Method for producing thermoplastic resin composition

文档序号：1431801 发布日期：2020-03-17 浏览：15次中文

阅读说明：本技术 热塑性树脂组合物的制造方法 (Method for producing thermoplastic resin composition ) 是由泽田广树吉村忠德坪井智也平井丈士尾之上昭弘于 2018-07-13 设计创作，主要内容包括：本发明提供一种热塑性树脂组合物的制造方法,该热塑性树脂组合物能够用作支撑材料用的三维造型用可溶性材料的材料,能够容易地控制重均分子量,即使用于利用FDM方式的3D打印机制造三维物体也具有充分的强度,着色少且外观品质也很优异,并且,在中性水中的溶解速度快,能够不使用强碱水溶液地快速地从三维物体前体除去。本发明的热塑性树脂组合物的制造方法是含有热塑性树脂的热塑性树脂组合物的制造方法,该热塑性树脂具有源自二羧酸成分的二羧酸单体单元,在该二羧酸单体单元中,源自具有磺酸基和/或磺酸盐基的芳香族二羧酸成分的芳香族二羧酸单体单元的比例为10mol％以上,该热塑性树脂组合物的制造方法包括混合下述通式(I)所示的有机盐化合物的工序。(R1-SO3-)nXn+ (I)。(The invention provides a method for producing a thermoplastic resin composition which can be used as a material for a soluble material for three-dimensional modeling for a support material, can easily control a weight average molecular weight, has sufficient strength even when used for producing a three-dimensional object by a 3D printer of FDM system, is less colored, has excellent appearance quality, andmoreover, the resin composition has a high dissolution rate in neutral water, and can be quickly removed from a three-dimensional object precursor without using a strong alkali aqueous solution. The method for producing a thermoplastic resin composition of the present invention is a method for producing a thermoplastic resin composition containing a thermoplastic resin having dicarboxylic acid monomer units derived from a dicarboxylic acid component, wherein the proportion of aromatic dicarboxylic acid monomer units derived from an aromatic dicarboxylic acid component having a sulfonic acid group and/or a sulfonate group in the dicarboxylic acid monomer units is 10 mol% or more, the method comprising a step of mixing an organic salt compound represented by the following general formula (I). (R) 1 ‑SO 3 ‑ ) n X n+ (I)。)

1. A method for producing a thermoplastic resin composition, characterized in that,

the thermoplastic resin composition contains a thermoplastic resin having dicarboxylic acid monomer units derived from a dicarboxylic acid component, wherein the proportion of aromatic dicarboxylic acid monomer units derived from an aromatic dicarboxylic acid component having a sulfonic acid group and/or a sulfonate group in the dicarboxylic acid monomer units is 10 mol% or more,

the method for producing the thermoplastic resin composition comprises a step of mixing an organic salt compound represented by the following general formula (I),

(R¹-SO₃ ^-)_nXⁿ⁺(I)

in the general formula (I), R¹Represents an optionally substituted hydrocarbon group having 1 to 30 carbon atoms, n represents a number of 1 or 2, and when n is 1, Xⁿ⁺Represents sodium ion, potassium ion, lithium ion, ammonium ion or phosphonium ion, and when n is 2, X isⁿ⁺Represents magnesium ion, calcium ion, barium ion or zinc ion.

2. The method of producing a thermoplastic resin composition according to claim 1,

the organic salt compound is added in a molar ratio of 0.005 or more to the total of the aromatic dicarboxylic acid monomer units derived from the aromatic dicarboxylic acid component having a sulfonic acid group and/or a sulfonate group.

3. The method of producing a thermoplastic resin composition according to claim 1 or 2,

the thermoplastic resin is polyester resin or polyamide resin.

4. The method of producing a thermoplastic resin composition according to claim 3,

the thermoplastic resin is produced by mixing the organic salt compound and reacting the dicarboxylic acid component with a diol component or a diamine component.

5. The method for producing a thermoplastic resin composition according to any one of claims 1 to 4,

the organic salt compound is added at the time of polymerization of the thermoplastic resin.

6. The method for producing a thermoplastic resin composition according to any one of claims 1 to 5,

the ratio of the amount of substances of the aromatic dicarboxylic acid monomer units derived from the aromatic dicarboxylic acid component having a sulfonic acid group and/or a sulfonate group in the polyester resin to the total amount of substances of all monomer units of the polyester resin is 10 mol% or more and 70 mol% or less.

7. The method for producing a thermoplastic resin composition according to any one of claims 1 to 6,

the ratio of the amount of substance of the aromatic dicarboxylic acid monomer units derived from the aromatic dicarboxylic acid component having a sulfonic acid group and/or a sulfonate group in the polyamide resin to the total amount of substance of all monomer units of the polyamide resin is 2.5 mol% or more and 40 mol% or less.

8. The method for producing a thermoplastic resin composition according to any one of claims 1 to 7,

the sum of the sulfonic acid group content and the sulfonate group content in the thermoplastic resin is 0.5mmol/g to 3.0 mmol/g.

9. The method for producing a thermoplastic resin composition according to any one of claims 1 to 8,

the weight average molecular weight of the thermoplastic resin is 3000-70000.

10. The method for producing a thermoplastic resin composition according to any one of claims 1 to 9,

the phosphonium ion is a tetraalkylphosphonium ion.

11. The method for producing a thermoplastic resin composition according to any one of claims 1 to 10,

the mass ratio of the organic salt compound to the thermoplastic resin is 0.5 to 30.

12. The method for producing a thermoplastic resin composition according to any one of claims 1 to 11,

alkylsulfonic acid ion (R) of the organic salt compound¹-SO₃ ^-) The ratio of the amount (mol) of the substance(s) of (a) to the amount (mol) of the substance(s) of the hydrophilic group(s) of the thermoplastic resin (the amount of the substance(s) of the alkylsulfonic acid ion(s) of the organic salt compound/the amount of the substance(s) of the hydrophilic group(s) of the thermoplastic resin) is 0.005 to 1.0.

Technical Field

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

Background

The 3D printer is one of Rapid Prototyping (Rapid Prototyping), and is a three-dimensional printer for molding a three-dimensional object based on 3D data such as 3D CAD and 3D CG. As a 3D printer system, a thermal fusion deposition system (hereinafter, also referred to as an FDM system), an inkjet ultraviolet curing system, a photo-modeling system, a laser sintering system, and the like are known. The FDM method is a method of molding a three-dimensional object by heating/melt-extruding and laminating polymer filaments, and is disadvantageous in terms of material reaction, unlike other methods. Therefore, the FDM type 3D printer is small and inexpensive, and has become popular in recent years as a device with less post-processing. In this FDM method, in order to mold a three-dimensional object having a more complicated shape, a three-dimensional object precursor can be obtained by laminating a molding material constituting the three-dimensional object and a support material for supporting a three-dimensional structure of the molding material, and then removing the support material from the three-dimensional object precursor, thereby obtaining a target three-dimensional object.

As a method of removing the support material from the three-dimensional object precursor, the following methods can be cited: the support material is removed by immersing the three-dimensional object precursor in an aqueous solution of a strong alkali using a methacrylic acid copolymer (for example, Japanese patent application laid-open No. 2008-507619). The method utilizes the property that carboxylic acid in methacrylic acid copolymer is neutralized by alkali and dissolved in strong alkali aqueous solution.

