阅读说明：本技术 树脂组合物的制造方法 (Method for producing resin composition ) 是由 吉田浩一郎 大田佳生 于 2019-11-15 设计创作，主要内容包括：本发明涉及树脂组合物的制造方法,即使在粉体状增强剂的供给量多的情况下,也能够稳定地供给粉体状增强剂。本发明是使用挤出机制造树脂组合物的方法,特征在于,挤出机具有上游供给口和连接有侧加料器的下游供给口,侧加料器具有侧加料螺杆和侧加料筒,从上游供给口供给包含(a)粉体状聚苯醚系树脂的第1供给原料,从下游供给口供给包含(b)粉体状增强剂的第2供给原料,第1供给原料的供给量相对于原料100质量％为30～60质量％,在第1供给原料100质量％中包含50～90质量％的(a)粉体状聚苯醚系树脂,从一个下游供给口供给的(b)粉体状增强剂的供给量相对于原料100质量％为15～35质量％,(b)粉体状增强剂的堆积密度为0.8g/mL以下,侧加料螺杆为单牙,且为双螺杆。(The present invention relates to a method for producing a resin composition, which can stably supply a powdery reinforcing agent even when the amount of the powdery reinforcing agent supplied is large. The present invention is a method for producing a resin composition using an extruder, characterized in that the extruder has an upstream supply port and a downstream supply port to which a side feeder is connected, the side feeder has a side feed screw and a side feed cylinder, a 1 st supply raw material containing (a) a powdery polyphenylene ether-based resin is supplied from the upstream supply port, a 2 nd supply raw material containing (b) a powdery reinforcing agent is supplied from the downstream supply port, the supply amount of the 1 st supply raw material is 30 to 60 mass% with respect to 100 mass% of the raw material, 50 to 90 mass% of the 1 st supply raw material contains (a) the powdery polyphenylene ether-based resin in 100 mass%, the supply amount of (b) the powdery reinforcing agent supplied from one downstream supply port is 15 to 35 mass% with respect to 100 mass% of the raw material, the bulk density of (b) the powdery reinforcing agent is 0.8g/mL or less, the side feed screw is a single tooth, and is a twin screw.)

1. A method for producing a resin composition by using an extruder, characterized in that,

the extruder has an upstream supply port and a downstream supply port to which is connected a side feeder having a side feed screw and a side feed barrel,

a 1 st supply raw material containing (a) a powdery polyphenylene ether resin is supplied from the upstream supply port,

a 2 nd supply raw material containing (b) a powdery reinforcing agent is supplied from the downstream supply port,

the 1 st supply raw material is supplied in an amount of 30 to 60 mass% based on 100 mass% of the total amount of raw materials, and the 1 st supply raw material contains 50 to 90 mass% of the (a) powdered polyphenylene ether resin based on 100 mass%,

the amount of the (b) powdery reinforcing agent supplied from one of the downstream supply ports is 15 to 35% by mass based on 100% by mass of the total amount of raw materials, and the bulk density of the (b) powdery reinforcing agent is 0.8g/mL or less,

the side feeding screw is single-tooth and double-screw.

2. The method for producing a resin composition according to claim 1, wherein the ratio of the major axis Do to the minor axis Di of the side-feed screw, i.e., Do/Di, is 1.8 to 2.2.

3. The method for producing a resin composition according to claim 1 or 2, wherein a ratio of the lead Ls of the side-feed screw to the major axis Do of the screw, i.e., Ls/Do, is 1.0 to 2.0.

4. The method for producing a resin composition according to any one of claims 1 to 3, wherein the ratio of the distance σ between the gap between the side-feed cylinder and the side-feed screw to the major axis Do of the side-feed screw, i.e., σ/Do, is 0.005 to 0.05.

5. The method for producing a resin composition according to any one of claims 1 to 4, wherein the bulk density of the component (a) is 0.8g/mL or less.

6. The method for producing a resin composition according to any one of claims 1 to 5, wherein the component (b) is at least one selected from the group consisting of mica, talc and wollastonite.

