Method for producing resin composition, and resin composition

Patent metadata

Field	Value
Publication number	US-2022010037-A1
Application number	US-202117486166-A
Country	US
Kind code	A1
Filing date	Sep 27, 2021
Priority date	Mar 28, 2019
Publication date	Jan 13, 2022
Grant date	—

Abstract

A resin composition is produced by a method including a step of rapidly freezing a latex containing fine polymer particles (A), a step of thawing the latex which has been frozen in the preceding step, a step of mixing, into the latex which has been subjected to the preceding step, a resin (B) having a specific viscosity, and after the preceding steps, a step of separating the latex into a resin composition and a water component. The resin composition is an agglutinate containing the fine polymer particles (A) and the resin (B).

First claim

1 . A method of producing a resin composition, comprising:
a rapid freezing step of rapidly freezing a latex containing fine polymer particles (A); a thawing step of thawing the latex which has been frozen in the rapid freezing step; a resin mixing step of mixing, into the latex which has been subjected to the rapid freezing step, a resin (B) which is, at 25° C., a liquid having a viscosity of 100 mPa·s to 1,000,000 mPa·s, a semisolid, or a solid; and after the thawing step and the resin mixing step, a separating step of separating the latex into the resin composition and a water component, the resin composition being an agglutinate containing the fine polymer particles (A) and the resin (B); wherein the fine polymer particles (A) having at least a graft part which is constituted by a polymer containing, as one or more structural units that derived from at least one type of monomer selected from the group consisting of aromatic vinyl monomers, vinyl cyanide monomers, and (meth)acrylate monomers; and in a case where a total amount of the fine polymer particles (A) and the resin (B) is regarded as 100% by weight, an amount of the fine polymer particles (A) be 1% by weight to 70% by weight and an amount of the resin (B) be 30% by weight to 99% by weight.

2 . A method of producing a resin composition, comprising:
a resin mixing step of mixing, into a latex containing fine polymer particles (A), a resin (B) which is, at 25° C., a liquid having a viscosity of 100 mPa·s to 1,000,000 mPa·s, a semisolid, or a solid; a shearing step of applying shearing stress to the latex which has been obtained in the resin mixing step; and after the shearing step, a first separating step of separating the latex into a resin composition and a water component, the resin composition being an agglutinate containing the fine polymer particles (A) and the resin (B); wherein the fine polymer particles (A) having at least a graft part which is constituted by a polymer containing, as one or more structural units that derived from at least one type of monomer selected from the group consisting of aromatic vinyl monomers, vinyl cyanide monomers, and (meth)acrylate monomers; and in a case where a total amount of the fine polymer particles (A) and the resin (B) is regarded as 100% by weight, an amount of the fine polymer particles (A) be 1% by weight to 70% by weight and an amount of the resin (B) be 30% by weight to 99% by weight.

3 . The method as set forth in claim 2 , further comprising:
an agglutinating step of agglutinating the fine polymer particles (A) and the resin (B) contained in the water component from which the agglutinate has been separated in the first separating step, so as to obtain the resin composition which is the agglutinate containing the fine polymer particles (A) and the resin (B); and after the agglutinating step, a second separating step of separating the resin composition, which is the agglutinate containing the fine polymer particles (A) and the resin (B), and the water component.

4 . The method as set forth in claim 3 , wherein the agglutinating step includes a step of freezing the water component from which the agglutinate has been separated in the first separating step.

5 . The method as set forth in claim 1 , wherein the separating step, a first separating step, or a second separating step includes a step of adjusting a water content of the agglutinate to 5% by weight to 60% by weight with respect to 100% by weight of the agglutinate.

6 . The method as set forth in claim 1 , further comprising a washing step of washing the resin composition.

7 . A resin composition comprising:
fine polymer particles (A) which have a graft part that is constituted by a polymer containing, as one or more structural units, the one or more structural units derived from at least one type of monomer selected from the group consisting of aromatic vinyl monomers, vinyl cyanide monomers, and (meth)acrylate monomers; and a resin (B) which is, at 25° C., a liquid having a viscosity of 100 mPa·s to 1,000,000 mPa·s, a semisolid, or a solid, in a case where a total amount of the fine polymer particles (A) and the resin (B) is regarded as 100% by weight, an amount of the fine polymer particles (A) being 1% by weight to 70% by weight and an amount of the resin (B) being 30% by weight to 99% by weight, in a case where an amount of the fine polymer particles (A) contained in the resin (B) is 5% by weight, dispersibility of the fine polymer particles (A) in the resin (B) being not more than 0 μm when evaluated in accordance with JIS K5101 with use of a grind gauge, the resin composition substantially not containing an organic solvent, the resin composition containing sulfur (S) and phosphorus (P) each in an amount of not more than 150 ppm, the resin composition having an electric conductivity of not more than 0.6 mS/cm; and the resin (B) is selected from the group consisting of: epoxy resins; phenolic resins; polyol resins; and amino-formaldehyde resins (melamine resins).

8 . The resin composition as set forth in claim 7 , wherein the resin composition contains calcium (Ca), magnesium (Mg), iron (Fe), zinc (Zn), barium (Ba), and aluminum (Al) each in an amount of not more than 100 ppm.

9 . The resin composition as set forth in claim 7 , wherein the fine polymer particles (A) are constituted by a rubber-containing graft copolymer which has an elastic body and the graft part grafted to the elastic body.

10 . The resin composition as set forth in claim 9 , wherein the elastic body includes at least one type of elastic body selected from the group consisting of diene-based rubbers, (meth)acrylate-based rubbers, and polysiloxane rubber-based elastic bodies.

11 . The resin composition as set forth in claim 7 , wherein the resin (B) includes a thermosetting resin.

Assignees

• Kaneka Corp

Inventors

• Nagaoka Yu

Classifications

• C08C1/16

  in floc form · CPC title

• C08F6/22

  Coagulation · CPC title

• C08L51/04

  grafted on to rubbers · CPC title

• C08F279/02

  on to polymers of conjugated dienes · CPC title

• C08F279/06 Primary

  Vinyl aromatic monomers and methacrylates as the only monomers · CPC title