Vinyl chloride resin composition for powder molding, molded vinyl chloride resin, and laminate

Abstract

The purpose of the present invention is to provide a vinyl chloride resin composition for powder molding which has excellent powder moldability even without containing any ester-based plasticizer. This vinyl chloride resin composition for powder molding comprises (a) a vinyl chloride resin and (b) a (meth)acrylic block copolymer, wherein the (meth)acrylic block copolymer (b) is a block copolymer comprising a hard segment comprising a methyl methacrylate block and a soft segment comprising an alkyl acrylate block, the vinyl chloride resin composition being characterized in that the median diameter D50 is 1,000 μm or less.

Description

Vinyl chloride resin composition for powder molding, vinyl chloride resin molded body, and laminate

[0001] The present invention relates to a vinyl chloride resin composition for powder molding, a vinyl chloride resin molded article, and a laminate.

[0002] Vinyl chloride resins are generally used in a variety of applications due to their excellent properties, such as cold resistance, heat resistance, and oil resistance. Specifically, for example, automotive interior parts such as automotive instrument panels and door trims are formed using automotive interior materials such as skins made of vinyl chloride resin molded articles and laminates made of vinyl chloride resin molded articles backed with foam such as polyurethane foam. Vinyl chloride resin molded articles constituting the skins of automotive interior parts such as automotive instrument panels are produced, for example, by molding a vinyl chloride resin composition containing vinyl chloride resin, an ester-based plasticizer such as polyester or trimellitic ester, and additives such as pigments using a known molding method such as powder slush molding.

[0003] In recent years, the leaching of ester-based plasticizers from vinyl chloride resin molded articles obtained using such vinyl chloride resin compositions has become a problem, and the use of polymeric materials that are thought to cause little leaching, instead of ester-based plasticizers, for plasticizing vinyl chloride resins has been studied. For example, Patent Document 1 discloses a vinyl chloride resin composition containing (A) a vinyl chloride resin and (B) a (meth)acrylic block copolymer that is a block copolymer containing, instead of the ester-based plasticizer, a hard segment composed of a methyl methacrylate block and a soft segment composed of an alkyl acrylate block.

[0004] Japanese Patent Application Laid-Open No. 2020-132657

[0005] However, the vinyl chloride resin compositions of the above-mentioned prior art have room for improvement in moldability when subjected to powder molding such as powder slush molding.

[0006] Therefore, an object of the present invention is to provide a vinyl chloride resin composition for powder molding that exhibits excellent powder moldability even without containing an ester-based plasticizer. Another object of the present invention is to provide a vinyl chloride resin molded article obtained using the vinyl chloride resin composition for powder molding. A further object of the present invention is to provide a laminate comprising the vinyl chloride resin molded article.

[0007] The present inventors have conducted extensive research with the aim of solving the above-mentioned problems, and have newly discovered that a vinyl chloride resin composition having excellent powder moldability can be obtained without containing an ester-based plasticizer by blending a predetermined (meth)acrylic block copolymer into a vinyl chloride resin composition in place of an ester-based plasticizer such as a polyester or a trimellitic ester, and adjusting the particle size of the vinyl chloride resin composition to a predetermined value or less, thereby completing the present invention.

[0008] The present invention aims to advantageously solve the above-mentioned problems. [1] The present invention provides a vinyl chloride resin composition for powder molding, comprising (a) a vinyl chloride resin and (b) a (meth)acrylic block copolymer, wherein the (b) (meth)acrylic block copolymer is a block copolymer containing a hard segment formed from a methyl methacrylate block and a soft segment formed from an alkyl acrylate block, and having a median diameter D50 of 1000 μm or less. When a vinyl chloride resin composition contains the (meth)acrylic block copolymer and has a median diameter D50 of the upper limit or less, excellent powder moldability can be imparted to a vinyl chloride resin composition that does not contain an ester-based plasticizer. In the present invention, the median diameter D50 of the vinyl chloride resin composition for powder molding can be measured by the method described in the Examples.

[0009] [2] The vinyl chloride resin composition for powder molding according to [1] above preferably further contains fine particles made of vinyl chloride resin. If the vinyl chloride resin composition for powder molding further contains fine particles made of vinyl chloride resin, the powder flowability of the vinyl chloride resin composition for powder molding can be improved.

[0010] [3] The vinyl chloride resin composition for powder molding according to [1] or [2] above preferably has a complex viscosity at 200°C of 9000 Pa s or less. If the complex viscosity at 200°C is equal to or less than the upper limit mentioned above, the powder moldability of the vinyl chloride resin composition for powder molding can be further improved. In the present invention, the complex viscosity at 200°C of the vinyl chloride resin composition for powder molding can be measured by the method described in the Examples.

[0011] [4] In the vinyl chloride resin composition for powder molding according to any one of [1] to [3] above, the mass ratio of the vinyl chloride resin (a) to the (meth)acrylic block copolymer (b) ((a) vinyl chloride resin / (b) (meth)acrylic block copolymer) is preferably 10 / 90 or more and 60 / 40 or less. When the mass ratio of the vinyl chloride resin (a) to the (meth)acrylic block copolymer (b) is within the above-mentioned range, the powder moldability of the vinyl chloride resin composition for powder molding can be further improved.

[0012] [5] The vinyl chloride resin composition for powder molding according to any one of [1] to [4] above is preferably used for powder slush molding. By using the vinyl chloride resin composition for powder molding according to powder slush molding, it is possible to more easily obtain a vinyl chloride resin molded article that can be used favorably as an automotive interior material, such as the skin for an automotive instrument panel.

[0013] Another object of the present invention is to advantageously solve the above-mentioned problems, and the present invention provides [6] a vinyl chloride resin molded article obtained by powder molding the vinyl chloride resin composition for powder molding according to any one of the above [1] to [5]. By powder molding the vinyl chloride resin composition for powder molding, a vinyl chloride resin molded article can be easily obtained.

[0014] [7] The vinyl chloride resin molded article according to [6] above is preferably used for the surface of an automobile instrument panel. The vinyl chloride resin molded article can be suitably used as the surface of an automobile instrument panel.

[0015] Another object of the present invention is to advantageously solve the above-mentioned problems, and the present invention relates to a laminate comprising [8] a polyurethane foam molded product and the vinyl chloride resin molded product of [6] or [7] above. By using the vinyl chloride resin molded product, a laminate comprising a polyurethane foam molded product and a vinyl chloride resin molded product can be easily obtained.

[0016] [9] The laminate of [8] above is preferably an automobile instrument panel. The laminate can be suitably used as an automobile instrument panel.