7. The method for producing a resin composition according to any one of claims 1 to 6, wherein the 1 st feedstock further comprises (c) a polystyrene-based resin.

8. The method for producing a resin composition according to any one of claims 1 to 7, wherein (d) a condensed phosphoric ester is further added by using a charge pump.

Technical Field

The present invention relates to a method for producing a resin composition.

Background

In general, a composite material of a resin containing a powdery reinforcing agent is produced by mixing the powdery reinforcing agent with the resin in an extruder, granulating the mixture, and then producing the product by a molding machine. In an extruder for producing the composite material, a resin is fed from an upstream supply port, the resin is melted in a first kneading zone, a powdery reinforcing agent is fed from a side feeder, and the reinforcing agent is mixed with the melted resin in a second kneading zone.

Since the powdery reinforcing agent entrains gas when supplied to the extruder, the conveying ability when supplied from the side feeder into the extruder is sometimes insufficient. The following may therefore occur: the amount of the powdery reinforcing agent supplied exceeds the conveying ability of the powdery reinforcing agent, and the powdery reinforcing agent is accumulated in the hopper of the side feeder and cannot be supplied.

Patent document 1 discloses a technique of providing a side feed screw with a special kneading disk to improve conveying ability.

Disclosure of Invention

Problems to be solved by the invention

In the case of producing a resin using a powdered polyphenylene ether resin, the powdered polyphenylene ether resin supplied from the upstream supply port is also introduced into the extruder with the gas entrained therein, and therefore the conveying ability when the powdered reinforcing agent is supplied from the side feeder is further reduced, and stable supply is made more difficult.

In this case, even if the side feeder disclosed in patent document 1 is used, the stability of supplying the powdery reinforcing agent is not necessarily sufficient, and when the amount of the powdery reinforcing agent to be supplied is large, it may be difficult to stably supply the powdery reinforcing agent.

Accordingly, an object of the present invention is to provide a method for producing a polyphenylene ether resin composition, which can stably supply a powdery reinforcing agent even when the amount of the powdery reinforcing agent supplied is large.

Means for solving the problems

The present inventors have conducted extensive studies to solve the above-mentioned problems, and as a result, they have found that the above-mentioned object can be achieved by a method for producing a polyphenylene ether resin composition, in which an extruder having an upstream supply port and a downstream supply port to which a side feeder is connected is used, a specific amount of a powdery polyphenylene ether resin is supplied from the upstream supply port, a specific amount of a powdery reinforcing agent is supplied from the downstream supply port, and a side feed screw of the side feeder has a specific shape.

Namely, the present invention is as follows.

[1]

A method for producing a resin composition by using an extruder, characterized in that,

the extruder having an upstream supply port and a downstream supply port to which is connected a side feeder having a side feed screw and a side feed barrel,

a 1 st supply raw material containing (a) a powdered polyphenylene ether resin is supplied from the upstream supply port,

a 2 nd supply raw material containing (b) a powdery reinforcing agent is supplied from the downstream supply port,

the amount of the 1 st supply raw material is 30 to 60 mass% based on the total amount (100 mass%) of the raw materials, and the 1 st supply raw material contains 50 to 90 mass% of the powder polyphenylene ether resin (a) based on 100 mass%,

the amount of the (b) powdery reinforcing agent supplied from one of the downstream supply ports is 15 to 35% by mass based on the total amount (100% by mass) of the raw materials, and the bulk density of the (b) powdery reinforcing agent is 0.8g/mL or less,

the side feeding screw is single-tooth and double-screw.

[2]

The method for producing a resin composition as described in [1], wherein a ratio of a major axis Do to a minor axis Di (Do/Di) of the side-feed screw is 1.8 to 2.2.

[3]

The process for producing a resin composition as described in [1] or [2], wherein the ratio of the lead Ls of the side-feed screw to the major axis Do of the screw (Ls/Do) is 1.0 to 2.0.

[4]

The method for producing a resin composition according to any one of [1] to [3], wherein a ratio (σ/Do) of a distance σ between the side feed cylinder and the gap of the side feed screw to a major axis Do of the side feed screw is 0.005 to 0.05.

