

[0158] (Configuration 8) The resin composition according to any one of Configurations 1 to 7, wherein the elastomer material constituting the plurality of elastomer particles has a Shore A hardness of 70 degrees or more.

[0159] (Configuration 9) The resin composition according to any one of Configurations 1 to 8, wherein the elastomer material constituting the plurality of elastomer particles is a thermoplastic elastomer.

[0160] (Configuration 10) The resin composition according to any one of Configurations 1 to 9, wherein the elastomer material constituting the plurality of elastomer particles is an acrylic elastomer or an ester elastomer.

[0161] (Configuration 11) The resin composition according to any one of Configurations 1 to 10, wherein the melting point of the elastomer material constituting the plurality of elastomer particles is lower than the glass transition point or melting point of the matrix.

[0162] (Configuration 12) The ΔHSP value of the elastomer material constituting the surfaces of the plurality of filler particles and the plurality of elastomer particles is 7.0 MPa １／２ 12. The resin composition according to any one of configurations 1 to 11, characterized in that:

[0163] (Configuration 13) The resin composition according to any one of Configurations 1 to 12, wherein the particle diameters of the first elastomer particles and the second elastomer particles are 10 μm or less.

[0164] (Configuration 14) The resin composition according to any one of Configurations 1 to 13, wherein the particle diameters of the first elastomer particles and the second elastomer particles are 0.5 μm or more and 5 μm or less.

[0165] (Configuration 15) The resin composition according to any one of Configurations 1 to 14, wherein the particle diameters of the first filler particles and the second filler particles are 10 μm or less.

[0166] (Configuration 16) The resin composition according to any one of Configurations 1 to 15, wherein the particle diameters of the first filler particles and the second filler particles are 0.2 μm or more and 5 μm or less.

[0167] (Configuration 17) The resin composition according to any one of Configurations 1 to 16, wherein at least one of the first filler particles and the second filler particles has a particle diameter of 2 μm or more.

[0168] (Configuration 18) The resin composition according to any one of Configurations 1 to 17, wherein the first filler particles and the second filler particles contain silica or calcium carbonate.

[0169] (Configuration 19) The resin composition according to any one of Configurations 1 to 18, wherein the first filler particles and the second filler particles are fibrous.

[0170] (Configuration 20) The resin composition according to any one of Configurations 1 to 19, wherein the first filler particles and the second filler particles have an aspect ratio of 5 or more and 100 or less.

[0171] (Configuration 21) The resin composition according to any one of Configurations 1 to 20, wherein the first filler particles and the second filler particles contain glass fibers or carbon fibers.

[0172] (Configuration 22) The resin composition according to any one of Configurations 1 to 21, further comprising particles dispersed in the elastomer particles.

[0173] (Configuration 23) The resin composition according to Configuration 22, wherein the particles dispersed in the elastomer particles contain a phosphorus compound and / or a flame retardant.

[0174] (Configuration 24) The resin composition according to any one of Configurations 1 to 23, wherein the plurality of filler particles have a surface layer formed by surface treatment of a base made of the inorganic material.

[0175] (Configuration 25) The resin composition according to Configuration 24, wherein the surface treatment is a surface treatment with a silane coupling agent.

[0176] (Configuration 26) The resin composition according to any one of Configurations 1 to 25, wherein the polar polymer is a polyester.

[0177] (Configuration 27) The resin composition according to any one of Configurations 1 to 26, wherein the polar polymer is polyethylene terephthalate.

[0178] (Configuration 28) The resin composition according to any one of Configurations 1 to 27, wherein the polar polymer has a carbodiimide group.

[0179] (Configuration 29) The resin composition according to any one of Configurations 1 to 28, further comprising at least one of a metal material containing a transition metal element, a compound material containing a transition metal element, a metal material containing a typical metal element, and a compound material containing a typical metal element, which is different from the inorganic material that is the main component of the first filler particles.