When the methacrylic acid copolymer disclosed in japanese patent application laid-open No. 2008-507619 is used as a support material, it is necessary to use a strong alkaline aqueous solution in order to remove the support material from the three-dimensional object precursor, but the strong alkaline aqueous solution is dangerous to the human body and places a heavy burden on the environment. Further, when the three-dimensional object precursor is immersed in a strong alkaline aqueous solution for a long period of time, the three-dimensional object in the three-dimensional object precursor tends to be corroded by an alkali, and the use of a polyester resin such as polylactic acid (PLA) having low resistance to an alkali as a material for the three-dimensional object is limited. Therefore, a support material capable of being removed by neutral water having a pH of 6 to 8 in a non-alkali aqueous solution is required.

The following method is disclosed in Japanese patent application laid-open No. 2002-516346: the support material is removed by immersing the three-dimensional object precursor in water using water-soluble poly (2-ethyl-2-oxazoline). According to the method described in japanese patent application laid-open No. 2002-516346, although the support material of the three-dimensional object precursor can be removed without using a strong alkali aqueous solution, the poly (2-ethyl-2-oxazoline) contained in the soluble material for three-dimensional modeling has a high affinity for moisture, and therefore, the soluble material for three-dimensional modeling containing the poly (2-ethyl-2-oxazoline) absorbs moisture in the air when exposed to high humidity. When a soluble material for three-dimensional modeling containing water-containing poly (2-ethyl-2-oxazoline) or the like is heated, melted, extruded, and laminated by a 3D printer of the FDM method, foaming may occur due to evaporation of the water at high temperature, and dimensional accuracy of a three-dimensional object may be significantly impaired (in this specification, dimensional accuracy is also simply referred to as "accuracy").

In view of the above problems, the inventors of the present application have made a patent application for an invention of a soluble material for three-dimensional modeling for a support material which is suitable for producing a three-dimensional object by FDM method, has moisture absorption resistance, has a high dissolution rate in neutral water, and can be quickly removed from a three-dimensional object precursor without using a strong alkali aqueous solution (japanese patent application laid-open No. 2017-30346).

Disclosure of Invention

The method for producing a thermoplastic resin composition of the present invention comprises a step of mixing an organic salt compound represented by the following general formula (I) with a thermoplastic resin containing dicarboxylic acid monomer units derived from a dicarboxylic acid component, wherein the proportion of aromatic dicarboxylic acid monomer units derived from an aromatic dicarboxylic acid component having a sulfonic acid group and/or a sulfonate group in the dicarboxylic acid monomer units is 10 mol% or more.

(R¹-SO₃ ^-)_nXⁿ⁺(I)

(in the above general formula (I), R¹Represents an optionally substituted hydrocarbon group having 1 to 30 carbon atoms, n represents a number of 1 or 2, and when n is 1, Xⁿ⁺Represents sodium ion, potassium ion, lithium ion, ammonium ion or phosphonium ion, and when n is 2, X isⁿ⁺Represents magnesium ion, calcium ion, barium ion or zinc ion. )

Drawings

FIG. 1 is a graph plotting the power consumption of the blender and the weight average molecular weight of the sample.

FIG. 2 is a diagram showing the hue of the evaluation sample of the example.

Fig. 3 is a diagram showing the hue of an evaluation sample of a comparative example.

FIG. 4 is a diagram showing the hues of the evaluation samples of the examples and comparative examples.

Detailed Description

When a thermoplastic resin such as a polyester resin or a polyamide resin is used as a material of the soluble material for three-dimensional modeling, the thermoplastic resin preferably has a weight average molecular weight of at least a certain degree in order to exhibit strength such as toughness required for the soluble material for three-dimensional modeling, but on the other hand, if the weight average molecular weight is large, the dissolution rate in neutral water becomes small, and it tends to be difficult to rapidly remove the support material from the three-dimensional object precursor. That is, it is important to control the weight average molecular weight of the thermoplastic resin used as a material for the three-dimensional molding soluble material during production. In addition, from the viewpoint of improving the performance, a thermoplastic resin composition having high solubility in neutral water even when the molecular weight is further increased is desired.

As a method for controlling the weight average molecular weight in the production of the thermoplastic resin, a method of controlling the weight average molecular weight using stirring torque as an index can be considered, but since the viscosity rapidly increases as the polycondensation proceeds and it is difficult to stir uniformly even with high stirring power, no correlation between the stirring torque and the weight average molecular weight is found, and it is difficult to control the weight average molecular weight by this method. Further, since the stirring is not uniform, there is a problem that the by-product cannot be smoothly discharged out of the system and the weight average molecular weight is difficult to increase to a certain degree or more. In order to avoid these problems, a method of lowering the viscosity by raising the reaction temperature is conceivable, but this is not preferable because it causes thermal deterioration of the product.

As another method for controlling the weight average molecular weight in the production of the thermoplastic resin, a method of performing a condensation reaction at a low temperature and measuring the weight average molecular weight by appropriately sampling the thermoplastic resin may be considered, but this method is not practical because of the cost.

In addition, polyester resins and polyamide resins, which are thermoplastic resins, may be colored during production, and this coloring is caused by kneading at high temperatures or a long thermal history, and the color changes irreversibly from yellow to brown. Once coloring occurs, recovery by filtration, decoloration, purification, and the like is difficult, and coloring is not preferable from the viewpoint of appearance and quality of a product as a 3D printer support material. In addition, in order to improve removability of the support material of the three-dimensional object precursor, the support material may be intentionally colored to make it easy to visually distinguish the modeling material from the support material, but if coloring is present during production of the thermoplastic resin, the soluble material for three-dimensional modeling containing the thermoplastic resin cannot be colored arbitrarily, which is not preferable.

The present invention provides a method for producing a thermoplastic resin composition which can be used as a material for a soluble material for three-dimensional modeling for a support material, can easily control a weight average molecular weight, has sufficient strength even when used for producing a three-dimensional object by a 3D printer of FDM system, has a high dissolution rate in neutral water, can be quickly removed from a three-dimensional object precursor without using a strong alkali aqueous solution, and is less colored and excellent in appearance quality.

(R¹-SO₃ ^-)_nXⁿ⁺(I)

According to the present invention, there can be provided a method for producing a thermoplastic resin composition which can be used as a material for a soluble material for three-dimensional modeling for a support material, can easily control a weight average molecular weight, has sufficient strength even when used for producing a three-dimensional object by a 3D printer of FDM system, has a high dissolution rate in neutral water, can be quickly removed from a three-dimensional object precursor without using a strong alkali aqueous solution, is less colored, and has excellent appearance quality.

Next, an embodiment of the present invention will be explained.

< method for producing thermoplastic resin composition >

In the method for producing a thermoplastic resin composition of the present embodiment, the thermoplastic resin composition contains a thermoplastic resin having dicarboxylic acid monomer units derived from a dicarboxylic acid component, and the proportion of aromatic dicarboxylic acid monomer units derived from an aromatic dicarboxylic acid component having a sulfonic acid group and/or a sulfonate group in the dicarboxylic acid monomer units is 10 mol% or more, and the method for producing a thermoplastic resin composition includes a step of mixing an organic salt compound represented by the following general formula (I).

(R¹-SO₃ ^-)_nXⁿ⁺(I)

According to the method for producing a thermoplastic resin composition of the present embodiment, a thermoplastic resin composition used as a material of a soluble material for three-dimensional modeling for a support material can be provided, a weight average molecular weight can be easily controlled, a sufficient strength can be obtained even when the thermoplastic resin composition is used for producing a three-dimensional object by a 3D printer of FDM system, the dissolution rate in neutral water is high, the thermoplastic resin composition can be quickly removed from a three-dimensional object precursor without using a strong alkali aqueous solution, coloring is little, and appearance quality is excellent.