[0017] According to the present invention, a vinyl chloride resin composition for powder molding that exhibits excellent powder molding properties even without containing an ester-based plasticizer can be provided. The present invention also provides a vinyl chloride resin molded article obtained using the vinyl chloride resin composition for powder molding. Furthermore, the present invention also provides a laminate comprising the vinyl chloride resin molded article.

[0018]

[0023] Hereinafter, embodiments of the present invention will be described in detail. The vinyl chloride resin composition for powder molding of the present invention can be used, for example, to form the vinyl chloride resin molded article of the present invention. The vinyl chloride resin molded article of the present invention can be suitably used, for example, as an automobile interior material such as the skin of automobile interior parts such as automobile instrument panels and door trims.

[0019] (Vinyl chloride resin composition for powder molding) The vinyl chloride resin composition for powder molding of the present invention comprises a mixture particle containing (a) a vinyl chloride resin and (b) a (meth)acrylic block copolymer. In addition to the mixture particle, the vinyl chloride resin composition for powder molding of the present invention preferably further comprises fine particles made of vinyl chloride resin (hereinafter also referred to as "vinyl chloride resin fine particles"). Furthermore, the vinyl chloride resin composition for powder molding of the present invention may further comprise components (other components) other than the mixture particle and the vinyl chloride resin fine particles, as long as the desired effects of the present invention are obtained.

[0020] The vinyl chloride resin composition for powder molding of the present invention is characterized in that (b) the (meth)acrylic block copolymer is a block copolymer containing a hard segment composed of a methyl methacrylate block and a soft segment composed of an alkyl acrylate block. The vinyl chloride resin composition for powder molding of the present invention is also characterized in that the median diameter D50 is 1000 μm or less. The vinyl chloride resin composition for powder molding of the present invention contains the (b) (meth)acrylic block copolymer instead of an ester-based plasticizer. Furthermore, the vinyl chloride resin composition for powder molding of the present invention has excellent powder moldability because of its median diameter D50 of 1000 μm or less. The vinyl chloride resin composition for powder molding of the present invention is particularly suitable for use in powder slush molding.

[0021] <Mixture Particles> The mixture particles contain (a) a vinyl chloride resin and (b) a (meth)acrylic block copolymer. The mixture particles may further contain components (other components) other than (a) the vinyl chloride resin and (b) the (meth)acrylic block copolymer. That is, the mixture particles are particles made of a mixture containing a vinyl chloride resin and a (meth)acrylic block copolymer and, optionally, further containing other components.

[0022] <<Vinyl Chloride Resin>> Examples of the vinyl chloride resin contained in the mixture particles include vinyl chloride homopolymers and vinyl chloride copolymers containing preferably 50% by mass or more, more preferably 70% by mass or more, of vinyl chloride units. The comonomer for the vinyl chloride copolymer is not particularly limited, and for example, those described in International Publication No. 2016 / 098344 can be used alone or in combination of two or more in any ratio. Among these, from the viewpoint of further improving the powder moldability of the vinyl chloride resin composition for powder molding, vinyl chloride homopolymers are preferred as the vinyl chloride resin.

[0023] The vinyl chloride resin can be produced by any conventionally known production method, such as suspension polymerization, emulsion polymerization, solution polymerization, or bulk polymerization.

[0024] The average degree of polymerization of the vinyl chloride resin contained in the mixture particles is preferably 800 or more, more preferably 900 or more, and preferably 5000 or less, more preferably 3000 or less, and even more preferably 2800 or less. When the average degree of polymerization of the vinyl chloride resin contained in the mixture particles is above the above-mentioned lower limit, the physical strength of a vinyl chloride resin molded body formed using the vinyl chloride resin composition for powder molding can be sufficiently ensured while improving tensile elongation (particularly low-temperature tensile elongation). Furthermore, vinyl chloride resin molded bodies with excellent tensile elongation are suitable for use as automotive interior materials, such as the skin of an automobile instrument panel, which has excellent ductility and breaks as designed without scattering fragments when an airbag is inflated and deployed. On the other hand, when the average degree of polymerization of the vinyl chloride resin contained in the mixture particles is below the above-mentioned upper limit, the meltability of the vinyl chloride resin composition for powder molding can be improved. In the present invention, the "average degree of polymerization" can be measured in accordance with JIS K6720-2. The proportion of vinyl chloride resin in the mixture particles contained in the vinyl chloride resin composition for powder molding is preferably 70% by mass or more, more preferably 80% by mass or more, and can be 100% by mass, preferably 95% by mass or less, and more preferably 90% by mass or less, when the total content of vinyl chloride resin in the vinyl chloride resin composition for powder molding is taken as 100% by mass. If the proportion of vinyl chloride resin contained in the mixture particles relative to the total content of vinyl chloride resin in the vinyl chloride resin composition for powder molding is above the above-mentioned lower limit, the vinyl chloride resin molded body formed using the vinyl chloride resin composition for powder molding can be formed with good tensile elongation (particularly low-temperature tensile elongation) while ensuring sufficient physical strength. On the other hand, if the proportion of vinyl chloride resin contained in the mixture particles relative to the total content of vinyl chloride resin in the vinyl chloride resin composition for powder molding is below the above-mentioned upper limit, the powder flowability of the vinyl chloride resin composition for powder molding can be ensured to be sufficiently high.

[0025] In this specification, the "total content of vinyl chloride resin in the vinyl chloride resin composition for powder molding" includes the amount of vinyl chloride resin contained in the above-mentioned mixture particles and the amount of vinyl chloride resin fine particles, which are an optional component described below.

[0026] The vinyl chloride resin used in preparing the mixture particles is usually a particulate vinyl chloride resin (vinyl chloride resin particles). The vinyl chloride resin used in preparing the mixture particles may contain, for example, one or more types of vinyl chloride resin particles. In this specification, the term "resin particles" refers to particles having a particle diameter of 30 μm or more.

[0027] The average particle size of the vinyl chloride resin particles that can be used to prepare the mixture particles is usually 30 μm or more, preferably 50 μm or more, more preferably 100 μm or more, and preferably 500 μm or less, more preferably 200 μm or less. If the average particle size of the vinyl chloride resin particles is within the above-mentioned range, the vinyl chloride resin can be well mixed in the prepared mixture particles, thereby further improving the low-temperature tensile elongation of vinyl chloride resin molded articles formed using a vinyl chloride resin composition for powder molding containing the mixture particles. In the present invention, the "average particle size of the vinyl chloride resin particles" can be measured as the volume average particle size by laser diffraction in accordance with JIS Z8825.