[5]

The method for producing a resin composition according to any one of [1] to [4], wherein the bulk density of the component (a) is 0.8g/mL or less.

[6]

The method for producing a resin composition according to any one of [1] to [5], wherein the component (b) is at least one selected from the group consisting of mica, talc and wollastonite.

[7]

The method for producing a resin composition according to any one of [1] to [6], wherein the 1 st feedstock further comprises (c) a polystyrene-based resin.

[8]

The method for producing a resin composition according to any one of [1] to [7], wherein the condensed phosphoric ester (d) is further added using a charge pump.

ADVANTAGEOUS EFFECTS OF INVENTION

According to the present invention, it is possible to provide a method for producing a polyphenylene ether resin composition, which can stably supply a powdery reinforcing agent even when the amount of the powdery reinforcing agent supplied is large.

Drawings

Fig. 1 is a schematic diagram showing an example of a single-screw twin screw of the side feeder of the present embodiment provided in a side feeder drum. (A) The front view of the single-tooth twin screw of the side feeder, and (B) the side view of the single-tooth twin screw of the side feeder.

FIG. 2 is a schematic view showing an example of a double twin screw of a side feeder provided in a side feed cylinder. (A) The front view of the twin screw of the side feeder, and (B) the side view of the twin screw of the side feeder.

Detailed Description

The following describes in detail a specific embodiment of the present invention (hereinafter referred to as "the present embodiment"). The following embodiments are illustrative of the present invention, and the present invention is not limited to the following embodiments. The present invention can be suitably modified and implemented within the scope of the gist thereof.

In the present specification, regarding the upstream side and the downstream side, in the extruder or the side feeder of the present embodiment, the upstream side of the raw material flow is defined as the upstream side and the downstream side is defined as the downstream side.

< method for producing resin composition >

The method for producing a resin composition of the present embodiment is a method for producing a resin composition using an extruder, wherein the extruder has an upstream supply port and a downstream supply port to which a side feeder having a side feed screw and a side feed cylinder is connected, a 1 st supply raw material containing (a) a powdery polyphenylene ether-based resin is supplied from the upstream supply port, a 2 nd supply raw material containing (b) a powdery reinforcing agent is supplied from the downstream supply port, the supply amount of the 1 st supply raw material is 30 to 60 mass% with respect to the total amount of raw materials (100 mass%), the 1 st supply raw material contains 50 to 90 mass% of the (a) powdery polyphenylene ether-based resin in 100 mass%, the supply amount of the (b) powdery reinforcing agent supplied from one of the downstream supply ports is 15 to 35 mass% with respect to the total amount of raw materials (100 mass%), the bulk density of the powdery reinforcing agent (b) is 0.8g/mL or less, and the side-feed screw is single-screw and twin-screw.

(extruding machine)

The extruder used in the method for producing a resin composition of the present embodiment has an upstream supply port and a downstream supply port to which a side feeder is connected. The number of the downstream supply ports to which the side feeders are connected may be 2 or more.

The type of the extruder used in the present embodiment is not particularly limited, and a twin-screw co-rotating twin-screw extruder is preferable. Examples of the extruder include "ZSK" series manufactured by COPERION, Germany, a "TEM" series manufactured by Toshiba machine, and "TEX" series manufactured by Nippon Steel.

The specification and size of the extruder are not particularly limited, but the barrel diameter is preferably 40 to 200 mm. The productivity is improved by making the diameter of the cylinder more than 40 mm; by setting the cylinder diameter to 200mm or less, it is possible to prevent excessive increase in heat generation during melt kneading.

The length of the extruder is not particularly limited, but is preferably 30 to 60 times the diameter of the barrel. By setting the length of the extruder to 30 times or more the cylinder diameter, it becomes easier to sufficiently knead the raw material supplied from the side feeder, and by setting the length of the extruder to 60 times or less the cylinder diameter, the shaft vibration of the screw shaft can be reduced, which is preferable.

((upstream supply port))

The upstream supply port of the extruder of the present embodiment is preferably located in the most upstream barrel (barrel No. 1) of the extruder.

