Thermoplastic resin composition, method of producing thermoplastic resin composition, molded article of cellulose-reinforced resin, and method of producing molded article of cellulose-reinforced resin

Patent metadata

Field	Value
Publication number	US-11466140-B2
Application number	US-201816143846-A
Country	US
Kind code	B2
Filing date	Sep 27, 2018
Priority date	Mar 31, 2016
Publication date	Oct 11, 2022
Grant date	Oct 11, 2022

Abstract

A method of producing a thermoplastic resin composition containing a thermoplastic synthetic resin and a cellulose, in which at least one type of the thermoplastic synthetic resin is a resin having a group containing a partial structure of an acid anhydride in the polymer molecule;a molded article of a cellulose-reinforced resin; anda method of producing a molded article of a cellulose-reinforced resin.

First claim

The invention claimed is:

1. A thermoplastic resin composition, comprising:
a thermoplastic synthetic resin,
a cellulose, and
an ionic compound;
wherein at least one type of the thermoplastic synthetic resin is a resin having a group containing a partial structure of an acid anhydride in the polymer molecule, wherein the ionic compound is represented by Formula (1) or (2):

wherein, in Formulas (1) and (2), Z 1 designates ═C(Ra)— or ═N—; Ra designates a hydrogen atom or a substituent; L 1 designates a divalent linking group; R 1 to R 5 each independently designate an alkyl group, an alkenyl group, a cycloalkyl group, an aryl group or a heterocyclic group; at least two of R 2 to R 5 may be bonded to each other to form a ring; and X − designates an anion,
wherein a content of the ionic compound is 0.001 times or more and less than 1.000 time of the mass content of the cellulose,
wherein a content of the cellulose is from 1 to 100 parts by mass, with respect to 100 parts by mass of the thermoplastic synthetic resin,
wherein a content of the resin having a group containing a partial structure of an acid anhydride in the polymer molecule is from 1 to 50% by mass in the thermoplastic synthetic resin, and
wherein the cellulose is in a bundle form of un-fibrillated cellulose, and plant fiber-derived cellulose.

2. The thermoplastic resin composition according to claim 1 , wherein the compound represented by Formula (1) or (2) is represented by any one of Formulas (1a), (1b) and (2a) to (2c):

wherein, in Formulas (1a), (1b) and (2a) to (2c), R 1 , R 2 and X − have the same meanings as R 1 , R 2 and X − in Formula (1) or (2), respectively; and R 11 and R 12 each independently designate a substituent; n 11 is an integer of 0 to 3; n 12 is an integer of 0 to 5; when there exists two or more R 11 's, the R 11 's may be the same or different from each other; at least two of R 11 's may be bonded to each other to form a ring; R 13 to R 15 each independently designate an alkyl group, an alkenyl group, a cycloalkyl group, an aryl group, or a heterocyclic group; at least two of R 2 and R 13 to R 15 do not bonded to each other to form any ring; R 21 has the same meaning as R 2 ; Z 2 designates a single bond, a methylene group, —C(═O)—, —O—, —S—, —S(═O)—, —SO 2 —, —N(Rα1)-, or —N + (Rα1)(Rα2)-; Rα1 designates a hydrogen atom or a substituent; Rα2 designates a substituent; and Rα1 and Rα2 may be bonded to each other to form a ring.

3. The thermoplastic resin composition according to claim 1 , wherein the X − is a halogen ion, a carboxylic acid anion, a sulfonic acid anion, a phosphate anion, a phosphonic acid anion, a dicyanamide ion, or a bis(trifluoromethanesulfonyl)imide ion.

4. The thermoplastic resin composition according to claim 1 , wherein an apparent elastic modulus (Ef 1 ) of the cellulose contained in the thermoplastic resin composition at the time when a uniform dispersion element is formed by applying a shear force to the thermoplastic resin composition, is 1.1 times or more with respect to an apparent elastic modulus (Ef 0 ) of the cellulose contained in the thermoplastic resin composition at the time when a uniform dispersion element is formed by applying a shear force to the thermoplastic resin composition that does not contain the ionic compound or the resin having a group containing a partial structure of an acid anhydride in the polymer molecule.