[0180] (Configuration 30) A method for producing a resin composition according to any one of Configurations 1 to 29, comprising a step of melt-kneading the matrix, the filler particles, and an elastomer material constituting the elastomer particles.

[0181] (Configuration 31) A pellet comprising the resin composition according to any one of Configurations 1 to 29.

[0182] (Configuration 32) A molded article comprising the resin composition according to any one of Configurations 1 to 29, wherein the polar polymer is a crystalline polymer.

[0183] (Configuration 33) An injection-molded article comprising the resin composition according to any one of Configurations 1 to 29.

[0184] (Configuration 34) An apparatus comprising: a member molded from the resin composition according to any one of Configurations 1 to 29; and at least one of an electrical part, a metal part, and an optical part.

[0185] (Configuration 35) The device according to Configuration 34, wherein the member is an exterior body.

[0186] The present invention is not limited to the above-described embodiments, and various modifications and variations can be made without departing from the spirit and scope of the present invention. Therefore, the following claims are appended to apprise the public of the scope of the present invention.

[0187] This application claims priority based on Japanese Patent Application No. 2023-132069 filed on August 14, 2023, Japanese Patent Application No. 2023-177773 filed on October 13, 2023, and Japanese Patent Application No. 2024-130700 filed on August 7, 2024, the entire contents of which are incorporated herein by reference.

[0188] 1 Matrix 2 Filler particle 3 Elastomer particle 4 Elastomer material 5 Craze 6 Crack

Claims

1. A resin composition comprising a matrix mainly composed of a polar polymer, a plurality of filler particles mainly composed of an inorganic material and having a particle diameter of 0.1 μm or more, and a plurality of elastomer particles having a particle diameter of 0.1 μm or more, wherein the plurality of filler particles and the plurality of elastomer particles are in contact with the matrix and dispersed in the matrix, a first elastomer particle and a second elastomer particle among the plurality of elastomer particles are present at an interval of 10 μm or less in a cross section of the resin composition, a first filler particle among the plurality of filler particles that is closest to the first elastomer particle in the cross section is separated from the first elastomer particle via the matrix, and a second filler particle among the plurality of filler particles that is closest to the second elastomer particle in the cross section is separated from the second elastomer particle via the matrix.

2. The resin composition described in claim 1, characterized in that the distance between the first filler particles and the second filler particles is 100 μm or less, the distance between the first filler particles and the first elastomer particles is 10 μm or less, and the distance between the second filler particles and the second elastomer particles is 10 μm or less.

3. 10 of the above cross section ２ μm ２ Greater than or equal to 1000 ２ μm ２ 50% or more by number of the 10 or more filler particles in the following area range are separated from the plurality of elastomer particles via the matrix; ２ μm ２ Greater than or equal to 1000 ２ μm ２ and 50% or more by number of the 10 or more elastomer particles in the following area range are separated from the plurality of filler particles via the matrix.

4. 10 particles including the first elastomer particles, the second elastomer particles, the first filler particles, and the second filler particles of the cross section. ２ μm ２ Greater than or equal to 1000 ２ μm ２ The resin composition according to claim 1, characterized in that the occupancy in the following area ranges is 30 area % or more and 90 area % or less, the plurality of filler particles is 1 area % or more and 50 area % or less, and the plurality of elastomer particles is 1 area % or more and 50 area % or less.

5. 100% by weight of the first elastomer particles, the second elastomer particles, the first filler particles, and the second filler particles in the resin composition. ３ μm ３ More than 1mm ３ The resin composition according to claim 1, characterized in that the composition in the following volume ranges is: the matrix is ​​30% by mass or more and 90% by mass or less, the plurality of filler particles is 1% by mass or more and 50% by mass or less, and the elastomer material constituting the plurality of elastomer particles is 1% by mass or more and 50% by mass or less.

6. A resin composition according to any one of claims 1 to 5, characterized in that the elastomer material constituting the plurality of elastomer particles has a polar group.

7. A resin composition according to any one of claims 1 to 5, characterized in that the elastomer material constituting the plurality of elastomer particles has an ester bond.