[0028] <<(b) (Meth)acrylic Block Copolymer>> The (b) (meth)acrylic block copolymer contained in the mixture particles is a block copolymer containing a hard segment composed of a methyl methacrylate block and a soft segment composed of an alkyl acrylate block. The (b) (meth)acrylic block copolymer preferably consists solely of a hard segment composed of a methyl methacrylate block and a soft segment composed of an alkyl acrylate block. By incorporating the (b) (meth)acrylic block copolymer into a vinyl chloride resin composition for powder molding, a vinyl chloride resin composition for powder molding can be obtained that plasticizes the vinyl chloride resin and produces vinyl chloride resin molded articles with excellent flexibility without using conventional ester-based plasticizers, which are prone to leaching. While the reason for this is unclear, it is believed that the methyl methacrylate block of the hard segment is compatible with the vinyl chloride resin, preventing leaching, and the alkyl acrylate block of the soft segment softens the vinyl chloride resin. In this specification, "(meth)acrylic" refers to acrylic and / or methacrylic. Thus, the vinyl chloride resin composition for powder molding of the present invention contains (b) a (meth)acrylic block copolymer instead of an ester-based plasticizer. Therefore, although the vinyl chloride resin composition for powder molding of the present invention may contain an ester-based plasticizer, it usually does not contain an ester-based plasticizer. Examples of such ester-based plasticizers include the polyesters and trimellitic esters described in WO 2016 / 098344.

[0029] [Structure] The (b) (meth)acrylic block copolymer may be a triblock copolymer having two blocks constituting hard segments on either side of one block constituting a soft segment, or a diblock copolymer having one block constituting a soft segment and one block constituting a hard segment. That is, the (b) (meth)acrylic block copolymer may be a triblock copolymer having a triblock structure consisting of a methyl methacrylate block-alkyl acrylate block-methyl methacrylate block, or a diblock copolymer having a diblock structure consisting of a methyl methacrylate block-alkyl acrylate block. Of these, the (b) (meth)acrylic block copolymer is preferably a triblock copolymer having two blocks constituting hard segments on either side of one block constituting a soft segment.

[0030] Examples of alkyl acrylates constituting the soft segment include n-propyl acrylate, isopropyl acrylate, n-butyl acrylate, isobutyl acrylate, tert-butyl acrylate, n-pentyl acrylate, n-hexyl acrylate, cyclohexyl acrylate, n-heptyl acrylate, n-octyl acrylate, 2-ethylhexyl acrylate, nonyl acrylate, decyl acrylate, dodecyl acrylate, phenyl acrylate, toluyl acrylate, benzyl acrylate, isobornyl acrylate, 2-methoxyethyl acrylate, 3-methoxybutyl acrylate, 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate, stearyl acrylate, glycidyl acrylate, and acrylic acid. Examples of suitable acrylates include 2-aminoethyl acrylate, γ-(acryloyloxypropyl)trimethoxysilane, γ-(acryloyloxypropyl)dimethoxymethylsilane, ethylene oxide adducts of acrylic acid, trifluoromethylmethyl acrylate, 2-trifluoromethylethyl acrylate, 2-perfluoroethylethyl acrylate, 2-perfluoroethyl-2-perfluorobutylethyl acrylate, 2-perfluoroethyl acrylate, perfluoromethyl acrylate, diperfluoromethylmethyl acrylate, 2-perfluoromethyl-2-perfluoroethylmethyl acrylate, 2-perfluorohexylethyl acrylate, 2-perfluorodecylethyl acrylate, and 2-perfluorohexadecylethyl acrylate. These may be used alone or in combination of two or more. Of these, n-butyl acrylate or a combination of n-butyl acrylate and 2-ethylhexyl acrylate is preferred.

[0031] The (b) (meth)acrylic block copolymer is not particularly limited as long as it can exhibit the effects of the present invention, but preferably has a diblock structure consisting of a methyl methacrylate block-butyl acrylate block, or a methyl methacrylate block-butyl acrylate / 2-ethylhexyl acrylate block; or a triblock structure consisting of a methyl methacrylate block-butyl acrylate block-methyl methacrylate block, or a methyl methacrylate block-butyl acrylate / 2-ethylhexyl acrylate block-methyl methacrylate block. Among these, the (b) (meth)acrylic block copolymer more preferably has a triblock structure consisting of a methyl methacrylate block-butyl acrylate block-methyl methacrylate block, or a methyl methacrylate block-butyl acrylate / 2-ethylhexyl acrylate block-methyl methacrylate block, and even more preferably has a triblock structure consisting of a methyl methacrylate block-butyl acrylate / 2-ethylhexyl acrylate block-methyl methacrylate block.

[0032] In the (b) (meth)acrylic block copolymer, the content of the hard segments is preferably 3% by mass or more, more preferably 5% by mass or more, and even more preferably 15% by mass or more, and preferably 40% by mass or less, more preferably 35% by mass or less, and even more preferably 30% by mass or less, when the total of the hard segments and soft segments in the (b) (meth)acrylic block copolymer is taken as 100% by mass. If the content of the hard segments is equal to or greater than the above-mentioned lower limit, compatibility with the vinyl chloride resin can be improved, powder moldability can be further improved, and elution from the resulting vinyl chloride resin molded article can be suppressed. On the other hand, if the content of the hard segments is equal to or less than the above-mentioned upper limit, the content of the soft segments can be sufficiently ensured, resulting in good softening of the vinyl chloride resin and increased flexibility of the resulting vinyl chloride resin molded article.

[0033] Here, the (b) (meth)acrylic block copolymer may be one synthesized as needed, or a commercially available product may be used. The (b) (meth)acrylic block copolymer can be synthesized, for example, by the method described in JP 2015-209504 A. Commercially available products include, for example, (meth)acrylic block copolymers using butyl acrylate in the soft segment, such as Kuraray Co., Ltd.'s KuraRity (registered trademark) LA series (LA1892, LA4285, LA2250, LA2140, LA2330, LA3320, etc.); and Arkema's NanoStrength (registered trademark) series (M51, M52, M22, etc.). Commercially available (meth)acrylic block copolymers using both butyl acrylate and 2-ethylhexyl acrylate in the soft segment include Kuraray Co., Ltd.'s KuraRity (registered trademark) LK series (LK9243, KL-LK9333, etc.); and the like.

[0034] [Properties] - Weight average molecular weight - The weight average molecular weight of the (b) (meth)acrylic block copolymer is not particularly limited, but from the viewpoint of further improving the powder moldability of the vinyl chloride resin composition for powder molding while suppressing elution from the obtained vinyl chloride resin molded article, it is preferably 50,000 or more, more preferably 60,000 or more, and even more preferably 65,000 or more, and is preferably 150,000 or less, more preferably 120,000 or less, and even more preferably 100,000 or less. In the present invention, the weight average molecular weight of the (b) (meth)acrylic block copolymer can be measured by gel permeation chromatography.

