Resin composition and resin molded article

Patent metadata

Field	Value
Publication number	US-10526486-B2
Application number	US-201715683874-A
Country	US
Kind code	B2
Filing date	Aug 23, 2017
Priority date	Dec 26, 2016
Publication date	Jan 7, 2020
Grant date	Jan 7, 2020

Abstract

A resin composition includes a thermoplastic resin, a carbon fiber, a resin containing at least one of an amide bond and an imide bond that includes a first resin containing at least one of an amide bond and an imide bond and having such a melting temperature that a difference in melting temperature between the first resin and the thermoplastic resin is from 0° C. to 90° C. and a second resin containing at least one of an amide bond and an imide bond and having a melting temperature which is higher than that of the thermoplastic resin and that of the first resin, and a compatibilizer.

First claim

What is claimed is:

1. A resin composition comprising:
(A) a thermoplastic resin comprising repeating units;
(B) a carbon fiber;
(C) a specific resin containing at least one of an amide bond and an imide bond that includes:
a first resin containing at least one of an amide bond and an imide bond, the first resin having a melting temperature that is greater than a melting temperature of the thermoplastic resin, and a difference between the melting temperature of the first resin and the melting temperature of the thermoplastic resin is less than or equal to 90° C., and
a second resin containing at least one of an amide bond and an imide bond, the second resin having a melting temperature which is at least 50° C. higher than the melting temperature of the first resin; and

(D) a compatibilizer,
wherein a content of the specific resin is from 0.1 to 100 parts by weight with respect to 100 parts by weight of the thermoplastic resin,
a content of the compatibilizer is from 0.1 to 50 parts by weight with respect to 100 parts by weight of the thermoplastic resin, and
a content of the carbon fiber is from 0.1 to 200 parts by weight with respect to 100 parts by weight of the thermoplastic resin; and
wherein the compatibilizer is a modified resin comprising the same repeating units as the thermoplastic resin and a modification site having affinity to the specific resin, and
the modification site is directly chemically bonded to repeating units of the modified resin, or the modification site is present on a graft chain bonded to the repeating units.

2. The resin composition according to claim 1 ,
wherein a weight ratio of [A]/[B] is from 9/1 to 3/7 when a content of the first resin is [A] and a content of the second resin is [B] with respect to a total amount of the specific resin.

3. The resin composition according to claim 1 ,
wherein the thermoplastic resin is a polyolefin.

4. The resin composition according to claim 1 ,
wherein at least one of the first resin and the second resin is polyamide.

5. The resin composition according to claim 1 ,
wherein at least one of the first resin and the second resin is a polyamide having a structural unit in which a lactam is ring-opened.

6. The resin composition according to claim 1 ,
wherein a combination of the first resin and the second resin is a combination of a polyamide having a structural unit in which a dicarboxylic acid and a diamine are condensation-polymerized and a polyamide having a structural unit in which a lactam is ring-opened.

7. The resin composition according to claim 1 ,
wherein the compatibilizer is a modified polyolefin.

8. The resin composition according to claim 1 ,
wherein an average fiber length of the carbon fiber is from 0.1 mm to 5.0 mm.

9. The resin composition according to claim 1 ,
wherein a content of the resin containing at least one of the amide bond and the imide bond is from 0.1% by weight to 200% by weight with respect to a weight of the carbon fiber.

10. The resin composition according to claim 1 ,
wherein the modification site contains at least one selected from the group consisting of a carboxy group, a carboxylic anhydride residue, a carboxylate residue, an imino group, an amino group and an epoxy group.

11. A resin molded article comprising:
(A) a thermoplastic resin comprising repeating units;
(B) a carbon fiber;
(C) a specific resin containing at least one of an amide bond and an imide bond that includes:
a first resin containing at least one of an amide bond and an imide bond, the first resin having a melting temperature that is greater than a melting temperature of the thermoplastic resin, and a difference between the melting temperature of the first resin and the melting temperature of the thermoplastic resin is less than or equal to 90° C., and
a second resin containing at least one of an amide bond and an imide bond, the second resin having a melting temperature which is at least 50° C. higher than the melting temperature of the first resin; and

(D) a compatibilizer,
wherein a content of the specific resin is from 0.1 to 100 parts by weight with respect to 100 parts by weight of the thermoplastic resin,
a content of the compatibilizer is from 0.1 to 50 parts by weight with respect to 100 parts by weight of the thermoplastic resin, and
a content of the carbon fiber is from 0.1 to 200 parts by weight with respect to 100 parts by weight of the thermoplastic resin; and
wherein the compatibilizer is a modified resin comprising the same repeating units as the thermoplastic resin and a modification site having affinity to the specific resin, and
the modification site is directly chemically bonded to repeating units of the modified resin, or the modification site is present on a graft chain bonded to the repeating units.

12. The resin molded article according to claim 11 ,
wherein a weight ratio of [A]/[B] is from 9/1 to 3/7 when a content of the first resin is [A] and a content of the second resin is [B] with respect to a total amount of the resin containing at least one of the amide bond and the imide bond.

13. The resin molded article according to claim 11 ,
wherein the thermoplastic resin is a polyolefin.

14. The resin molded article according to claim 11 ,
wherein at least one of the first resin and the second resin is polyamide.

15. The resin molded article according to claim 11 ,
wherein at least one of the first resin and the second resin is a polyamide having a structural unit in which a lactam is ring-opened.

16. The resin molded article according to claim 11 ,
wherein a combination of the first resin and the second resin is a combination of a polyamide having a structural unit in which a dicarboxylic acid and a diamine are condensation-polymerized and a polyamide having a structural unit in which a lactam is ring-opened.

17. The resin molded article according to claim 11 ,
wherein the compatibilizer is a modified polyolefin.

18. The resin molded article according to claim 11 ,
wherein an average fiber length of the carbon fiber is from 0.1 mm to 5.0 mm.

19. The resin molded article according to claim 11 ,
wherein a content of the resin containing at least one of the amide bond and the imide bond is from 0.1% by weight to 200% by weight with respect to a weight of the carbon fiber.

20. The resin composition according to claim 1 ,
wherein a content of the specific resin is from 1 to 80 parts by weight with respect to 100 parts by weight of the thermoplastic resin,
a content of the compatibilizer is from 0.1 to 30 parts by weight with respect to 100 parts by weight of the thermoplastic resin, and
a content of the carbon fiber is from 5 to 150 parts by weight with respect to 100 parts by weight of the thermoplastic resin.

Assignees

• Fuji Xerox Co Ltd

Inventors

• Miyamoto Tsuyoshi
• Nakayama Daisuke
• Okoshi Masayuki
• Moriya Hiroyuki

Classifications

• C08L77/06

  Polyamides derived from polyamines and polycarboxylic acids (C08L77/10 takes precedence) · CPC title

• B32B27/34

  comprising polyamides · CPC title

• C08L2205/02

  containing two or more polymers of the same C08L -group · CPC title

• C08L77/08 Primary

  from polyamines and polymerised unsaturated fatty acids · CPC title

• C08L79/08

  Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors · CPC title