The method for producing a resin composition according to the present embodiment supplies the 1 st supply raw material containing (a) a powdered polyphenylene ether resin from an upstream supply port.

((downstream supply port))

The downstream supply port of the extruder of the present embodiment is located downstream of the upstream supply port, and a side feeder is connected thereto. The downstream supply port of the extruder of the present embodiment may be plural.

In the method for producing a resin composition of the present embodiment, the 2 nd supply raw material containing (b) the powdery reinforcing agent is supplied from the downstream supply port.

Regarding the position of the downstream supply port of the extruder of the present embodiment, the ratio (L/D) of the length L up to the downstream supply port to the barrel diameter D is preferably 12 to 40, and more preferably 16 to 36.

Side feeder

The side feeder connected to the extruder of the present embodiment is connected to the lateral side surface or the upper portion of the cylinder of the extruder, and can be used as a device for producing a resin composition, for example. The side feeders are connected to a different side feeder barrel than the barrel with the upstream feed port, and may be 2 or more.

In the method for producing a resin composition according to the present embodiment, the 2 nd supply raw material containing (b) the powdery reinforcing agent is supplied from the side feeder.

(b) When the number of the powdery reinforcing agents is 2 or more, the extruder of the present embodiment may have 2 or more side feeders. In addition, even if the number of the (b) powdery reinforcing agents is 1, the (b) powdery reinforcing agents may be supplied separately from 2 or more side feeders.

The side feeder of this embodiment has a side feed screw and a side feed cylinder.

Side feed screw-

The side feeder of the present embodiment has a single-screw with 1 flight (long diameter portion), and is a twin screw. When the screw is a single screw, the conveying capacity is low, and when the screw is 3 or more, the mechanical structure is complicated, which is not preferable. From the viewpoint of conveying ability and structure, single-tooth twin screws are preferable.

Fig. 1 shows a schematic front view (a) and a schematic side view (B) of an example of the side feed screw 1 of the present embodiment.

In the side feed screw, the ratio of the major axis Do to the minor axis Di (Do/Di) is preferably 1.8 to 2.2, more preferably 1.86 to 2.2, and still more preferably 1.86 to 2.1. When Do/Di is less than 1.8, the transmission capability is lowered. When Do/Di is larger than 2.2, the minor axis Di becomes small, and the strength of the screw shaft is lowered.

In the side-feed screw, the ratio of the lead Ls to the major axis Do (Ls/Do) is preferably 1.0 to 2.0, more preferably 1.0 to 1.7, and still more preferably 1.1 to 1.7. The conveyance capacity can be further improved by setting Ls/Do to 1.0 or more, and the screw can be kept at a high mechanical strength by setting Ls/Do to 2.0 or less.

The rotation speed of the side feeding screw is preferably 100 to 450rpm, more preferably 150 to 400 rpm. When the screw rotation speed is within the above range, the raw material can be stably supplied into the extruder.

Fig. 2 shows a schematic front view (a) and a schematic side view (B) of an example of a double twin-screw side-feed screw. The number of flights (long diameter portions) was 2 in 1 lead, and the flights were smaller than that of the single-flight side feed screw, but since the flights engaged with each other, the leakage of the material from the engaged portion was reduced.

-side feed cartridge-

The side feed cylinder of this embodiment is in the shape of a twin screw that matches the shape of the side feed screw.

In addition, the cylinder diameter Ds of the side feeding cylinder does not exceed the cylinder diameter of the connected extruder.

The ratio (σ/Do) of the distance σ between the side feed cylinder and the side feed screw to the major axis Do of the side feed screw is preferably 0.005 to 0.05, more preferably 0.007 to 0.05, and still more preferably 0.008 to 0.05. When σ/Do is 0.005 or more, the blade width of the single-thread screw is too wide, whereby (b) the powdery reinforcing agent is clogged in the gap, the screw stops, or the screw portion of the single-thread screw is appropriately prevented from being worn. Further, by setting σ/Do to 0.05 or less, (b) the powdery reinforcing agent passing through the gap can be reduced, and the conveying ability can be further improved.