[ thermoplastic resin ]

The thermoplastic resin has dicarboxylic acid monomer units derived from a dicarboxylic acid component. The dicarboxylic acid monomer unit contains an aromatic dicarboxylic acid monomer unit derived from an aromatic dicarboxylic acid component having a sulfonic acid group and/or a sulfonate group, from the viewpoint of solubility in neutral water having a pH of 6 to 8 in a non-alkaline aqueous solution. Hereinafter, in the present specification, a dicarboxylic acid monomer unit derived from a dicarboxylic acid component is referred to as a dicarboxylic acid monomer unit a, and a dicarboxylic acid component for deriving the dicarboxylic acid monomer unit a is referred to as a dicarboxylic acid component a. In the monomer unit a, an aromatic dicarboxylic acid monomer unit derived from an aromatic dicarboxylic acid component having a sulfonic acid group and/or a sulfonate group is referred to as a dicarboxylic acid monomer unit a, and an aromatic dicarboxylic acid component from which the dicarboxylic acid monomer unit a is derived is referred to as an aromatic dicarboxylic acid component a.

[ dicarboxylic acid monomer units A ]

(dicarboxylic acid monomer unit a)

The sulfonate group is preferably-SO from the viewpoint of solubility in neutral water and the viewpoint of easiness of polymerization reaction in producing a thermoplastic resin₃M³(wherein, M³The counter ion representing the sulfonic acid group constituting the sulfonate group is preferably at least one or more selected from the group consisting of sodium ion, potassium ion, lithium ion, calcium ion, magnesium ion, ammonium ion, barium ion, and zinc ion, more preferably at least one or more selected from the group consisting of sodium ion, potassium ion, lithium ion, magnesium ion, and ammonium ion, even more preferably at least one or more selected from the group consisting of sodium ion and potassium ion, and even more preferably sodium ion) from the viewpoint of solubility in neutral water.

The aromatic dicarboxylic acid component a is at least one member selected from the group consisting of aromatic dicarboxylic acids containing sulfonic acid groups and aromatic dicarboxylic acids containing sulfonic acid groups. From the viewpoint of solubility in neutral water, moisture absorption resistance, heat resistance required for 3D printer formation, and ease of polymerization reaction in the production of a thermoplastic resin, the aromatic dicarboxylic acid component a is preferably at least one or more selected from the group consisting of 5-sulfoisophthalic acid, 2-sulfoterephthalic acid, and 4-sulfo-2, 6-naphthalenedicarboxylic acid, more preferably at least one or more selected from the group consisting of 5-sulfoisophthalic acid and 2-sulfoterephthalic acid, and even more preferably 5-sulfoisophthalic acid.

The proportion of the dicarboxylic acid monomer unit a in the dicarboxylic acid monomer unit a is 10 mol% or more, preferably 16 mol% or more, more preferably 20 mol% or more, and even more preferably 23 mol% or more from the viewpoint of solubility in neutral water, and is preferably 90 mol% or less, more preferably 80 mol% or less, even more preferably 70 mol% or less, and even more preferably 65 mol% or less from the viewpoint of moisture absorption resistance and heat resistance required for molding by a 3D printer. The proportion of the dicarboxylic acid monomer unit a in the dicarboxylic acid monomer unit a is preferably 10 to 90 mol%, more preferably 16 to 80 mol%, even more preferably 20 to 70 mol%, and even more preferably 23 to 65 mol%, from the viewpoints of solubility in neutral water, moisture absorption resistance, heat resistance required for molding with a 3D printer, and ease of polymerization reaction in the production of a thermoplastic resin.

The total of the content of the sulfonic acid group and the content of the sulfonate group in the thermoplastic resin is preferably 0.5mmol/g or more, more preferably 0.6mmol/g or more, further preferably 0.7mmol/g or more, from the viewpoint of solubility in neutral water, and is preferably 3.0mmol/g or less, more preferably 1.5mmol/g or less, further preferably 1.0mmol/g or less, from the viewpoint of moisture absorption resistance. In addition, from the viewpoint of solubility in neutral water and the viewpoint of moisture absorption resistance, the total of the content of the sulfonic acid group and the content of the sulfonate group in the thermoplastic resin is preferably 0.5 to 3.0mmol/g, more preferably 0.6 to 1.5mmol/g, and still more preferably 0.7 to 1.0 mmol/g.

The dicarboxylic acid monomer units a other than the dicarboxylic acid monomer units a are not particularly limited, and dicarboxylic acid monomer units derived from a dicarboxylic acid component having no hydrophilic group are preferable from the viewpoint of moisture absorption resistance and heat resistance required for molding with a 3D printer. Hereinafter, in the present specification, a dicarboxylic acid monomer unit derived from a dicarboxylic acid component having no hydrophilic group is referred to as a dicarboxylic acid monomer unit B, and a dicarboxylic acid component from which the dicarboxylic acid monomer unit B is derived is referred to as a dicarboxylic acid component B.

Examples of the hydrophilic group include a primary amino group, a secondary amino group, a tertiary amino group, a quaternary ammonium salt group, an oxyethylene group, a hydroxyl group, a carboxyl group, a carboxylate group, a phosphoric acid group, and a phosphate group.

The dicarboxylic acid component B is not particularly limited as long as it is a dicarboxylic acid having no hydrophilic group, and is preferably at least one selected from aromatic dicarboxylic acids, aliphatic dicarboxylic acids, and alicyclic dicarboxylic acids from the viewpoint of moisture absorption resistance, heat resistance required for molding by a 3D printer, and easiness of polymerization reaction in producing a polyester resin. Among these, from the same viewpoint, at least one or more selected from the group consisting of terephthalic acid, isophthalic acid, 2, 5-furandicarboxylic acid, 2, 6-naphthalenedicarboxylic acid, 1, 4-cyclohexanedicarboxylic acid and 1, 3-adamantanedicarboxylic acid is more preferable, at least one or more selected from the group consisting of terephthalic acid, 2, 5-furandicarboxylic acid and 2, 6-naphthalenedicarboxylic acid is further preferable, and 2, 6-naphthalenedicarboxylic acid is further preferable.

From the viewpoint of solubility in neutral water, moisture absorption resistance, heat resistance required for 3D printer molding, and ease of polymerization reaction in the production of a thermoplastic resin, the proportion of the amount of the substance of the dicarboxylic acid monomer unit a in the thermoplastic resin to the total amount of the substances of all the monomer units in the thermoplastic resin is preferably 5 mol% or more, more preferably 8 mol% or more, further preferably 10 mol% or more, preferably 45 mol% or less, more preferably 35 mol% or less, and further preferably 30 mol% or less. In addition, from the viewpoint of solubility in neutral water, moisture absorption resistance, heat resistance required for 3D printer molding, and ease of polymerization reaction in the production of the thermoplastic resin, the proportion of the amount of the substance of the dicarboxylic acid monomer unit a in the thermoplastic resin to the total amount of the substances of all the monomer units in the thermoplastic resin is preferably 5 to 45 mol%, more preferably 8 to 40 mol%, and still more preferably 10 to 35 mol%.