[0035] From the viewpoint of further improving the powder moldability of the vinyl chloride resin composition for powder molding while suppressing elution from the resulting vinyl chloride resin molded article, the (b) (meth)acrylic block copolymer preferably has a hard segment content of 5% by mass or more and 40% by mass or less and a weight-average molecular weight of 50,000 or more and 150,000 or less, and more preferably has a hard segment content of 15% by mass or more and 30% by mass or less and a weight-average molecular weight of 60,000 or more and 100,000 or less.

[0036] - Content ratio - From the viewpoint of further improving the powder moldability of the vinyl chloride resin composition for powder molding, the content ratio of the (b) (meth)acrylic block copolymer in the vinyl chloride resin composition for powder molding is such that the mass ratio of the (a) vinyl chloride resin to the (b) (meth)acrylic block copolymer ((a) vinyl chloride resin / (b) (meth)acrylic block copolymer) is preferably 10 / 90 or more, more preferably 20 / 80 or more, and is preferably 60 / 40 or less, and more preferably 50 / 50 or less.

[0037] Furthermore, from the viewpoint of further improving the powder moldability of the vinyl chloride resin composition for powder molding, the content of the (b) (meth)acrylic block copolymer in the vinyl chloride resin composition for powder molding is preferably 90 parts by mass or more, more preferably 100 parts by mass or more, and even more preferably 110 parts by mass or more, relative to 100 parts by mass of the vinyl chloride resin (the total of the (a) vinyl chloride resin and the vinyl chloride resin fine particles), and is preferably 210 parts by mass or less, and more preferably 200 parts by mass or less.

[0038] <<Other Components>> The mixture particles may further contain components (other components) other than the components described above. The other components are not particularly limited, and additives such as secondary plasticizers such as epoxidized soybean oil; processing aids; lubricants; stabilizers; mold release agents; impact modifiers; antioxidants; mildew inhibitors; flame retardants; antistatic agents; fillers; light stabilizers; foaming agents; pigments; and deodorizers can be used. These additives can be used alone or in combination of two or more in any ratio. Specific examples of these additives include those described in WO 2016 / 098344 and JP 2020-132657 A. Furthermore, the amount of the additives added is not particularly limited and can be the same as that described in WO 2016 / 098344 and JP 2020-132657 A. The secondary plasticizer does not include ester-based plasticizers such as the polyesters and trimellitic esters described above.

[0039] <Vinyl chloride resin fine particles> As described above, the vinyl chloride resin composition for powder molding of the present invention preferably further contains vinyl chloride resin fine particles in addition to the above-mentioned mixture particles. The vinyl chloride resin fine particles can function as a dusting agent (powder flowability improver) that improves the powder flowability of the vinyl chloride resin composition for powder molding. In this specification, the term "resin fine particles" refers to particles with a particle diameter of less than 30 μm.

[0040] <<Average Degree of Polymerization>> The average degree of polymerization of the vinyl chloride resin constituting the vinyl chloride resin microparticles is preferably 500 or more, more preferably 700 or more, and preferably 2600 or less, more preferably 2400 or less. If the average degree of polymerization of the vinyl chloride resin constituting the vinyl chloride resin microparticles is equal to or greater than the above-mentioned lower limit, the powder fluidity of the vinyl chloride resin composition for powder molding can be further improved, and molded articles obtained using the composition can have good tensile elongation at low temperatures (e.g., −10°C). Furthermore, if the average degree of polymerization of the vinyl chloride resin constituting the vinyl chloride resin microparticles is equal to or less than the above-mentioned upper limit, the meltability of the vinyl chloride resin composition for powder molding can be improved, and the surface smoothness of vinyl chloride resin molded articles formed using the composition can be improved.

[0041] <<Volume Average Particle Diameter>> The volume average particle diameter of the vinyl chloride resin microparticles is typically 30 μm or less, preferably 10 μm or less, more preferably 5 μm or less, and preferably 0.1 μm or more, more preferably 1 μm or more. (c) If the volume average particle diameter of the vinyl chloride resin microparticles is equal to or greater than the above-mentioned lower limit, the powder flowability of the vinyl chloride resin composition for powder molding can be further improved, for example, without excessively reducing the size of the dusting agent. Furthermore, if the volume average particle diameter of the vinyl chloride resin microparticles (c) is equal to or less than the above-mentioned upper limit, the meltability of the vinyl chloride resin composition for powder molding can be enhanced, and the surface smoothness of the resulting vinyl chloride resin molded article can be improved. In the present invention, the average particle diameter of the vinyl chloride resin microparticles is measured by laser diffraction in accordance with JIS Z8825, for example, using a "SALD-2300" manufactured by Shimadzu Corporation.

[0042] <<Content Ratio>> The content ratio of the vinyl chloride resin microparticles is preferably 3 parts by mass or more and 10 parts by mass or less relative to 100 parts by mass in total of (a) the vinyl chloride resin, (b) the (meth)acrylic block copolymer, and additives blended as needed.

[0043] <Other Components> Other components that may be contained in the vinyl chloride resin composition for powder molding include dusting agents other than the above-mentioned vinyl chloride resin fine particles (other dusting agents). Examples of other dusting agents include those described in WO 2016 / 098344. Furthermore, the amount of the other dusting agents added is not particularly limited, and can be, for example, the same as that described in WO 2016 / 098344.

[0044] <Properties of the vinyl chloride resin composition for powder molding> <<Median diameter D50>> The vinyl chloride resin composition for powder molding of the present invention must have a median diameter D50 of 1000 μm or less. If the median diameter D50 exceeds 1000 μm, the composition will not have powder moldability. From the viewpoint of further improving the powder moldability of the vinyl chloride resin composition for powder molding, the median diameter D50 is preferably 800 μm or less, more preferably 500 μm or less, and even more preferably 300 μm or less. The lower limit of the median diameter D50 is not particularly limited, but can be 100 μm or more.

[0045] << Aspect ratio b / l ３ >>The vinyl chloride resin composition for powder molding of the present invention has an aspect ratio b / l from the viewpoint of further improving powder moldability. ３ is preferably 0.60 or more, more preferably 0.65 or more, and is preferably 0.80 or less, more preferably 0.75 or less. ３ can be determined by the method described in the Examples.