8. A resin composition according to any one of claims 1 to 5, characterized in that the elastomer material constituting the plurality of elastomer particles has a Shore A hardness of 70 degrees or more.

9. A resin composition according to any one of claims 1 to 5, characterized in that the elastomer material constituting the plurality of elastomer particles is a thermoplastic elastomer.

10. A resin composition according to any one of claims 1 to 5, characterized in that the elastomer material constituting the plurality of elastomer particles is an acrylic elastomer or an ester elastomer.

11. A resin composition according to any one of claims 1 to 5, characterized in that the melting point of the elastomer material constituting the plurality of elastomer particles is lower than the glass transition point or melting point of the matrix.

12. The ΔHSP value of the elastomer material constituting the surfaces of the plurality of filler particles and the plurality of elastomer particles is 7.0 MPa. １／２ The resin composition according to any one of claims 1 to 5, characterized in that 13. A resin composition according to any one of claims 1 to 5, characterized in that the particle diameter of the first elastomer particles and the second elastomer particles is 10 μm or less.

14. A resin composition according to any one of claims 1 to 5, characterized in that the particle diameter of the first elastomer particles and the second elastomer particles is 0.5 μm or more and 5 μm or less.

15. A resin composition according to any one of claims 1 to 5, characterized in that the particle diameter of the first filler particles and the second filler particles is 10 μm or less.

16. A resin composition according to any one of claims 1 to 5, characterized in that the particle diameter of the first filler particles and the second filler particles is 0.2 μm or more and 5 μm or less.

17. A resin composition according to any one of claims 1 to 5, characterized in that at least one of the first filler particles and the second filler particles has a particle diameter of 2 μm or more.

18. A resin composition according to any one of claims 1 to 5, characterized in that the first filler particles and the second filler particles contain silica or calcium carbonate.

19. A resin composition according to any one of claims 1 to 5, characterized in that the first filler particles and the second filler particles are fibrous.

20. A resin composition according to any one of claims 1 to 5, characterized in that the first filler particles and the second filler particles have an aspect ratio of 5 or more and 100 or less.

21. A resin composition according to any one of claims 1 to 5, characterized in that the first filler particles and the second filler particles contain glass fibers or carbon fibers.

22. A resin composition according to any one of claims 1 to 5, characterized in that it contains dispersed particles among the elastomer particles.

23. The resin composition according to claim 22, characterized in that the particles dispersed in the elastomer particles contain a phosphorus compound and / or a flame retardant.

24. A resin composition according to any one of claims 1 to 5, characterized in that the plurality of filler particles have a surface layer formed by surface treatment of a base made of the inorganic material.

25. The resin composition according to claim 24, characterized in that the surface treatment is a surface treatment with a silane coupling agent.

26. A resin composition according to any one of claims 1 to 5, characterized in that the polar polymer is a polyester.

27. A resin composition according to any one of claims 1 to 5, characterized in that the polar polymer is polyethylene terephthalate.

28. A resin composition according to any one of claims 1 to 5, characterized in that the polar polymer has a carbodiimide group.

29. A resin composition described in any one of claims 1 to 5, characterized in that it contains at least one of a metal material containing a transition metal element, a compound material containing a transition metal element, a metal material containing a typical metal element, and a compound material containing a typical metal element, which are different from the inorganic material that is the main component of the first filler particles.

30. A method for producing a resin composition according to any one of claims 1 to 5, characterized in that it comprises a step of melt-kneading the matrix, the filler particles, and the elastomer material constituting the elastomer particles.

31. A pellet comprising the resin composition according to any one of claims 1 to 5.

32. A molded article comprising the resin composition according to any one of claims 1 to 5, wherein the polar polymer is a crystalline polymer.

33. An injection molded article comprising the resin composition according to any one of claims 1 to 5.

34. An apparatus comprising a member molded from the resin composition according to any one of claims 1 to 5, and at least one of an electrical part, a metal part, and an optical part.

35. The device of claim 34, wherein the member is an exterior body.

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