The proportion of the amount of the substance of the dicarboxylic acid monomer unit B in the thermoplastic resin to the total amount of the substances of all the monomer units in the thermoplastic resin is preferably 5 mol% or more, more preferably 15 mol% or more, and still more preferably 20 mol% or more from the viewpoint of moisture absorption resistance, and is preferably 45 mol% or less, more preferably 42 mol% or less, and still more preferably 40 mol% or less from the viewpoint of solubility in neutral water. From the viewpoint of moisture absorption resistance and solubility in neutral water, the ratio of the amount of substance of the dicarboxylic acid monomer units B in the thermoplastic resin to the total amount of substance of all the monomer units in the thermoplastic resin is preferably 5 to 45 mol%, more preferably 15 to 42 mol%, and still more preferably 20 to 40 mol%.

In addition, a modeling material having high heat resistance generally has a high melting point or a high glass transition temperature, but when there is a significant difference between the temperature at which the above modeling material is heated/melt extruded and laminated by a 3D printer and the temperature of a support material that contacts the modeling material, the accuracy of the three-dimensional object may be impaired. Therefore, in the case where a modeling material having a high melting point or glass transition temperature is heated/melt-extruded and laminated by a 3D printer, a soluble material for three-dimensional modeling as a material of the support material is also heated/melt-extruded and laminated at a temperature close to that of the modeling material. In this case, the soluble material for three-dimensional modeling, which is a material that can be removed by neutral water having a pH of 6 to 8 in a non-alkali aqueous solution and is used as a support material, preferably has a high melting point or a high glass transition temperature. Therefore, the thermoplastic resin is preferably at least one selected from the group consisting of polyester resins, polyamide resins, acrylic resins, polyvinyl alcohol resins, polyvinyl pyrrolidone resins, ester amide resins, and polyurethane resins, and more preferably at least one selected from the group consisting of polyester resins and polyamide resins.

[ polyester resin ]

The polyester resin may be exemplified by a polyester resin having the dicarboxylic acid monomer unit a and the diol monomer unit.

(diol monomer Unit)

The polyester resin has a diol monomer unit. The diol from which the above diol monomer units are derived is also referred to as diol C.

The diol C is not particularly limited, and aliphatic diols, aromatic diols, and the like can be used, and aliphatic diols are preferred from the viewpoint of the production cost of the polyester resin.

The number of carbon atoms of the diol C is preferably 2 or more from the viewpoint of solubility in neutral water, resistance to moisture absorption, and heat resistance required for molding by a 3D printer, and from the same viewpoint, is preferably 31 or less, more preferably 25 or less, further preferably 20 or less, and still further preferably 15 or less.

The aliphatic diol includes at least one or more selected from chain diols and cyclic diols, and chain diols are preferable from the viewpoint of solubility in neutral water, resistance to moisture absorption, and toughness (strength) required for 3D printer molding.

The chain diol preferably has 2 or more carbon atoms from the viewpoint of solubility in neutral water, resistance to moisture absorption, and heat resistance required for molding by a 3D printer, and from the same viewpoint, preferably has 6 or less, more preferably 4 or less, and still more preferably 3 or less.

The cyclic diol has preferably 6 or more carbon atoms, and from the same viewpoint of solubility in neutral water, resistance to moisture absorption, and heat resistance required for molding by a 3D printer, preferably 31 or less, more preferably 30 or less, and even more preferably 27 or less.

The diol C may have an ether oxygen, but in the case where the diol C is a chain aliphatic diol, the amount of the ether oxygen is preferably 1 or less from the viewpoint of solubility in neutral water, resistance to moisture absorption, and heat resistance required for molding by a 3D printer, and in the case where the diol C is a cyclic aliphatic diol, the amount of the ether oxygen is preferably 2 or less from the same viewpoint.

From the viewpoint of solubility in neutral water, resistance to moisture absorption, and heat resistance required for molding by a 3D printer, the chain diol is preferably at least one or more selected from the group consisting of ethylene glycol, 1, 2-propanediol, 1, 3-propanediol, diethylene glycol, and dipropylene glycol, and more preferably at least one or more selected from the group consisting of ethylene glycol, diethylene glycol, 1, 2-propanediol, and 1, 3-propanediol. Among them, diethylene glycol and dipropylene glycol may be charged as a raw material for polymerization reaction, or may be by-products during polymerization reaction.

From the viewpoint of solubility in neutral water, resistance to moisture absorption, and heat resistance required for molding by a 3D printer, the cyclic diol is preferably at least one member selected from the group consisting of 1, 4-cyclohexanedimethanol, hydrogenated bisphenol a, isosorbide anhydride, bisphenoxyethanol fluorene, bisphenol fluorene, bismethylphenoxyethanol fluorene, and bismethylphenol fluorene.

When the diol C is at least one member selected from the group consisting of ethylene glycol, 1, 2-propylene glycol, 1, 3-propylene glycol, diethylene glycol, dipropylene glycol, 1, 4-cyclohexanedimethanol, hydrogenated bisphenol a, isosorbide, bisphenoxyethanol fluorene, bisphenol fluorene, bismethylphenoxyethanol fluorene and bismethylphenol fluorene, the ratio of the total of ethylene glycol, 1, 2-propylene glycol, 1, 3-propylene glycol, diethylene glycol, dipropylene glycol, 1, 4-cyclohexanedimethanol, hydrogenated bisphenol a, isosorbide anhydride, bisphenoxyethanol fluorene, bisphenol fluorene, bismethylphenoxy ethanol fluorene and bismethylphenol fluorene to the total of all diol monomer units in the polyester resin is preferably 80 mol% or more from the viewpoints of solubility in neutral water, resistance to moisture absorption and heat resistance required for molding by a 3D printer, more preferably 90 mol% or more, still more preferably 95 mol% or more, still more preferably 98 mol% or more, still more preferably substantially 100 mol%, and still more preferably 100 mol%.

The polyester resin can be exemplified by the following general formulae (II) and (III).

(in the above general formula (II), p1 represents the number of degrees of polymerization of ethylene 2, 6-naphthalate and q1 represents the number of degrees of polymerization of ethylene 5-sulfoisophthalate, wherein ethylene 2, 6-naphthalate and ethylene 5-sulfoisophthalate are block-bonded and/or randomly-bonded, and random-bonded is more preferable from the viewpoint of solubility in neutral water.)

(in the general formula (III), p2 represents the number of polymerization degrees of ethylene 2, 6-naphthalate, q2 represents the number of polymerization degrees of ethylene 5-sulfoisophthalate, r2 represents the number of polymerization degrees of a condensate of bisphenoxyethanolfluorene and 2, 6-naphthalenedicarboxylic acid, and s2 represents the number of polymerization degrees of a condensate of bisphenoxyethanolfluorene and 5-sulfoisophthalic acid, wherein the condensates of ethylene 2, 6-naphthalate, ethylene 5-sulfoisophthalate, bisphenoxyethanolfluorene and 2, 6-naphthalenedicarboxylic acid, and bisphenoxyethanolfluorene and 5-sulfoisophthalic acid are block-bonded and/or randomly bonded, and more preferably randomly bonded from the viewpoint of solubility in neutral water.)

[ Polyamide resin ]

The polyamide resin may be a polyamide resin having the dicarboxylic acid monomer unit a and the diamine monomer unit.

(diamine monomer Unit)

The polyamide resin has a diamine monomer unit. The diamine from which the diamine monomer units are derived is also referred to as diamine C.

The diamine C is not particularly limited, and at least one or more selected from aliphatic diamines, alicyclic diamines, and aromatic diamines can be used, and aliphatic diamines are preferable from the viewpoint of ease of polymerization reaction in the production of a polyamide resin.