In the present invention, the distance σ between the gaps between the side feed cylinder and the side feed screw is calculated by the following formula (1).

σ＝(Ds－Do)/2·············(1)

The side feeder of this embodiment may be connected to a hopper, a barrel cooling device, etc. as desired.

When a liquid raw material is supplied to an extruder, the liquid raw material may be directly fed into a cylinder of the extruder by using a charge pump or the like to perform kneading. The charge pump is not particularly limited, and examples thereof include a gear pump and a flange pump. Among these, a gear pump is preferable. Further, it is more preferable that a tank for storing the liquid raw material used in the charging pump, a pipe between the tank and the pump, a pipe between the pump and the extruder barrel, and the like, which are portions to be flow paths of the liquid raw material, are heated by a heater or the like. This makes it possible to reduce the viscosity of the liquid material, and therefore, the load applied to the charge pump can be reduced, which is preferable from the viewpoint of workability and the like.

In the present embodiment, the structure of the extruder is not particularly limited, and for example, an upstream supply port may be provided on the upstream side, a first kneading zone may be provided downstream of the upstream supply port, a downstream supply port may be provided downstream of the first kneading zone (if necessary, a 2 nd downstream supply port may be further provided downstream of the downstream supply port), a second kneading zone may be provided downstream of the downstream supply port, a charge pump may be provided downstream of the second kneading zone, a third kneading zone may be provided downstream of the charge pump, and a vacuum exhaust port may be provided downstream of the third kneading zone.

(production of resin composition)

The method for producing the resin composition of the present embodiment includes: the extruder was used to supply the 1 st feed material containing (a) a powdery polyphenylene ether resin from an upstream feed port and the 2 nd feed material containing (b) a powdery reinforcing agent from a downstream feed port to which a side feeder was connected.

In the method for producing the resin composition of the present embodiment, (d) the condensed phosphoric ester may be further added using a charge pump.

In the method for producing the resin composition of the present embodiment, the extrusion temperature is not particularly limited, and may be 100 to 370 ℃, and the screw rotation speed is not particularly limited, and may be 100 to 1200 rpm.

((1 st feed material))

In the method for producing a resin composition of the present embodiment, the 1 st supply raw material supplied from the upstream supply port contains (a) a powdery polyphenylene ether resin. The 1 st feed material may contain (c) a polystyrene resin.

The amount of the 1 st feed raw material is 30 to 60% by mass based on the total amount (100% by mass) of the raw materials. The amount of the 2 nd feed raw material is preferably 60 mass% or less, because the filling ratio in the extruder before adding the powdery reinforcing agent (b) is not excessively increased and the 2 nd feed raw material is easily supplied. The amount of the component (b) to be supplied is preferably 30% by mass or more, from the viewpoint that the filling rate in the extruder before the component (b) is added is not excessively reduced. The supply amount is more preferably 35 to 55 mass%, and still more preferably 40 to 55 mass%.

Powder polyphenylene ether resin (a)

(a) The powdery polyphenylene ether resin (in the present specification, referred to as "PPE" or simply as "component (a)") may be a homopolymer of a phenylene ether or a copolymer of a phenylene ether and another monomer.

The component (a) may be used alone in 1 kind, or may be used in combination in 2 or more kinds.

Examples of the component (a) include homopolymers and/or copolymers having a repeating unit structure (unit structure derived from a phenylene ether) represented by the following formula (1).

[ solution 1]

[ in the formula, R¹、R²、R³And R⁴Each independently represents a monovalent group selected from the group consisting of a primary alkyl group having 1 to 7 carbon atoms or a secondary alkyl group having 1 to 7 carbon atoms, a phenyl group, a haloalkyl group, an aminoalkyl group, a hydrocarbonoxy group, and a halohydrocarbonoxy group having at least 2 carbon atoms separating the halogen atom from the oxygen atom.]