[0046] <<Complex Viscosity at 200°C>> From the viewpoint of further improving powder moldability, the vinyl chloride resin composition for powder molding of the present invention preferably has a complex viscosity at 200°C of 10,000 Pa s or less, more preferably 9,000 Pa s or less, even more preferably 6,000 Pa s or less, even more preferably 4,000 Pa s or less, and particularly preferably 3,000 Pa s or less. The lower limit of the complex viscosity at 200°C is not particularly limited, but can usually be 1,000 Pa s or more.

[0047] <Method for Preparing Vinyl Chloride Resin Composition for Powder Molding> The vinyl chloride resin composition for powder molding of the present invention is not particularly limited, and can be prepared, for example, by a method comprising a step of kneading (a) a vinyl chloride resin, (b) a (meth)acrylic block copolymer, and optional additives to obtain a mixture (kneading step), a step of pulverizing the obtained mixture to obtain mixture particles (pulverization step), and optionally other steps other than the kneading step and the pulverization step.

[0048] <<Kneading Step>> In the kneading step, (a) vinyl chloride resin, (b) (meth)acrylic block copolymer, and optional additives are kneaded to obtain a mixture. Here, the (a) vinyl chloride resin is not particularly limited, but for example, the vinyl chloride resin particles described above as specific examples of vinyl chloride resins that can be used to prepare the mixture particles in the section "Vinyl Chloride Resin Composition for Powder Molding" can be used. Furthermore, the (b) (meth)acrylic block copolymer is not particularly limited, but for example, the (b) (meth)acrylic block copolymer that can be used to prepare the mixture particles in the section "Vinyl Chloride Resin Composition for Powder Molding" can be used. Furthermore, the additives are not particularly limited, but for example, the additives exemplified as other components that can be included in the mixture particles in the section "Vinyl Chloride Resin Composition for Powder Molding" can be used.

[0049] In the kneading step, for example, (a) vinyl chloride resin, (b) (meth)acrylic block copolymer, and any additives may be separately charged into a kneader described below and kneaded. However, when additives are added, for example, it is preferable to premix (a) vinyl chloride resin and additives to form a premix, and then feed the resulting premix and (b) (meth)acrylic block copolymer into the kneader using a feeder or the like and knead them together. If the above components are premixed in advance and then the resulting premix is ​​kneaded with the (meth)acrylic block copolymer, the above components can be more effectively mixed and dispersed in the resulting kneaded product and in the mixture particles obtained by pulverizing the kneaded product, thereby further improving the powder moldability of the vinyl chloride resin composition for powder molding.

[0050] The method for premixing the above components is not particularly limited, and examples thereof include a method of mixing by dry blending. For example, a method of mixing (a) vinyl chloride resin and optional additives by dry blending is exemplified. Here, the use of a Henschel mixer is preferred for dry blending. The temperature during dry blending is not particularly limited, and is preferably 50°C or higher, more preferably 70°C or higher, and preferably 200°C or lower.

[0051] The kneading of (a) vinyl chloride resin (or pre-mixture) and (b) (meth)acrylic block copolymer is preferably carried out using a kneader, although not particularly limited thereto. Examples of kneaders that can be used include open-roll continuous kneaders, extruders, and twin-screw extruders. Examples of open-roll continuous kneaders that can be used include the "Kneedex" manufactured by Nippon Coke & Engineering Co., Ltd. Examples of twin-screw extruders that can be used include the "ZSK32Mc18" manufactured by Coperion.

[0052] The temperature during kneading is not particularly limited, but is preferably 40° C. or higher and 200° C. or lower. For example, when kneading is performed using an open-roll continuous kneader (Kneedex), it is preferable to set the inlet temperature to 90 to 200° C., preferably 100 to 180° C., and the outlet temperature to 40 to 170° C., preferably 50 to 150° C. Furthermore, for example, when kneading is performed using a twin-screw extruder, it is preferable to set the barrel temperature to 30 to 140° C., the rotation speed to 200 rpm, and the resin temperature at the outlet to 150 to 200° C.

[0053] Furthermore, the kneaded product obtained in the kneading step is preferably formed into pellets by a known method, although this is not particularly limited. If the kneaded product obtained in the kneading step is formed into pellets, the kneaded product can be easily pulverized in the pulverization step described later to obtain mixed particles.

[0054] <Pulverization Step> In the pulverization step, the mixture obtained in the kneading step is pulverized to obtain mixed particles. The pulverization of the mixture is not particularly limited as long as it can reduce the median diameter D50 of the resulting vinyl chloride resin composition for powder molding to 1000 μm or less. For example, it can be performed using a freeze-pulverization method or a pulverizer. Among these, freeze-pulverization is preferred from the viewpoint of easily reducing the median diameter D50 to a predetermined value or less. The pulverizer is not particularly limited, but examples include a disk mill, ball mill, bead mill, and jet mill. The freeze-pulverization and pulverizer conditions for pulverizing the mixture can be appropriately adjusted within a range that achieves the desired effects of the present invention. The mixed particles obtained in the pulverization step can also be used directly as a vinyl chloride resin composition for powder molding.

[0055] <Other Steps> Examples of other steps include adding and mixing vinyl chloride resin fine particles and / or a dusting agent other than vinyl chloride resin fine particles to the mixture particles obtained in the pulverization step. The vinyl chloride resin composition for powder molding obtained by adding and mixing a dusting agent to the mixture particles has excellent powder fluidity. Here, examples of dusting agents that can be used include vinyl chloride resin fine particles and dusting agents other than vinyl chloride resin fine particles, such as those described above in the section "Vinyl chloride resin composition for powder molding." The addition and mixing of the dusting agent is not particularly limited, and can be carried out using, for example, a Henschel mixer.

[0056] (Vinyl chloride resin molded body) The vinyl chloride resin molded body of the present invention can be obtained by powder molding, preferably powder slush molding, of the vinyl chloride resin composition for powder molding of the present invention. When forming a vinyl chloride resin molded body by powder slush molding, the mold temperature during powder slush molding is not particularly limited, but is preferably 200°C or higher, more preferably 220°C or higher, and preferably 300°C or lower, and more preferably 280°C or lower. The vinyl chloride resin molded body can be produced by any method, but is not particularly limited to the following method. That is, the vinyl chloride resin composition for powder molding is sprinkled onto a mold at the above temperature range, and the mixture is left for 5 to 30 seconds, after which the excess vinyl chloride resin composition for powder molding is shaken off. The mixture is then left at a desired temperature for 30 seconds to 3 minutes. The mold is then cooled to 10 to 60°C, and the resulting vinyl chloride resin molded body is demolded from the mold. A sheet-like molded body conforming to the shape of the mold is obtained.