The number of carbon atoms of the diamine C is preferably 2 or more, more preferably 3 or more, and even more preferably 4 or more from the viewpoint of solubility in neutral water, moisture absorption resistance, heat resistance required for molding with a 3D printer, and ease of polymerization reaction in the production of a polyamide resin, and is preferably 20 or less, more preferably 15 or less, and even more preferably 10 or less from the viewpoint of solubility in neutral water, moisture absorption resistance, and heat resistance required for molding with a 3D printer.

Examples of the aliphatic diamine include ethylenediamine, trimethylenediamine, tetramethylenediamine, pentamethylenediamine, hexamethylenediamine, heptamethylenediamine, octamethylenediamine, nonanediamine, and decanediamine. Among them, hexamethylenediamine is preferable from the viewpoint of solubility in neutral water, resistance to moisture absorption, and toughness (strength) required for molding by a 3D printer.

Examples of the alicyclic diamine include 4,4 '-diamino-3, 3' -dimethyldicyclohexylmethane, diaminocyclohexane, isophoronediamine, and the like. Among them, from the viewpoint of solubility in neutral water, resistance to moisture absorption, and toughness (strength) required for molding by a 3D printer, at least one or more selected from the group consisting of diamine cyclohexane and isophorone diamine is preferable, and at least one or more selected from the group consisting of diamine cyclohexane is more preferable.

Examples of the aromatic diamine include phenylenediamine, diethyltoluenediamine, and 4, 4' -diaminodiphenylmethane. Among them, from the viewpoint of solubility in neutral water, resistance to moisture absorption, and toughness (strength) required for molding by a 3D printer, at least one or more selected from phenylenediamine and diethyltoluenediamine is preferable, and at least one or more selected from phenylenediamine is more preferable.

The diamine C is preferably at least one or more selected from hexamethylenediamine, diaminocyclohexane, and phenylenediamine, more preferably at least one or more selected from hexamethylenediamine and phenylenediamine, and even more preferably hexamethylenediamine, from the viewpoints of solubility in neutral water, resistance to moisture absorption, and toughness (strength) required for molding by a 3D printer.

When the diamine C is at least one selected from the group consisting of hexamethylenediamine, diaminocyclohexane, and phenylenediamine, the ratio of the total amount of substances of hexamethylenediamine, diaminocyclohexane, and phenylenediamine to the total amount of substances of all diamine monomer units in the polyamide resin is preferably 50 mol% or more, more preferably 70 mol% or more, even more preferably 80 mol% or more, even more preferably 90 mol% or more, even more preferably substantially 100 mol%, and even more preferably 100 mol%, from the viewpoints of solubility in neutral water, resistance to moisture absorption, and heat resistance required for molding by a 3D printer. The term "substantially 100 mol% means that the composition contains a substance other than hexamethylenediamine, diaminocyclohexane, and phenylenediamine, which are inevitably mixed.

The polyamide resin can be exemplified by the following general formulae (IV) to (IX).

(in the general formula (IV), p3 and q3 each represent a number of degrees of polymerization, each polymer is a block bond and/or a random bond, and the random bond is more preferable from the viewpoint of solubility in neutral water.)

(in the above general formula (V), p4 and q4 each represent a number of degrees of polymerization, and each polymer is a block bond and/or a random bond, and is more preferably a random bond from the viewpoint of solubility in neutral water.)

(in the above general formula (VI), p5 and q5 each represent a number of degrees of polymerization, and each polymer is a block bond and/or a random bond, and is more preferably a random bond from the viewpoint of solubility in neutral water.)

(in the above general formula (VII), p6 and q6 each represent a number of degrees of polymerization, and each polymerization is a block bond and/or a random bond, and is more preferably a random bond from the viewpoint of solubility in neutral water.)

(in the above general formula (VIII), p7 and q7 each represent a number of degrees of polymerization, and each polymer is a block bond and/or a random bond, and is more preferably a random bond from the viewpoint of solubility in neutral water.)

(in the general formula (IX), p8 and q8 each represent a number of degrees of polymerization. each polymer is a block bond and/or a random bond, and is more preferably a random bond from the viewpoint of solubility in neutral water.)

The thermoplastic resin may have monomer units other than the monomer unit a, the diol unit, and the diamine monomer unit, within a range in which the effects of the present embodiment are not impaired.

The weight average molecular weight of the thermoplastic resin is preferably 3000 or more, more preferably 10000 or more, and further preferably 16000 or more from the viewpoint of improving toughness required for the soluble material for three-dimensional modeling, and is preferably 70000 or less, more preferably 50000 or less, further preferably 40000 or less, and further preferably 35000 or less from the viewpoint of solubility in neutral water and modeling performance by a 3D printer. In the present specification, the weight average molecular weight is measured by the method described in examples.

From the viewpoint of moldability by a 3D printer, the glass transition temperature (Tg) of the thermoplastic resin is 50 ℃ or higher, preferably 60 ℃ or higher, more preferably 70 ℃ or higher, and still more preferably 80 ℃ or higher, and from the same viewpoint, 250 ℃ or lower, preferably 220 ℃ or lower, more preferably 180 ℃ or lower, still more preferably 160 ℃ or lower, still more preferably 140 ℃ or lower, and still more preferably 120 ℃ or lower. In the present specification, the glass transition temperature is measured by the method described in examples.

From the viewpoint of moldability by a 3D printer, the content of the thermoplastic resin in the thermoplastic resin composition is preferably 70% by mass or more, more preferably 80% by mass or more, preferably 95% by mass or less, and more preferably 90% by mass or less.

[ organic salt Compound ]

In the general formula (I), R is selected from the viewpoint of controlling the molecular weight during production, suppressing coloration, solubility in neutral water, moisture absorption resistance, and heat resistance required for molding by a 3D printer¹The hydrocarbon group may have a substituent and has 1 to 30 carbon atoms including the substituent. The hydrocarbon group may be any of an aliphatic hydrocarbon group, an alicyclic hydrocarbon group, and an aromatic hydrocarbon group. When the hydrocarbon group is an aliphatic hydrocarbon group, the number of carbon atoms of the hydrocarbon group is preferably 1 or more, more preferably 4 or more, further preferably 8 or more, preferably 30 or less, more preferably 25 or less, and further preferably 20 or less, from the viewpoint of suppression of coloring, solubility in neutral water, moisture absorption resistance, and heat resistance required for molding by a 3D printer. In the case where the hydrocarbon group is an alicyclic hydrocarbon group, the number of carbon atoms of the hydrocarbon group is preferably 3 or more, more preferably 5 or more, further preferably 6 or more, further preferably 10 or more, preferably 30 or less, more preferably 25 or less, and further preferably 20 or less, from the viewpoint of suppression of coloring, solubility in neutral water, resistance to moisture absorption, and heat resistance required for molding by a 3D printer. In the case where the hydrocarbon group is an aromatic hydrocarbon group, the number of carbon atoms of the hydrocarbon group is preferably 6 or more, more preferably 8 or more, further preferably 10 or more, and preferably 30 or more, from the viewpoint of controlling the molecular weight at the time of production, suppressing coloring, solubility in neutral water, moisture absorption resistance, and heat resistance required for molding by a 3D printerThe lower limit is more preferably 25 or less.

