Thermoplastic resin powder and method for producing same

Patent metadata

Field	Value
Publication number	US-9758663-B2
Application number	US-201414758995-A
Country	US
Kind code	B2
Filing date	Jan 6, 2014
Priority date	Jan 7, 2013
Publication date	Sep 12, 2017
Grant date	Sep 12, 2017

Abstract

The objective of the present invention is to provide a thermoplastic resin powder that suppresses a decrease in fluidity of a composition during melt molding and that has a suppressed alteration of the resin resulting from retention. The thermoplastic resin powder is obtained by coagulating a polymer from a latex produced by means of emulsion polymerization of a monomer, the content of metal-corroding free acids in the thermoplastic resin powder is no greater than 500 ppm, and the thermoplastic resin powder satisfies a predetermined formula (1).

First claim

The invention claimed is:

1. A thermoplastic resin powder obtained by coagulating a polymer from a latex produced by means of emulsion polymerization of a monomer, in which the content of metal corroding free acids in the thermoplastic resin powder is no greater than 500 ppm, and the thermoplastic resin powder satisfies the following Formula (1):
75≦flow retention rate (%)≦200  (1)

with the proviso that the above flow retention rate is defined by (MFR 20 /MFR 4 )×100, wherein:
MFR 20 indicates melt flow rate after maintaining for 20 minutes at conditions including 250° C. and a load of 49 N,
MFR 4 indicates melt flow rate after maintaining for 4 minutes at conditions including 250° C. and a load of 49 N, and
the thermoplastic resin powder does not contain butadiene as a copolymerization component.

2. The thermoplastic resin powder according to claim 1 , wherein the resin powder satisfies the following Formula (2):
90≦flow retention rate (%)≦120  (2).

3. The thermoplastic resin powder according to claim 1 , wherein the monomer contains (meth)acrylic acid ester at 50 to 100% by mass.

4. The thermoplastic resin powder according to claim 1 , wherein calcium content is less than 50 ppm.

5. The thermoplastic resin powder according to claim 4 , wherein sum of the calcium content and magnesium content is less than 50 ppm.

6. The thermoplastic resin powder according to claim 1 , wherein aluminum content is 60 ppm or more and 300 ppm or less.

7. The thermoplastic resin powder according to claim 1 , wherein phosphorus content is 50 ppm or more.

8. The thermoplastic resin powder according to claim 1 , wherein the polymer is coagulated by a coagulating agent selected from the group consisting of sulfuric acid, nitric acid, hydrochloric acid, acetic acid, aluminum sulfate, magnesium sulfate, sodium sulfate, sodium nitrate, aluminum chloride, calcium chloride, sodium chloride, potassium acetate and sodium acetate.

9. The thermoplastic resin powder according to claim 8 , wherein the coagulating agent is present in an amount of 0.03 to 2.0 parts by mass relative to 100 parts by mass of the polymer.

10. The thermoplastic resin powder according to claim 8 , wherein the coagulating agent is aluminum sulfate.

11. The thermoplastic resin powder according to claim 10 , wherein the aluminum sulfate is present in an amount of 0.03 to 0.9 parts by mass of the polymer.

12. A resin molded product obtained by molding a thermoplastic resin composition which contains the thermoplastic resin powder according to claim 1 .

13. The resin molded product according to claim 12 , wherein the resin molded product has a film shape.

Assignees

• Mitsubishi Rayon Co
• Mitsubishi Chem Corp

Inventors

• Nakaya Fuminori
• Abe Junichi

Classifications

• C08K2003/309

  Sulfur containing acids · CPC title

• C08L33/06

  of esters containing only carbon, hydrogen and oxygen, which oxygen atoms are present only as part of the carboxyl radical · CPC title

• C08K2003/3081

  Aluminum sulfate · CPC title

• C08F6/22 Primary

  Coagulation · CPC title

• C08J2333/06

  of esters containing only carbon, hydrogen, and oxygen, the oxygen atom being present only as part of the carboxyl radical · CPC title