[0057] <Uses> The vinyl chloride resin molded article of the present invention is suitably used as an automobile interior material, for example, the surface of an instrument panel, door trim, or the like.

[0058] (Laminate) The laminate of the present invention comprises a polyurethane foam molded body and the vinyl chloride resin molded body described above. The vinyl chloride resin molded body typically constitutes one surface of the laminate. The method for laminating the polyurethane foam molded body and the vinyl chloride resin molded body is not particularly limited, and the following methods can be used, for example: (1) a method in which a polyurethane foam molded body and a vinyl chloride resin molded body are separately prepared and then bonded together by heat fusion, heat adhesion, or using a known adhesive; (2) a method in which isocyanates and polyols, which are raw materials for the polyurethane foam molded body, are reacted on the vinyl chloride resin molded body to polymerize, and polyurethane is foamed by a known method, thereby directly forming a polyurethane foam molded body on the vinyl chloride resin molded body; and the like. Among these, the latter method (2) is preferred because of its simple process and the ease with which the vinyl chloride resin molded body and the polyurethane foam molded body can be firmly bonded together even when laminates of various shapes are obtained.

[0059] <Uses> The laminate of the present invention is suitably used as an automobile interior material, for example, an instrument panel, a door trim, and the like.

[0060] The present invention will be specifically described below based on examples, but the present invention is not limited to these examples. In the following description, "%" and "parts" representing amounts are based on mass unless otherwise specified. The physical properties of the vinyl chloride resin composition for powder molding and the vinyl chloride resin molded article were measured or evaluated by the following methods.

[0061] <Median diameter D50, aspect ratio b / l ３ For the vinyl chloride resin compositions for powder molding obtained in the examples and comparative examples, the particle width X was measured using a dynamic image analysis (Camsizer X2 (X-JET)) that records the projection of the shadow of the particulate matter with a camera to obtain the particle shape. Ｃ　ｍｉｎ and particle length X Ｆｅ　ＭＡＸ The volume-based aspect ratio b / l was calculated using the following formula: ３ The aspect ratio b / l was calculated. ３ = particle width Ｃ　ｍｉｎ / particle length Ｆｅ　ＭＡＸHere, the particle width X Ｃ　ｍｉｎ is the total measured particle width X Ｃ indicates the narrowest particle width among Ｆｅ　ＭＡＸ is the total measured Feret diameter X Ｆｅ Specifically, a sample of about 1 to 5 g is placed in the chute, and the aspect ratio b / l is measured with a feeder vibration of 70%, a dispersion pressure of 50 kPa, and 10,000 captured images. ３ The calculation was carried out using the CAMSIZER X2 evaluation software DIMENSIONS. The median diameter D50 of the vinyl chloride resin composition for powder molding was measured by X Ｃ　ｍｉｎ That is, the median diameter D50 is the X at 50% of the integrated value in the particle size distribution on a volume basis. Ｃ　ｍｉｎThe value is the value of . <Complex Viscosity> The complex viscosity at 200°C of the vinyl chloride resin compositions for powder molding obtained in the Examples and Comparative Examples was measured using an MCR 102 manufactured by Anton Paar. Here, the measurement cells used were P-ETD400 and H-ETD400, the measurement jig used was PP25, and the measurement conditions were a constant load of 1N, a strain of 1%, and a frequency of 1Hz. Specifically, samples of the vinyl chloride resin compositions for powder molding obtained in the Examples and Comparative Examples were heated to 220°C and melted, sandwiched between the measurement cell and the measurement jig, and cooled to 30°C with a gap of 1mm. The temperature was then increased from 30°C to 250°C at a rate of 0.5°C / min, and the complex viscosity (Pa s) at 200°C was measured. <Sz Maximum Height> The Sz maximum height (the distance from the highest point to the lowest point on the surface) of the surface not in contact with the mold of the vinyl chloride resin sheet (vinyl chloride resin molded product) produced in the Examples was measured. Specifically, using a Keyence VR-6200 One-Shot 3D Shape Measuring Instrument, the surface of the vinyl chloride resin molded article not in contact with the mold was measured at 12x magnification, dividing a measurement area of ​​24 mm x 18 mm into four sections, and the maximum Sz height of each section was determined in μm units. The average value was then obtained. The above measurement was performed at a total of three locations, and the average value was taken as the maximum Sz height (μm) of the vinyl chloride resin molded article. The smaller the maximum Sz height value, the better the vinyl chloride resin composition for powder molding melts, indicating superior powder moldability. It should be noted that if the maximum Sz height is 900 μm or less, the vinyl chloride resin composition for powder molding is deemed to have melted. <Tensile Elongation> [Initial] The vinyl chloride resin molded article (sheet) produced in the examples was punched out with a No. 1 dumbbell punch as specified in JIS K6251 to prepare a measurement sample. The measurement samples were then measured for breaking elongation (%) at low temperatures of 23°C and -10°C at a tensile speed of 200 mm / min in accordance with JIS K7113. A larger breaking elongation value indicates that the vinyl chloride resin molded article has better tensile elongation. [After heating (heat aging test)] The vinyl chloride resin molded article (sheet) laminated with foamed polyurethane produced in the examples was placed in an oven and heated for 400 hours in an environment at a temperature of 120°C.The urethane foam was then removed, and the elongation at break (%) of the vinyl chloride resin molded article after 400 hours of heating was measured at a low temperature of -10°C under the same conditions as in the initial case. A larger value of the elongation at break indicates that the vinyl chloride resin molded article has better tensile elongation at low temperatures after heating. <Loss Modulus E" (Peak-Top Temperature)> The loss modulus E" of the vinyl chloride resin molded article (sheet) after heating (thermal aging test) was measured using a dynamic viscoelasticity evaluation device (EPLEXOR500N, manufactured by GABO Corporation) according to the following method. (Measurement Conditions) Measurement mode: Tension Measurement frequency: 10 Hz Heating rate: 2°C / min Temperature range: -80°C to +80°C Strain: Static strain 1%, dynamic strain 0.1% Test piece dimensions: Length 50 mm x Width 10 mm x Thickness 1 mm The temperature at which the loss modulus E" obtained at each temperature became maximum within the measurement range was defined as the E" peak-top temperature, and was used as an index of low-temperature flexibility. The lower the value, the more flexible it is at low temperatures.

[0062] (Production Example 1) <Preparation of Premix A> Of the ingredients shown in Table 1, the ingredients except for epoxidized soybean oil were placed in a Henschel mixer and mixed. Then, when the temperature of the mixture rose to 80°C, epoxidized soybean oil was added, and the mixture was allowed to dry up (referring to the state in which the epoxidized soybean oil was absorbed into the vinyl chloride resin and the mixture became smooth), to prepare Premix A.