The substituent preferably contains at least one member selected from the group consisting of a carbon atom, an oxygen atom, a nitrogen atom, a sulfur atom, a phosphorus atom, a silicon atom and a halogen atom, among them, a hydrocarbon group having 1 to 22 carbon atoms or a haloalkyl group having 1 to 22 carbon atoms is preferable, a hydrocarbon group having 1 to 16 carbon atoms or a haloalkyl group having 1 to 22 carbon atoms is more preferable, a hydrocarbon group having 1 to 12 carbon atoms is even more preferable, and a hydrocarbon group having 1 to 12 carbon atoms is even more preferable, from the viewpoint of controlling the molecular weight during production, from the viewpoint of suppressing coloring, from the viewpoint of solubility in neutral water, from the viewpoint of moisture absorption resistance, and from the viewpoint of heat resistance required for molding by a 3D printer.

In the general formula (I), X is selected from the viewpoint of controlling the molecular weight during production, suppressing coloration, solubility in neutral water, moisture absorption resistance, and heat resistance required for molding by a 3D printerⁿ⁺The ion means a sodium ion, a potassium ion, a lithium ion, an ammonium ion, a phosphonium ion, a magnesium ion, a calcium ion, a barium ion, a zinc ion or a phosphonium ion, preferably a sodium ion, a potassium ion, a lithium ion, a magnesium ion, an ammonium ion or a phosphonium ion, more preferably a sodium ion, a lithium ion, an ammonium ion or a phosphonium ion, further preferably a lithium ion or a phosphonium ion, and further preferably a phosphonium ion. Among the phosphonium ions, tetraalkylphosphonium ions are preferable, and tetrabutylphosphonium ion is more preferable, from the viewpoint of controlling the molecular weight at the time of production, suppressing coloring, from the viewpoint of solubility in neutral water, from the viewpoint of moisture absorption resistance, and from the viewpoint of heat resistance required for molding by a 3D printer.

In the general formula (I), n is preferably 1 from the viewpoint of controlling the molecular weight at the time of production, suppressing coloring, solubility in neutral water, moisture absorption resistance, and heat resistance required for molding by a 3D printer.

The method for producing a thermoplastic resin according to the present embodiment includes a step of mixing the organic salt compound, and a conventionally known method for producing a thermoplastic resin can be applied. For example, in the case where the thermoplastic resin is the polyester resin, the polyester resin is produced by a two-stage process as follows: in the first stage, the two carboxylic acid component a two methyl ester, two methyl terephthalate and the two carboxylic acid component B alkyl ester and the glycol C in the presence of ester exchange catalyst under normal pressure heating, so as to generate ester exchange reaction; in the second stage, the reaction product obtained by the atmospheric reaction is heated under reduced pressure in the presence of a polymerization catalyst to cause polycondensation reaction until the desired weight average molecular weight is reached. In addition to carrying out these reactions in the presence of the above organic salt compounds, a conventionally known method for producing a polyester resin can be applied.

In the production of the polyester resin, the timing of adding the organic salt compound is not particularly limited, but from the viewpoint of handling during production and the viewpoint of controlling the weight average molecular weight, the organic salt compound is preferably added before the start of the reduced pressure reaction, and from the viewpoint of suppressing the decomposition of the organic salt compound by the thermal history, the organic salt compound is preferably added during the normal pressure reaction, and more preferably added immediately before the start of the reduced pressure reaction.

The polyester resin is produced by heating under reduced pressure in the presence of a catalyst to perform a reduced-pressure reaction, and performing a polycondensation reaction until a desired weight-average molecular weight is reached, which can be grasped by detecting the viscosity of the reaction product in the reduced-pressure reaction. As a method for detecting the melt viscosity of the reaction product, a method of measuring the load on a stirrer that stirs at the time of reduced pressure reaction can be cited. In the conventional method for producing a polyester resin, the polyester resin tends to be rapidly thickened in the decompression reaction, and the load applied to the stirrer tends not to be constant. Therefore, in the method of detecting the melt viscosity of the reaction product, it is difficult to adjust the weight average molecular weight of the polyester resin used for the soluble material for three-dimensional modeling to a preferable weight average molecular weight, but rapid thickening of the polyester resin can be suppressed by performing the reduced pressure reaction in the presence of the organic salt compound, and the viscosity of the reaction product containing the polyester resin increases as polymerization of the polyester resin proceeds, so that it is easier to grasp the weight average molecular weight of the polyester resin by the viscosity of the reaction product than in the prior art, and the weight average molecular weight of the polyester resin used for the soluble material for three-dimensional modeling can be easily adjusted to a preferable weight average molecular weight.

The addition of the organic salt compound is preferably an alkylsulfonic acid ion (R) of the organic salt compound, from the viewpoint of solubility in neutral water, easy control of the weight average molecular weight of the thermoplastic resin during production, and suppression of coloring¹-SO₃ ^-) The amount of the substance(s) to be added is preferably 0.35 or less, more preferably 0.25 or less, and still more preferably 0.2 or less, from the viewpoint of solubility in neutral water and the viewpoint of heat resistance required for the 3D printer configuration, from the viewpoint of solubility in neutral water and from the viewpoint of heat resistance required for the 3D printer configuration.

The thermoplastic resin composition has moisture absorption resistance and a high dissolution rate in neutral water.

< soluble Material for three-dimensional Molding >

The soluble material for three-dimensional modeling of the present embodiment is a thermoplastic resin composition obtained by the above-described production method.

The soluble material for three-dimensional modeling may contain other components within a range not to impair the effects of the present embodiment. Examples of the other component include polymers other than the above thermoplastic resins, plasticizers such as polyalkylene glycol benzoate diesters, fillers such as calcium carbonate, magnesium carbonate, glass spheres, graphite, carbon black, carbon fibers, glass fibers, talc, wollastonite, mica, alumina, silica, kaolin, whiskers, and silicon carbide, compatibilizers, and elastomers.

From the viewpoint of moldability by a 3D printer, the glass transition temperature of the soluble material for three-dimensional molding is preferably 50 ℃ or higher, more preferably 60 ℃ or higher, further preferably 70 ℃ or higher, and further preferably 80 ℃ or higher, and from the same viewpoint, preferably 250 ℃ or lower, more preferably 220 ℃ or lower, and further preferably 200 ℃ or lower.

The method for producing the soluble material for three-dimensional modeling is not particularly limited, and the soluble material can be produced by a known method. Examples of the method for producing the soluble material for three-dimensional modeling include a method in which a raw material such as the thermoplastic resin composition is kneaded by a kneader such as a batch kneader or a twin-screw extruder.

The shape of the soluble material for three-dimensional modeling is not particularly limited, and examples thereof include granular, powdery, and filamentous materials, and the material is preferably filamentous from the viewpoint of modeling performance by a 3D printer.

From the viewpoint of moldability by a 3D printer and improvement in the precision of a three-dimensional object, the diameter of the wire is preferably 0.5mm or more, more preferably 1.0mm or more, and from the same viewpoint, preferably 3.0mm or less, more preferably 2.0mm or less, and further preferably 1.8mm or less. In the case of producing a yarn, it is preferable to perform drawing from the viewpoint of improving toughness. From the viewpoint of achieving both of the improvement of toughness and water solubility, the stretching ratio in the stretching process is preferably 1.5 times or more, more preferably 2 times or more, further preferably 3 times or more, and further preferably 5 times or more, and from the same viewpoint, preferably 200 times or less, more preferably 150 times or less, further preferably 100 times or less, and further preferably 50 times or less. The stretching temperature in the stretching process is preferably in a range from a temperature lower than the glass transition temperature of the soluble material for three-dimensional modeling by 20 ℃ to a temperature higher than the glass transition temperature by 110 ℃. From the viewpoint of improving toughness and thermal stability, the lower limit of the stretching temperature is more preferably a temperature lower than the glass transition temperature by 10 ℃, and still more preferably the same temperature as the glass transition temperature. From the same viewpoint, the upper limit of the stretching temperature is preferably a temperature higher than the glass transition temperature by 110 ℃, more preferably a temperature higher than the glass transition temperature by 100 ℃, and still more preferably a temperature higher than the glass transition temperature by 90 ℃. The stretching may be performed while air-cooling the resin discharged from the extruder, or may be performed by heating with hot air or a laser. The drawing may be performed at a predetermined draw ratio and a predetermined yarn diameter by one-step drawing, or may be performed at a predetermined draw ratio and a predetermined yarn diameter by multi-step drawing.