Examples of the component (a) include homopolymers such as poly (2, 6-dimethyl-1, 4-phenylene ether), poly (2-methyl-6-ethyl-1, 4-phenylene ether), poly (2-methyl-6-phenyl-1, 4-phenylene ether), and poly (2, 6-dichloro-1, 4-phenylene ether); and copolymers of 2, 6-dimethylphenol with other phenols (e.g., 2,3, 6-trimethylphenol or 2-methyl-6-butylphenol), and the like. Of these, poly (2, 6-dimethyl-1, 4-phenylene ether), a copolymer of 2, 6-dimethylphenol and 2,3, 6-trimethylphenol are preferable, and poly (2, 6-dimethyl-1, 4-phenylene ether) is more preferable.

The component (a) can be produced by a conventionally known method. Examples of the method for producing the component (a) include: a method for producing a compound by oxidative polymerization of 2, 6-xylenol or the like using a complex of a cuprous salt and an amine as a catalyst; and the methods described in, for example, Japanese patent application laid-open Nos. 50-150798, 50-051197, and 63-152628.

The reduced viscosity of the component (a) (0.5g/dL in chloroform, measured at 30 ℃ C., and measured by a Ubbelohde viscometer) is preferably 0.7dL/g or less, more preferably 0.6dL/g or less from the viewpoint of fluidity, and is preferably 0.2dL/g or more, more preferably 0.3dL/g or more from the viewpoint of mechanical properties.

The component (a) may have a structure converted into a functionalized polyphenylene ether by reacting (modifying) all or part of the structural units constituting the polyphenylene ether with a functionalizing agent containing 1 or more functional groups selected from the group consisting of an acyl functional group, a carboxyl group, an acid anhydride group, an amide group, an imide group, an amine group, an orthoester group, a hydroxyl group, and a group derived from an ammonium carboxylate salt.

In the present embodiment, the component (a) that can achieve the effects of the present invention is in the form of powder.

The bulk density of the component (a) is preferably 0.8g/mL or less, more preferably 0.7g/mL or less, and still more preferably 0.6g/mL or less. (a) When the bulk density of the component (a) is 0.8g/mL or less, the amount of entrained gas increases when the component (a) is supplied into the extruder, and the conveying ability of the powder-like reinforcing agent (b) supplied from the side feeder is more likely to decrease, and the effect of the present invention is more remarkably exhibited.

The bulk density of the component (a) can be measured by a Powder characteristic evaluation apparatus (Powder Tester PT-X, manufactured by Hosokawa micron Co.).

The content of the component (a) in 100 mass% of the first feedstock is 50 to 90 mass%. If the content is more than 90% by mass, the amount of entrained gas increases when the feed material 1 is fed into the extruder. Accordingly, the 2 nd supply raw material supplied from the side feeder is difficult to be fed into the extruder, and the conveyance capacity is lowered, so that stable supply cannot be performed. When the content is less than 50% by mass, the amount of gas entrained when the component (a) is supplied into the extruder is reduced, and the problem that the No. 2 feed material supplied from the side feeder is difficult to be fed into the extruder is unlikely to occur, and therefore, the effect of the present invention is difficult to be exerted. The content is more preferably 55 to 90 mass%, and still more preferably 55 to 85 mass%.

- (c) polystyrene resin-

The 1 st feed raw material of the present embodiment may contain (c) a polystyrene-based resin (in the present specification, it may be simply referred to as a "component (c)") in order to reduce the melt viscosity of the resin in the extruder.

The polystyrene resin (c) of the present embodiment is a polymer obtained by polymerizing a styrene compound or a compound copolymerizable with the styrene compound in the presence or absence of a rubber polymer.

The styrene compound constituting the polystyrene resin (c) is a compound represented by the following formula (2).

[ solution 2]

(wherein R represents hydrogen, lower alkyl or halogen, Z is selected from the group consisting of vinyl, hydrogen, halogen and lower alkyl, and p is an integer of 0 to 5.)

Specific examples of the styrene-based compound include styrene, α -methylstyrene, 2, 4-dimethylstyrene, monochlorostyrene, p-methylstyrene, p-tert-butylstyrene, and ethylstyrene.

Examples of the compound copolymerizable with the styrene compound include methacrylates such as methyl methacrylate and ethyl methacrylate; unsaturated nitrile compounds such as acrylonitrile and methacrylonitrile; maleic anhydride and the like, and they are used together with the styrene compound.