[0063] (Production Example 2) <Preparation of Premix B> The ingredients shown in Table 1, except for epoxidized soybean oil, were placed in a Henschel mixer and mixed. Then, when the temperature of the mixture rose to 80°C, epoxidized soybean oil was added, and the mixture was allowed to dry up (referring to the state in which the epoxidized soybean oil was absorbed into the vinyl chloride resin and the mixture became smooth), to prepare Premix B. (Example 1) <Preparation of Vinyl Chloride Resin Composition for Powder Molding> 36 parts of Premix A obtained in Production Example 1 and 70 parts of a (meth)acrylic block copolymer (product name "LA2270" manufactured by Kuraray Co., Ltd.) were kneaded in a co-rotating twin-screw extruder (ZSK32Mc18 manufactured by Coperion, φ32, L / D=52) with a barrel temperature of 190°C, a rotation speed of 200 rpm, and a discharge rate of 25 kg / h, using a 5 mmφ three-hole die. The strand was cooled in a water bath with the resin temperature at the outlet set to 150-200°C, and then cut with a pelletizer to obtain mixture pellets approximately 3 mm in diameter and 2 mm in length. The resulting mixture pellets were then placed in a hammer-type grinder adjusted to -60°C using liquid nitrogen and frozen and ground to obtain mixture fine particles. A dusting agent (vinyl chloride resin fine particles) shown in Table 2 was added to and mixed with the resulting mixture particle powder using a Henschel mixer to obtain a vinyl chloride resin composition for powder molding. The formulation of the vinyl chloride resin composition for powder molding is shown in Table 2. Various measurements and evaluations were then performed using the resulting vinyl chloride resin composition for powder molding. The results are shown in Table 3. <Formation of Evaluation Resin Molded Sheet (Vinyl Chloride Resin Molded Product)> The resulting vinyl chloride resin composition for powder molding was sprinkled onto a textured mold heated to 250°C and left to melt for a desired period of time, after which the excess vinyl chloride resin composition for powder molding was shaken off. The textured mold onto which the vinyl chloride resin composition for powder molding had been sprinkled was then placed in an oven set at 200°C, and 60 seconds after being placed therein, the textured mold was cooled with cooling water. When the mold temperature had cooled to 40°C, a vinyl chloride resin molded sheet measuring 145 mm x 175 mm x 1 mm was removed from the mold as a vinyl chloride resin molded article. Various measurements and evaluations were then carried out. The results are shown in Table 3.<Skin / Polyurethane (PU) Laminate> One of the obtained vinyl chloride resin molded sheets was placed with the grained side down in a 200 mm × 300 mm × 10 mm mold. Separately, 50 parts of a propylene oxide (PO)-ethylene oxide (EO) block adduct of propylene glycol (hydroxyl value 28, terminal EO unit content = 10%, internal EO unit content = 4%), 50 parts of a glycerin PO-EO block adduct (hydroxyl value 21, terminal EO unit content = 14%), 2.5 parts of water, 0.2 parts of an ethylene glycol solution of triethylenediamine (manufactured by Tosoh Corporation, trade name "TEDA-L33"), 1.2 parts of triethanolamine, 0.5 parts of triethylamine, and 0.5 parts of a foam stabilizer (manufactured by Shin-Etsu Chemical Co., Ltd., trade name "F-122") were mixed to obtain a polyol mixture. A mixed solution was prepared by mixing the obtained polyol mixture and polymethylene polyphenylene polyisocyanate (polymeric MDI) in a ratio such that the index was 98. The prepared mixed solution was then poured onto a vinyl chloride resin molded sheet placed in a mold. The mold was then covered with an aluminum plate measuring 348 mm x 255 mm x 10 mm and sealed. The mold was left to stand for 5 minutes after sealing, and a laminate was formed in the mold, in which a vinyl chloride resin molded sheet (thickness: 1 mm) as a skin was backed by a foamed polyurethane molded body (thickness: 9 mm, density: 0.2 g / cm3).

[0064] Example 2 A vinyl chloride resin composition for powder molding, a vinyl chloride resin molded product, and a skin / polyurethane (PU) laminate were produced in the same manner as in Example 1, except that 53 parts of Premix B was used instead of 36 parts of Premix A, and 30 parts of LA2140 (manufactured by Kuraray Co., Ltd.) was used as the (meth)acrylic block copolymer instead of 70 parts of LA2270 (manufactured by Kuraray Co., Ltd.). The formulation of the vinyl chloride resin composition for powder molding is shown in Table 2. Measurements and evaluations were then carried out in the same manner as in Example 1. The results are shown in Table 3.

[0065] Example 3 A vinyl chloride resin composition for powder molding, a vinyl chloride resin molded product, and a skin / polyurethane (PU) laminate were produced in the same manner as in Example 1, except that 47 parts of Premix B was used instead of 36 parts of Premix A, and 40 parts of LA2140 (manufactured by Kuraray Co., Ltd.) was used as the (meth)acrylic block copolymer instead of 70 parts of LA2270 (manufactured by Kuraray Co., Ltd.). The formulation of the vinyl chloride resin composition for powder molding is shown in Table 2. Measurements and evaluations were then carried out in the same manner as in Example 1. The results are shown in Table 3.

[0066] Example 4 A vinyl chloride resin composition for powder molding, a vinyl chloride resin molded product, and a skin / polyurethane (PU) laminate were produced in the same manner as in Example 1, except that 32 parts of Premix B was used instead of 36 parts of Premix A, and 40 parts of LA2140 (manufactured by Kuraray Co., Ltd.) was used as the (meth)acrylic block copolymer instead of 70 parts of LA2270 (manufactured by Kuraray Co., Ltd.). The formulation of the vinyl chloride resin composition for powder molding is shown in Table 2. Measurements and evaluations were then carried out in the same manner as in Example 1. The results are shown in Table 3.

[0067] Example 5 A vinyl chloride resin composition for powder molding, a vinyl chloride resin molded product, and a skin / polyurethane (PU) laminate were produced in the same manner as in Example 1, except that 23 parts of Premix B was used instead of 36 parts of Premix A, and 45 parts of LA2140 (manufactured by Kuraray Co., Ltd.) was used as the (meth)acrylic block copolymer instead of 70 parts of LA2270 (manufactured by Kuraray Co., Ltd.). The formulation of the vinyl chloride resin composition for powder molding is shown in Table 2. Measurements and evaluations were then carried out in the same manner as in Example 1. The results are shown in Table 3.