< method for producing three-dimensional object >

The method for manufacturing a three-dimensional object according to the present embodiment is a method for manufacturing a three-dimensional object by a thermal fusion deposition method, and includes: obtaining a three-dimensional object precursor having a three-dimensional object and a support material; and a support material removing step of contacting the three-dimensional object precursor with neutral water to remove the support material. The material of the support material is the soluble material for three-dimensional modeling. According to the method for producing a three-dimensional object, the three-dimensional object can be rapidly dissolved in neutral water while suppressing a decrease in the precision of the three-dimensional object, and can be rapidly removed from the three-dimensional object precursor without using a strong alkali aqueous solution.

[ procedure for obtaining a three-dimensional object precursor having a three-dimensional object and a support Material ]

As the step of obtaining the three-dimensional object precursor having the three-dimensional object and the support material, in addition to the point that the material of the support material is the soluble material for three-dimensional modeling, the step of obtaining the three-dimensional object precursor having the three-dimensional object and the support material can be obtained by a known method of manufacturing a three-dimensional object by a 3D printer of a thermal fusion deposition method.

The molding material as the material of the three-dimensional object is not particularly limited as long as it is a resin that can be used as a molding material in the conventional method for producing a three-dimensional object by the FDM method. Examples of the molding material include thermoplastic resins such as ABS resin, PP resin, ASA resin, PS resin, HIPS resin, PVC resin, polylactic acid resin, polycarbonate resin, polyamide resin, polyetherimide resin, polyetheretherketone resin, and polyphenylsulfone resin, and from the viewpoint of moldability in a 3D printer, more preferably at least one selected from the group consisting of ABS resin, polylactic acid resin, polycarbonate resin, and polyamide resin, and still more preferably at least one selected from the group consisting of ABS resin, polycarbonate resin, and polyamide resin.

The glass transition temperature of the support material used in the step of obtaining the three-dimensional object precursor is preferably (the glass transition temperature of the modeling material used is-20 ℃) to (the glass transition temperature of the modeling material used is +20 ℃) and more preferably (the glass transition temperature of the modeling material used is-15 ℃) to (the glass transition temperature of the modeling material used is +15 ℃) from the viewpoint of modeling properties by a 3D printer.

[ support material removal step of contacting the three-dimensional object precursor with neutral water to remove the support material ]

In the support material removing step, the support material is removed by bringing the three-dimensional object precursor into contact with neutral water. From the viewpoint of cost and ease of handling, the method of bringing the three-dimensional object precursor into contact with neutral water is preferably a method of immersing the three-dimensional object precursor in neutral water. From the viewpoint of improving the removability of the support material, it is also possible to irradiate ultrasonic waves during immersion to promote dissolution of the support material.

[ neutral Water ]

Examples of the neutral water include ion-exchanged water, purified water, tap water, and industrial water, and from the viewpoint of economy, ion-exchanged water and tap water are preferable. The neutral water may contain a water-soluble organic solvent within a range that does not damage the three-dimensional object after the modeling. Examples of the water-soluble organic solvent include lower alcohols such as methanol, ethanol and 2-propanol, glycol ethers such as propylene glycol monomethyl ether, ethylene glycol monoethyl ether, ethylene glycol tert-butyl ether and diethylene glycol monobutyl ether, and ketones such as acetone and methyl ethyl ketone. When the neutral water contains the water-soluble organic solvent, the content of the water-soluble organic solvent in the neutral water is preferably 0.1% by mass or more, more preferably 0.5% by mass or more, further preferably 1% by mass or more, further preferably 3% by mass or more, and preferably 50% by mass or less, preferably 40% by mass or less, more preferably 30% by mass or less, further preferably 20% by mass or less, from the viewpoint of solubility and damage to the three-dimensional object after the formation.

The amount of the neutral water to be used is preferably 10 times by mass or more, more preferably 20 times by mass or more, relative to the support material, from the viewpoint of solubility of the support material, and is preferably 10000 times by mass or less, more preferably 5000 times by mass or less, further preferably 1000 times by mass or less, and further preferably 100 times by mass or less, relative to the support material, from the viewpoint of economy.

The time for bringing the soluble material for three-dimensional modeling into contact with neutral water is preferably 5 minutes or longer from the viewpoint of removability of the support material, and is preferably 180 minutes or shorter, more preferably 120 minutes or shorter, and even more preferably 90 minutes or shorter from the viewpoint of reducing damage to the three-dimensional object due to contact with neutral water for a long time and from the viewpoint of economy. The cleaning temperature varies depending on the type of the molding material, and is preferably 15 ℃ or higher, more preferably 25 ℃ or higher, further preferably 30 ℃ or higher, and further preferably 40 ℃ or higher, from the viewpoint of removability of the support material, reduction of damage to the three-dimensional object, and from the viewpoint of economy, and is preferably 85 ℃ or lower, more preferably 70 ℃ or lower, and further preferably 60 ℃ or lower from the same viewpoint.

< support Material >

The support material of the present embodiment is a support material that supports a three-dimensional object when the three-dimensional object is produced by a 3D printer of a hot melt deposition method, and contains the thermoplastic resin composition. The support material has sufficient strength, little coloration, excellent appearance quality, and high dissolution rate in neutral water, and can be quickly removed from a three-dimensional object precursor without using a strong alkaline aqueous solution.

< thermoplastic resin composition >

The thermoplastic resin composition of the present embodiment contains a thermoplastic resin having a sulfonic acid group and/or a sulfonate group, and an organic salt compound represented by the following general formula (I).

(R¹-SO₃ ^-)_nXⁿ⁺(I)

[ thermoplastic resin ]

[ dicarboxylic acid monomer units A ]

(dicarboxylic acid monomer unit a)

The sulfonate group is preferably-SO from the viewpoint of solubility in neutral water and the ease of polymerization reaction in the production of a thermoplastic resin₃M³(wherein, M³The counter ion representing the sulfonic acid group constituting the sulfonate group is preferably at least one or more selected from the group consisting of sodium ion, potassium ion, lithium ion, calcium ion, magnesium ion, ammonium ion, barium ion, and zinc ion, more preferably at least one or more selected from the group consisting of sodium ion, potassium ion, lithium ion, magnesium ion, and ammonium ion, even more preferably at least one or more selected from the group consisting of sodium ion and potassium ion, and even more preferably sodium ion) from the viewpoint of solubility in neutral water.

