Fiber-sizing agent, inorganic reinforcement material, resin composition, and molded article

Patent metadata

Field	Value
Publication number	US-11577995-B2
Application number	US-201816642281-A
Country	US
Kind code	B2
Filing date	Aug 22, 2018
Priority date	Aug 29, 2017
Publication date	Feb 14, 2023
Grant date	Feb 14, 2023

Abstract

The purpose of the present invention is to provide a fiber-sizing agent which when applied to an inorganic reinforcement material contained in a resin composition, can provide a molded article having excellent impact resistance and high surface gloss properties. The fiber-sizing agent according to the present invention contains a modified olefin wax (A), a polyolefin resin (B), and a silane-coupling agent (C), wherein the mass ratio (A)/(B) of the modified olefin wax (A) to the polyolefin resin (B) is in the range of 0.2-10.

First claim

The invention claimed is:

1. A resin composition comprising an inorganic reinforcing material (D) and a resin (E),
wherein the resin (E) includes a thermoplastic resin selected from the group consisting of a polycarbonate resin, a polyester resin and a polyamide resin,
wherein the inorganic reinforcing material (D) comprises an inorganic reinforcing material (D′) coated with a fiber-sizing agent, the fiber-sizing agent comprising a modified olefin wax (A), an unmodified polyolefin resin (B) and a silane coupling agent (C),
wherein the modified olefin wax (A) is a modified product of an ethylene-based polymer (a) having ethylene-derived structural units of 70 mol % to 100 mol % based on the total of all monomers forming the ethylene-based polymer (a),
wherein the unmodified polyolefin resin (B) is an ethylene-based polymer (b) having ethylene-derived structural units of 70 mol % to 100 mol % based on the total of all monomers forming the ethylene-based polymer (b), and
wherein a mass ratio (A)/(B) of the modified olefin wax (A) to the unmodified polyolefin resin (B) is in the range of 0.2 to 10.

2. The resin composition according to claim 1 , wherein the mass ratio (A)/(B) is in the range of 0.5 to 10.

3. The resin composition according to claim 1 , wherein the modified olefin wax (A) meets the following requirements (i) to (iv):
(i) a number average molecular weight (Mn) in terms of polystyrene as measured by gel permeation chromatography (GPC) is in the range of 300 to 20,000;
(ii) a softening point measured according to JIS K2207 is in the range of 70 to 170° C.;
(iii) a density measured by a density-gradient tube method is in the range of 830 to 1200 kg/m 3 ; and
(iv) an acid value is in the range of 10 to 200 mgKOH/g.

4. The resin composition according to claim 1 , wherein the modified olefin wax (A) is a carboxylic acid-modified product of the ethylene-based polymer (a) or an oxide of the ethylene-based polymer (a).

5. The resin composition according to claim 1 , wherein the modified olefin wax (A) is a maleic anhydride-modified product of the ethylene-based polymer (a).

6. A fiber-sizing agent comprising a modified olefin wax (A), a polyolefin resin (B) and a silane coupling agent (C),
wherein a mass ratio (A)/(B) of the modified olefin wax (A) to the polyolefin resin (B) is in the range of 0.2 to 10, and
the modified olefin wax (A) is contained as a water-dispersible emulsion having an average particle diameter of 0.1 to 30 μm.

7. The resin composition according to claim 1 , wherein the modified olefin wax (A) meets the following requirement (i)′:
(i)′ the number average molecular weight (Mn) in terms of polystyrene as measured by gel permeation chromatography (GPC) is in the range of 300 to 10,000.

8. The resin composition according to claim 1 , wherein the inorganic reinforcing material (D′) is a glass fiber filament, and
the inorganic reinforcing material (D) is a glass fiber strand in which a plurality of the glass fiber filaments are sized by the fiber-sizing agent.

9. An inorganic reinforcing material (D) in which an inorganic reinforcing material (D′) is coated with the fiber-sizing agent,
wherein the inorganic reinforcing material (D′) is a carbon fiber filament, and
the inorganic reinforcing material (D) is a carbon fiber strand in which a plurality of the carbon fiber filaments are sized by the fiber-sizing agent, and
wherein the fiber-sizing agent comprises a modified olefin wax (A), a polyolefin resin (B) and a silane coupling agent (C), and
a mass ratio (A)/(B) of the modified olefin wax (A) to the polyolefin resin (B) is in the range of 0.2 to 10.

10. A molded article obtained from the resin composition according to claim 1 .

Assignees

• Mitsui Chemicals Inc

Inventors

• Kanaya Hirotaka
• Kawabe Kuniaki
• Takahashi Yosuke
• Matsunaga Koji
• Kusumoto Masaya
• Tamura Takuya

Classifications

• C08L101/00

  Compositions of unspecified macromolecular compounds · CPC title

• C08J5/06

  using pretreated fibrous materials · CPC title

• C03C25/255 Primary

  Oils, waxes, fats or derivatives thereof · CPC title

• C08L23/00 Primary

  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

• D06M2101/40

  Fibres of carbon · CPC title