[0068] Example 6 A vinyl chloride resin composition for powder molding, a vinyl chloride resin molded product, and a skin / polyurethane (PU) laminate were produced in the same manner as in Example 1, except that 53 parts of Premix B was used instead of 36 parts of Premix A, and 40 parts of LK9243 (manufactured by Kuraray Co., Ltd.) was used as the (meth)acrylic block copolymer instead of 70 parts of LA2270 (manufactured by Kuraray Co., Ltd.). The formulation of the vinyl chloride resin composition for powder molding is shown in Table 2. Measurements and evaluations were then carried out in the same manner as in Example 1. The results are shown in Table 3.

[0069] Example 7 A vinyl chloride resin composition for powder molding, a vinyl chloride resin molded product, and a skin / polyurethane (PU) laminate were produced in the same manner as in Example 1, except that 47 parts of Premix B was used instead of 36 parts of Premix A, and 40 parts of LK9243 (manufactured by Kuraray Co., Ltd.) was used as the (meth)acrylic block copolymer instead of 70 parts of LA2270 (manufactured by Kuraray Co., Ltd.). The formulation of the vinyl chloride resin composition for powder molding is shown in Table 2. Measurements and evaluations were then carried out in the same manner as in Example 1. The results are shown in Table 3.

[0070] Example 8 A vinyl chloride resin composition for powder molding, a vinyl chloride resin molded product, and a skin / polyurethane (PU) laminate were produced in the same manner as in Example 1, except that 23 parts of Premix B was used instead of 36 parts of Premix A, and 45 parts of LK9243 (manufactured by Kuraray Co., Ltd.) was used as the (meth)acrylic block copolymer instead of 70 parts of LA2270 (manufactured by Kuraray Co., Ltd.). The formulation of the vinyl chloride resin composition for powder molding is shown in Table 2. Measurements and evaluations were then carried out in the same manner as in Example 1. The results are shown in Table 3.

[0071] Comparative Examples 1 to 7 Vinyl chloride resin compositions (pellets) for powder molding were produced in the same manner as in Examples 2 to 8, respectively, except that freeze-pulverization was not performed and vinyl chloride resin fine particles were not added as a dusting agent. The formulation of the resulting pellets is shown in Table 2. Measurements and evaluations were then carried out in the same manner as in Example 1. The results are shown in Table 3. Note that in the Comparative Examples, the vinyl chloride resin compositions for powder molding could not be powder-molded, and therefore various measurements and evaluations of the vinyl chloride resin molded articles could not be carried out.

[0072] (Comparative Example 8) A vinyl chloride resin composition for powder molding was produced in the same manner as in Comparative Example 1, except that the pellets in Comparative Example 1 were pulverized (rotation speed: 500 rpm, screen: 2 mm) using a rotary cutter (RC-1 manufactured by Glow Engineering Co., Ltd.). Measurements and evaluations were then carried out in the same manner as in Example 1. The results are shown in Table 3. In Comparative Example 8, the vinyl chloride resin composition for powder molding could not be powder-molded, and therefore various measurements and evaluations of the vinyl chloride resin molded article could not be carried out. 1) Shin-Dai-Ichi Vinyl Corporation, product name "ZEST (registered trademark) 1300SI" (prepared by suspension polymerization, average degree of polymerization: 1300, average particle size: 132 μm) 2) ADEKA Corporation, product name "ADEKA Cizer O-130S" 3) Mitsubishi Chemical Corporation, product name "Metablen P-530A" 4) Kyowa Chemical Industry Co., Ltd., product name "Alkamizer (registered trademark) 5" 5) Mizusawa Industrial Chemicals Co., Ltd., product name "MIZUKALIZER DS" 6) BASF Japan Ltd., product name "Tinuvin 144" 7) Sakai Chemical Industry Co., Ltd., product name "SAKAI SZ2000" 8) ADEKA Corporation, product name "ADEKA STAB LS-12" 9) Dainichiseika Color & Chemicals Co., Ltd., product name "DA P 4720 Black" 10) Kuraray Co., Ltd., product name "LA2140" (hard segment ratio: 25% by mass, weight average molecular weight: approximately 60,000) 11) Kuraray Co., Ltd., product name "LK9243" (hard segment ratio: 25% by mass, weight average molecular weight: approximately 60,000) 12) Kuraray Co., Ltd., product name "LA2270" (hard segment ratio: 40% by mass, weight average molecular weight: approximately 60,000) 13) Shin-Dai-Vinyl Corporation, product name "ZEST PQLTX" (vinyl chloride resin microparticles, prepared by emulsion polymerization, average degree of polymerization: 800, average particle size: 1.8 μm)

[0073] The results shown in Table 3 show that the vinyl chloride resin compositions for powder molding of Examples 1 to 8, which contain (a) vinyl chloride resin and (b) (meth)acrylic block copolymer having a predetermined structure instead of an ester-based plasticizer and have a median diameter D50 of 1000 μm or less, can be successfully powder molded.

[0074] According to the present invention, a vinyl chloride resin composition for powder molding that exhibits excellent powder moldability even without containing an ester-based plasticizer can be provided. The present invention also provides a vinyl chloride resin molded article obtained using the vinyl chloride resin composition for powder molding. Furthermore, the present invention also provides a laminate comprising the vinyl chloride resin molded article.

Claims

1. A vinyl chloride resin composition for powder molding, comprising (a) a vinyl chloride resin and (b) a (meth)acrylic block copolymer, wherein the (b) (meth)acrylic block copolymer is a block copolymer containing hard segments consisting of methyl methacrylate blocks and soft segments consisting of alkyl acrylate blocks, and having a median diameter D50 of 1000 μm or less.

2. The vinyl chloride resin composition for powder molding according to claim 1, further comprising fine particles made of vinyl chloride resin.

3. The vinyl chloride resin composition for powder molding according to claim 1, which has a complex viscosity at 200°C of 9000 Pa·s or less.

4. A vinyl chloride resin composition for powder molding according to claim 1, wherein the mass ratio of the vinyl chloride resin (a) to the (meth)acrylic block copolymer (b) (a) vinyl chloride resin / (b) (meth)acrylic block copolymer) is 10 / 90 or more and 60 / 40 or less.

5. The vinyl chloride resin composition for powder molding according to claim 1, which is used in powder slush molding.

6. A vinyl chloride resin molded article obtained by powder molding the vinyl chloride resin composition for powder molding according to any one of claims 1 to 5.

7. The vinyl chloride resin molded article according to claim 6, which is used for the surface of an automobile instrument panel.

8. A laminate comprising a polyurethane foam molded article and the vinyl chloride resin molded article according to claim 6.

9. The laminate according to claim 8, which is used for an automobile instrument panel.

Images