Examples of the rubbery polymer include a conjugated diene rubber, a copolymer of a conjugated diene and an aromatic vinyl compound, or a hydrogenated product thereof, and an ethylene-propylene copolymer rubber.

Examples of the polystyrene resin (c) include polystyrene, rubber-reinforced polystyrene (high impact polystyrene (HIPS)), a styrene-acrylonitrile copolymer (AS resin), a rubber-reinforced styrene-acrylonitrile copolymer (ABS resin), and other styrene copolymers.

These can be used alone in 1 kind, also can be combined with more than 2 kinds.

The content of the component (c) in 100 mass% of the 1 st feed material is preferably 5 to 50 mass%, more preferably 10 to 45 mass%, and still more preferably 15 to 40 mass%, from the viewpoint of reducing the melt viscosity of the 1 st feed material and stabilizing the supply of the component (b) to the extruder.

The 1 st feedstock of the present embodiment may contain, in addition to the component (a) and the component (c), a plasticizer, a stabilizer such as an antioxidant and an ultraviolet absorber, an antistatic agent, a releasing agent, an additive such as a dye-pigment, and other resins other than the component (a) and the component (c).

The content of the other components in 100 mass% of the 1 st feed material is preferably 3 mass% or less.

((2 nd feed material))

In the method for producing a resin composition according to the present embodiment, the 2 nd supply raw material supplied from the downstream supply port to which the side feeder is connected contains (b) a powdery reinforcing agent.

The amount of the 2 nd feed raw material is preferably 15 to 60 mass%, more preferably 15 to 55 mass%, and still more preferably 20 to 50 mass% based on the total amount (100 mass%) of the raw materials, from the viewpoint of stabilizing the feed into the extruder.

- (b) enhancer in powder form-

Examples of the powdery reinforcing agent (b) (which may be abbreviated as "component (b)" in the present specification) include ground calcium carbonate, colloidal calcium carbonate, soft calcium carbonate, silica, kaolin, clay, barium sulfate, zinc oxide, alumina, magnesium hydroxide, talc, chlorite, mica, milled fibers, hydrotalcite, needle-like fillers (wollastonite, potassium titanate, basic magnesium sulfate, sepiolite, xonotlite, aluminum borate), glass beads, silica beads, alumina beads, carbon beads, glass hollow spheres, carbon, magnetic fillers, piezoelectric-pyroelectric fillers, sliding fillers, fillers for sealing materials, ultraviolet absorbing fillers, vibration-damping fillers, and conductive fillers (ketjen black and acetylene black). These may be used alone or in combination of two or more.

The bulk density of the component (b) is 0.8g/mL or less, preferably 0.7g/mL or less, and more preferably 0.5g/mL or less. (b) When the bulk density of the component is 0.8g/mL or less, the conveying ability when supplied from the side feeder is lowered, and the effect of the present invention is exhibited.

The bulk density of the component (b) can be measured by a Powder characteristic evaluation apparatus (Powder Tester PT-X, manufactured by Hosokawa micron Co.).

The amount of the component (b) supplied from 1 downstream supply port is 15 to 35 mass%, preferably 15 to 30 mass%, and more preferably 15 to 25 mass% with respect to the total amount (100 mass%) of the raw materials.

When the amount of the (b) powdery reinforcing agent supplied from 1 downstream supply port is 35% by mass or more based on the total amount of the raw materials, the amount of gas entrained when supplying the (b) component into the extruder increases, and the (b) component is difficult to be fed into the extruder and the conveying ability is lowered, and therefore, stable supply cannot be achieved. On the other hand, if the amount of the powdery reinforcing agent (b) supplied from 1 downstream supply port is less than 15 mass% based on the total amount of the raw materials, the amount of entrained gas is reduced when the component (b) is supplied into the extruder, and the problem that the component (b) is difficult to be fed into the extruder does not occur easily, and therefore the effect of the present invention is difficult to be exerted.

