Resin composition, pellet, composite molded article, method for manufacturing composite molded article and tank

Patent metadata

Field	Value
Publication number	US-11597827-B2
Application number	US-201917271503-A
Country	US
Kind code	B2
Filing date	Aug 28, 2019
Priority date	Aug 29, 2018
Publication date	Mar 7, 2023
Grant date	Mar 7, 2023

Abstract

To provide a resin composition, a pellet, a composite molded article, a method for manufacturing a composite molded article and a tank, all capable of enabling tight joining and integration of the polyacetal resin molded article and the polyethylene resin molded article, and of suppressing formaldehyde emission and occurrence of mold deposit. The resin composition contains a resin ingredient and melamine, the resin ingredient containing a polyacetal resin and a maleic anhydride-modified polyethylene resin, the polyacetal resin and the maleic anhydride-modified polyethylene resin following a mass proportion of (20 to 49):(80 to 51), and molar concentration of the maleic anhydride group capable of reacting with amino group of melamine contained in the resin composition being 5 to 25 μmol/g.

First claim

The invention claimed is:

1. A resin composition comprising a resin ingredient and melamine,
the resin ingredient containing a polyacetal resin and a maleic anhydride-modified polyethylene resin,
the polyacetal resin and the maleic anhydride-modified polyethylene resin following a mass proportion of 20 to 49:80 to 51, and
molar concentration of the maleic anhydride-derived carbonyl group capable of reacting with amino group of melamine contained in the resin composition being 5 to 25 μmol/g; and,
the molar concentration of the maleic anhydride-derived carbonyl group, capable of reacting with amino group of melamine contained in the resin composition, representing molar concentration (μmol/g) of maleic anhydride-derived carbonyl group or molar concentration (μmol/g) of melamine-derived amino group, whichever is smaller, or a common value if both molar concentrations agree.

2. The resin composition of claim 1 , wherein a content of melamine accounts for 0.005 to 1% by mass in the composition.

3. The resin composition of claim 1 , wherein a ratio of maleic anhydride modification of the maleic anhydride-modified polyethylene resin is 0.10 to 1.0% by mass.

4. The resin composition of claim 1 , wherein the polyacetal resin has a melt flow rate, when measured at 190° C. under 2.16 kg load, of 60 g/10 min or smaller.

5. The resin composition of claim 1 , wherein the maleic anhydride-modified polyethylene resin has a melt flow rate, when measured at 190° C. under 2.16 kg load, of 10 g/10 min or smaller.

6. The resin composition of claim 1 , wherein the maleic anhydride-modified polyethylene resin has a density of 0.954 g/cm 3 or smaller.

7. The resin composition of claim 1 , wherein the polyacetal resin and the maleic anhydride-modified polyethylene resin follow a mass proportion of 20 to 40:60 to 80.

8. A pellet formed of a resin composition described in claim 1 .

9. A composite molded article comprising:
a polyacetal resin molded article that contains a polyacetal resin;
a polyethylene resin molded article that contains a polyethylene resin; and
an intermediate layer arranged between the polyacetal resin molded article and the polyethylene resin molded article, so as to be brought into contact with the polyacetal resin molded article and the polyethylene resin molded article,
and,
the intermediate layer being formed of a resin composition described in claim 1 .

10. A method for manufacturing a composite molded article described in claim 9 , the method comprising:
stacking the polyacetal resin molded article, the polyethylene resin molded article and the intermediate layer, while placing the intermediate layer between the polyacetal resin molded article and the polyethylene resin molded article.

11. A method for manufacturing a composite molded article, the method comprising:
forming a polyacetal resin molded article, on one face of an intermediate layer that is formed of a resin composition described in claim 1 ; and
forming a polyethylene resin molded article, on the other face of the intermediate layer.

12. The method for manufacturing a composite molded article of claim 11 ,
wherein the step of forming the polyacetal resin molded article includes molding a molten composition that contains a polyacetal resin, in contact with the intermediate layer, and
the step of forming the polyethylene resin molded article include molding a molten composition that contains a polyethylene resin, in contact with the intermediate layer.

13. The method for manufacturing the composite molded article of claim 10 ,
wherein the polyacetal resin molded article, the intermediate layer and the polyethylene resin molded article are integrally formed by three-color molding or insert molding.

14. A tank comprising a composite molded article described in claim 9 .

15. The tank of claim 14 , used for storing at least either one of fuel or alcohols.

16. The tank of claim 15 , used for storing the fuel that contains gasoline, light oil or biodiesel.

17. The resin composition of claim 2 ,
wherein a ratio of maleic anhydride modification of the maleic anhydride-modified polyethylene resin is 0.10 to 1.0% by mass;
the polyacetal resin has a melt flow rate, when measured at 190° C. under 2.16 kg load, of 60 g/10 min or smaller; and
the maleic anhydride-modified polyethylene resin has a melt flow rate, when measured at 190° C. under 2.16 kg load, of 10 g/10 min or smaller.

18. The resin composition of claim 17 , wherein the maleic anhydride-modified polyethylene resin has a density of 0.954 g/cm 3 or smaller.

19. The resin composition of claim 17 , wherein the polyacetal resin and the maleic anhydride-modified polyethylene resin follow a mass proportion of 20 to 40:60 to 80.

20. The resin composition of claim 18 , wherein the polyacetal resin and the maleic anhydride-modified polyethylene resin follow a mass proportion of 20 to 40:60 to 80.

Assignees

• Mitsubishi Eng Plastics Corp
• Japan Polyethylene Corp

Inventors

• Fujimoto Kunihiko
• Takahashi Kei
• Matsumoto Ritsuya

Classifications

• C08L51/006

  grafted on to block copolymers containing at least one sequence of polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds · CPC title

• B32B2307/72

  Density · CPC title

• B32B27/20

  using fillers, pigments, thixotroping agents · CPC title

• B29C45/14467

  Joining articles or parts of a single article (B29C45/14377, B29C45/14385, B29C45/14581, B29C45/14614 and B29C45/006 take precedence) · CPC title

• B29C45/16

  Making multilayered or multicoloured articles {(B29C45/0062 takes precedence; feeding colouring materials into the injection unit B29C45/1816)} · CPC title