Molded body and production method thereof

Patent metadata

Field	Value
Publication number	US-11091616-B2
Application number	US-201816480067-A
Country	US
Kind code	B2
Filing date	Jan 19, 2018
Priority date	Jan 30, 2017
Publication date	Aug 17, 2021
Grant date	Aug 17, 2021

Abstract

Disclosed is a molded body and a method for producing the same. The molded body includes: a continuous phase containing first and second polyolefin resins; and a dispersed phase containing a polyamide resin and a modified elastomer and composed of a melt-kneaded product of the polyamide resin and the modified elastomer, the modified elastomer has a reactive group that reacts with the polyamide resin, the elastomer is an olefin-based thermoplastic elastomer having, as a skeleton, a copolymer of ethylene or propylene and an α-olefin having 3-8 carbon atoms or a styrene-based thermoplastic elastomer having a styrene skeleton, when a total of the continuous and dispersed phases is taken as 100% by mass, the dispersed phase is 70% by mass or less, and when a total of the first and second polyolefin resins is taken as 100% by mass, the second polyolefin resin is 80% by mass or less.

First claim

The invention claimed is:

1. A molded body obtained by molding a thermoplastic resin, the molded body comprising:
a continuous phase (A) containing a first polyolefin resin and a second polyolefin resin; and
a dispersed phase (B) dispersed in the continuous phase (A) and containing a polyamide resin and a modified elastomer, wherein
the dispersed phase (B) is composed of a melt-kneaded product of the polyamide resin and the modified elastomer,
the modified elastomer is an elastomer having a reactive group that reacts with the polyamide resin,
the elastomer is an olefin-based thermoplastic elastomer having, as a skeleton, a copolymer of ethylene and an α-olefin having 3 to 8 carbon atoms or a copolymer of propylene and an α-olefin having 4 to 8 carbon atoms or a styrene-based thermoplastic elastomer having a styrene skeleton,
when a total of the continuous phase (A) and the dispersed phase (B) is taken as 100% by mass, a content of the dispersed phase (B) is 70% by mass or less, and
when a total of the first polyolefin resin and the second polyolefin resin is taken as 100% by mass, a content of the second polyolefin resin is 80% by mass or less,
wherein the first polyolefin resin is a block copolymerized polyolefin resin having an ethylene block as a dispersed phase, and
at least part of the ethylene block is aggregated at an interface between the continuous phase (A) and the dispersed phase (B).

2. The molded body according to claim 1 , wherein the thermoplastic resin is a mixture of an impact-resistant resin containing the second polyolefin resin, the polyamide resin, and the modified elastomer and the first polyolefin resin.

3. The molded body according to claim 1 , wherein when a total of the polyamide resin and the modified elastomer is taken as 100% by mass, a content of the polyamide resin is 10% by mass or more but 80% by mass or less.

4. The molded body according to claim 1 , wherein the dispersed phase (B) has a continuous phase (B 1 ) containing the polyamide resin and a fine dispersed phase (B 2 ) dispersed in the continuous phase (B 1 ) and containing the modified elastomer.

5. The molded body according to claim 1 , wherein the polyamide resin is polyamide 6.

6. The molded body according to claim 5 , wherein the second polyolefin resin has a number-average molecular weight of 300,000 or more.

7. A method for producing the molded body according to claim 1 , comprising:
dry blending an impact-resistant resin and a first polyolefin resin to obtain a molded body raw material, wherein the impact-resistant resin is obtained by melt-kneading a second polyolefin resin and a melt-kneaded product formed from a polyamide resin and a modified elastomer; and
molding the molded body raw material to obtain the molded body,
wherein the molded body comprises:
a continuous phase (A) containing a first polyolefin resin and a second polyolefin resin; and
a dispersed phase (B) dispersed in the continuous phase (A) and containing a polyamide resin and a modified elastomer, wherein
the dispersed phase (B) is composed of a melt-kneaded product of the polyamide resin and the modified elastomer,
the modified elastomer is an elastomer having a reactive group that reacts with the polyamide resin,
the elastomer is an olefin-based thermoplastic elastomer having, as a skeleton, a copolymer of ethylene and an α-olefin having 3 to 8 carbon atoms or a copolymer of propylene and an α-olefin having 4 to 8 carbon atoms or a styrene-based thermoplastic elastomer having a styrene skeleton,
when a total of the continuous phase (A) and the dispersed phase (B) is taken as 100% by mass, a content of the dispersed phase (B) is 70% by mass or less, and
when a total of the first polyolefin resin and the second polyolefin resin is taken as 100% by mass, a content of the second polyolefin resin is 80% by mass or less.

8. The method for producing the molded body according to claim 7 , wherein the impact-resistant resin has a continuous phase (C) containing the second polyolefin resin and a dispersed phase (B) dispersed in the continuous phase (C) and containing the polyamide resin and the modified elastomer, and
the dispersed phase (B) has a continuous phase (B 1 ) containing the polyamide resin and a fine dispersed phase (B 2 ) dispersed in the continuous phase (B 1 ) and containing the modified elastomer.

9. The method for producing the molded body according to claim 7 , wherein the first polyolefin resin is a block copolymerized polyolefin resin having an ethylene block as a dispersed phase.

Assignees

• Toyota Boshoku Kk

Inventors

• Kato Keisuke

Classifications

• C08L25/10

  with conjugated dienes · CPC title

• C08L23/00

  Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers · CPC title

• C08L53/02

  of vinyl-aromatic monomers and conjugated dienes · CPC title

• C08L25/00

  Compositions of, homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Compositions of derivatives of such polymers · CPC title

• C08L2205/02

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