The total amount of the component (b) to be supplied is 15 to 50% by mass, preferably 15 to 45% by mass, and more preferably 15 to 40% by mass, based on the total amount (100% by mass) of the raw materials.

The feed material 2 of the present embodiment may contain, in addition to the component (b), a plasticizer, a stabilizer such as an antioxidant and an ultraviolet absorber, an antistatic agent, a releasing agent, an additive such as a dye-pigment, a resin other than the above, a reinforcing agent other than the component (b) such as glass fiber and glass flake, and the like.

The content of the other components in 100 mass% of the 2 nd feed material is preferably 55 mass% or less.

In the method for producing the resin composition of the present embodiment, (d) the condensed phosphoric ester may be further added using a charge pump.

- (d) condensed phosphoric acid ester-

The raw material of the present embodiment may contain (d) a condensed phosphate ester-based flame retardant (in the present specification, may be simply referred to as "component (d)") for the purpose of imparting flame retardancy to the obtained resin composition.

The component (d) preferably contains at least one selected from the group consisting of condensed phosphates represented by the following formulae (3) and (4) as a main component in the condensed phosphate-based flame retardant.

The term "main component" as used herein means that the component (d) contains 90% by mass or more, preferably 95% by mass or more, and more preferably 100% by mass.

[ solution 3]

[ solution 4]

In the formulae (3) and (4), Q¹、Q²、Q³And Q⁴Each independently represents an alkyl group having 1 to 6 carbon atoms, R⁵And R⁶Represents a methyl group, R⁷And R⁸Each independently represents a hydrogen atom or a methyl group.

n is an integer of 0 or more, n¹And n²Each independently an integer of 0 to 2, m¹、m²、m³And m⁴Each independently an integer of 0 to 3.

In the formulae (3) and (4), n is an integer of 0 or more, preferably an integer of 1 to 3.

Among them, the following condensed phosphoric esters are more preferably contained in an amount of 50% by mass or more in total: r in the formula (3)⁷And R⁸Represents a methyl group, m¹、m²、m³、m⁴、n¹And n²A condensed phosphoric ester of 0; and Q in the formula (3)¹、Q²、Q³、Q⁴、R⁷And R⁸Represents a methyl group, n¹And n²Is 0, m¹、m²、m³And m⁴The condensed phosphoric ester is an integer of 1 to 3, wherein n is an integer of 1 to 3, and particularly a phosphoric ester in which n is 1.

By using these condensed phosphoric esters, the volatility of the resin composition during molding can be further reduced.

The amount of the component (d) to be supplied is preferably 2 to 25% by mass, more preferably 3 to 20% by mass, and still more preferably 5 to 15% by mass, based on the total amount of the raw materials (100% by mass), from the viewpoint of reducing the melt viscosity in the extruder and suppressing the increase in torque of the main screw of the extruder.

Other raw materials-

In the raw materials of the present embodiment, additives such as a plasticizer, a stabilizer such as an antioxidant and an ultraviolet absorber, an antistatic agent, a releasing agent, a dye-pigment, and other resins than those described above may be further added to impart other characteristics to the obtained resin composition.

The additive may be contained in the 1 st feed material and/or the 2 nd feed material as described above, or may be supplied from a supply port different from the supply port through which the 1 st feed material or the 2 nd feed material is supplied.

In order to further improve the mechanical properties, a reinforcing agent other than the component (b) may be used in combination, and examples thereof include glass fibers and glass flakes.

The reinforcing agent other than the component (b) may be contained in the 2 nd supply material as described above, or may be supplied from a supply port different from the supply port for supplying the 1 st supply material or the 2 nd supply material.

The amount of the other raw materials to be supplied may be 30% by mass or less based on the total amount (100% by mass) of the raw materials.

< resin composition >

The resin composition of the present embodiment is produced by the method for producing a resin composition of the present embodiment, and is produced by melt-kneading raw materials of the resin composition using the extruder.

The resin composition produced by the method for producing a resin composition according to the present embodiment contains (a) a powdery polyphenylene ether resin and (b) a powdery reinforcing agent, and may contain (c) a polystyrene resin, (d) a condensed phosphate ester, and other raw materials, as necessary.