5. A cellulose-reinforced resin, which is obtained by subjecting the thermoplastic resin composition according to claim 1 to a kneading processing,
wherein at least one type of the thermoplastic synthetic resin is a resin having at least one group selected from a group containing a partial structure of an acid anhydride and a group containing an acylated cellulose structure, in the polymer molecule.

6. The cellulose-reinforced resin according to claim 5 , wherein the ionic compound is represented by Formula (1).

7. A molded article of a cellulose-reinforced resin, which is obtained by molding the cellulose-reinforced resin composition according to claim 5 .

8. The molded article of a cellulose-reinforced resin according to claim 7 , wherein an application of the molded article is a material for a vehicle.

9. The molded article of a cellulose-reinforced resin according to claim 7 , wherein the molded article is a door trim, a pillar, an instrumental panel, a console, a rocker panel, an armrest, an inner panel of door, a spare tire cover, a door knob, a bumper, a spoiler, a fender, a side step, an outer panel of door, an air intake duct, a coolant reserve tank, a radiator reserve tank, a window-washer tank, a fender liner, a fan, or a front-end panel.

10. A method of producing a cellulose-reinforced resin, which comprises a step of subjecting the thermoplastic resin composition according to claim 1 to a kneading processing.

11. The method of producing a cellulose-reinforced resin according to claim 10 , which comprises a step of blending a mixture of a thermoplastic synthetic resin, the cellulose, and the ionic compound,
wherein a content of the ionic compound in the mixture is 0.1% by mass or more and less than 50% by mass, and
wherein the cellulose is in a bundle form of un-fibrillated cellulose, and plant fiber-derived cellulose.

12. A method of producing a molded article of a cellulose-reinforced resin, which comprises molding the cellulose-reinforced resin composition produced by the method of producing a cellulose-reinforced resin composition according to claim 10 .

13. A method of producing a cellulose-reinforced resin, which comprises a step of, after kneading a mixture of a thermoplastic synthetic resin having a group containing a partial structure of an acid anhydride in the polymer molecule, a cellulose and an ionic compound, blending the resultant kneaded composition with a thermoplastic synthetic resin other than the thermoplastic synthetic resin having a group containing a partial structure of an acid anhydride in the polymer molecule,
wherein the cellulose is in a bundle form of un-fibrillated cellulose, and plant fiber-derived cellulose,
wherein the ionic compound is represented by Formula (1) or (2):

wherein, in Formulas (1) and (2), Z 1 designates ═C(Ra)— or ═N—; Ra designates a hydrogen atom or a substituent L1 designates a divalent linking group; R 1 to R 5 each independently designate an alkyl group, an alkenyl group, a cycloalkyl group, an aryl group or a heterocyclic group; at least two of R 2 to R 5 may be bonded to each other to form a ring; and X − designates an anion,
wherein a content of the ionic compound is 0.001 times or more and less than 1.000 time of the mass content of the cellulose,
wherein a content of the cellulose is from 1 to 100 parts by mass, with respect to 100 parts by mass of total of the thermoplastic synthetic resin having a group containing a partial structure of an acid anhydride in the polymer molecule and the thermoplastic synthetic resin other than the thermoplastic synthetic resin having a group containing a partial structure of an acid anhydride in the polymer molecule, and
wherein a content of the thermoplastic synthetic resin having a group containing a partial structure of an acid anhydride in the polymer molecule is from 1 to 50% by mass in the to

Assignees

• Furukawa Electric Co Ltd

Inventors

• Kozawa Eiji
• Yagi Takeshi
• Nakajima Yasuo
• Kim Jae Kyung

Classifications

• B29C48/022

  characterised by the choice of material · CPC title

• C08J2423/06

  Polyethene · CPC title

• C08J2323/06

  Polyethene · CPC title

• C08J3/005

  Processes for mixing polymers · CPC title

• B29K2023/065

  HDPE, i.e. high density polyethylene · CPC title