The proportion of the dicarboxylic acid monomer unit a in the dicarboxylic acid monomer unit a is preferably 10 mol% or more, more preferably 16 mol% or more, still more preferably 20 mol% or more, and still more preferably 23 mol% or more from the viewpoint of solubility in neutral water, and is preferably 90 mol% or less, more preferably 80 mol% or less, still more preferably 70 mol% or less, and still more preferably 65 mol% or less from the viewpoint of moisture absorption resistance and heat resistance required for molding by a 3D printer. The proportion of the dicarboxylic acid monomer unit a in the dicarboxylic acid monomer unit a is preferably 10 to 90 mol%, more preferably 16 to 80 mol%, even more preferably 20 to 70 mol%, and even more preferably 23 to 65 mol%, from the viewpoints of solubility in neutral water, moisture absorption resistance, heat resistance required for molding with a 3D printer, and ease of polymerization reaction in the production of a thermoplastic resin.

[ polyester resin ]

The polyester resin may be exemplified by a polyester resin having the dicarboxylic acid monomer unit a and the diol monomer unit.

From the viewpoint of solubility in neutral water, resistance to moisture absorption, and heat resistance required for molding by a 3D printer, the proportion of the amount of substance of the dicarboxylic acid monomer unit a in the polyester resin to the total amount of substance of all monomer units of the polyester resin is preferably 10 mol% or more, more preferably 20 mol% or more, and from the same viewpoint, is preferably 70 mol% or less, more preferably 65 mol% or less, further preferably 60 mol% or less, further preferably 40 mol% or less, and further preferably 27 mol% or less.

From the viewpoint of solubility in neutral water, resistance to moisture absorption, and heat resistance required for molding by a 3D printer, the proportion of the amount of substance of the dicarboxylic acid monomer units B in the polyester resin to the total amount of substance of all the monomer units in the polyester resin is preferably 30 mol% or more, more preferably 35 mol% or more, further preferably 40 mol% or more, further preferably 65 mol% or more, further preferably 73 mol% or more, and from the same viewpoint, preferably 90 mol% or less, and more preferably 80 mol% or less.

(diol monomer Unit)

The polyester resin has a diol monomer unit. The diol from which the above diol monomer units are derived is also referred to as diol C.

The polyester resin can be exemplified by the following general formulae (II) and (III).

[ Polyamide resin ]

The polyamide resin may be a polyamide resin having the dicarboxylic acid monomer unit a and the diamine monomer unit.

From the viewpoint of solubility in neutral water, the proportion of the amount of substance of the dicarboxylic acid monomer units a in the polyamide resin to the total amount of substance of all the monomer units of the polyamide resin is 2.5 mol% or more, preferably 4 mol% or more, more preferably 6 mol% or more, further preferably 8 mol% or more, and further preferably 10 mol% or more, and from the viewpoint of moisture absorption resistance, 40 mol% or less, preferably 35 mol% or less, more preferably 31 mol% or less, further preferably 25 mol% or less, further preferably 20 mol% or less, further preferably 15 mol% or less, further preferably 10 mol% or less, and further preferably 8 mol% or less.

From the viewpoint of moisture absorption resistance, the proportion of the amount of the substance of the dicarboxylic acid monomer unit B in the polyamide resin to the total amount of the substances of all the monomer units in the polyamide resin is preferably 10 mol% or more, more preferably 20 mol% or more, further preferably 30 mol% or more, further preferably 35 mol% or more, further preferably 40 mol% or more, and further preferably 42 mol% or more, and from the viewpoint of solubility in neutral water, is preferably 47.5 mol% or less, more preferably 45 mol% or less, further preferably 42 mol% or less, and further preferably 40 mol% or less.

(diamine monomer Unit)

The polyamide resin has a diamine monomer unit. The diamine from which the diamine monomer units are derived is also referred to as diamine C.

The polyamide resin can be exemplified by the following general formulae (IV) to (IX).

[ organic salt Compound ]

In the general formula (I), R is selected from the viewpoint of controlling the molecular weight during production, suppressing coloration, solubility in neutral water, moisture absorption resistance, and heat resistance required for molding by a 3D printer¹The hydrocarbon group may have a substituent and has 1 to 30 carbon atoms including the substituent. The hydrocarbon group may be any of an aliphatic hydrocarbon group, an alicyclic hydrocarbon group, and an aromatic hydrocarbon group. When the hydrocarbon group is an aliphatic hydrocarbon group, the number of carbon atoms of the hydrocarbon group is preferably 1 or more, more preferably 4 or more, further preferably 8 or more, preferably 30 or less, more preferably 25 or less, and further preferably 20 or less, from the viewpoint of suppression of coloring, solubility in neutral water, moisture absorption resistance, and heat resistance required for molding by a 3D printer. In the case where the hydrocarbon group is an alicyclic hydrocarbon group, the number of carbon atoms of the hydrocarbon group is preferably 3 or more, more preferably 5 or more, further preferably 6 or more, further preferably 10 or more, preferably 30 or less, more preferably 25 or less from the viewpoint of suppression of coloring, solubility in neutral water, moisture absorption resistance, and heat resistance required for molding by a 3D printer,more preferably 20 or less. When the hydrocarbon group is an aromatic hydrocarbon group, the number of carbon atoms of the hydrocarbon group is preferably 6 or more, more preferably 8 or more, further preferably 10 or more, preferably 30 or less, and more preferably 25 or less, from the viewpoint of controlling the molecular weight at the time of production, suppressing coloring, solubility in neutral water, moisture absorption resistance, and heat resistance required for molding by a 3D printer.

The mass ratio of the organic salt compound to the thermoplastic resin is preferably 0.5 or more, more preferably 2 or more, and still more preferably 6 or more from the viewpoint of improving adhesiveness to a molding material, and is preferably 30 or less, more preferably 20 or less, and still more preferably 15 or less from the viewpoint of solubility in neutral water, moisture absorption resistance, and heat resistance required for molding by a 3D printer.

The alkylsulfonic acid ion (R) of the organic salt compound is selected from the group consisting of alkyl sulfonic acid ion (R) of the organic salt compound, and alkyl sulfonic acid ion (R) of the organic salt compound, from the viewpoints of¹-SO₃ ^-) The ratio of the amount of substance(s) (i.e., the amount of substance(s) of alkylsulfonic acid ions of the organic salt compound/the total amount of substance(s) of sulfonic acid groups and substance(s) of sulfonate groups of the thermoplastic resin) to the total amount of substance(s) (i.e., the amount of substance(s) of alkylsulfonic acid ions of the organic salt compound/the total amount of substance(s) of sulfonate groups and substance(s) of sulfonate groups of the thermoplastic resin) is preferably 0.005 or more, more preferably 0.01 or more, still more preferably 0.02 or more, and still more preferably 0.03 or more, and from the viewpoint of solubility in neutral water and the viewpoint of heat resistance required for molding by a 3D printer, is preferably 0.35 or less, more preferably 0.25.

In the thermoplastic resin composition, from the viewpoint of solubility in neutral water and moisture absorption resistance, the dicarboxylic acid monomer unit a, the dicarboxylic acid monomer unit B, the diol monomer unit, and the organic salt compound are preferably 10 to 30 mol%, the dicarboxylic acid monomer unit B is preferably 20 to 40 mol%, the diol monomer unit is preferably 40 to 60 mol%, and the organic salt compound is preferably 0.05 to 2 mol%, based on the total ratio of the amounts of the dicarboxylic acid monomer unit a, the dicarboxylic acid monomer unit B, the diol monomer unit, and the organic salt compound to the total amount of the substances of all the monomer units of the thermoplastic resin.

The thermoplastic resin composition has moisture absorption resistance and a high dissolution rate in neutral water. Therefore, the thermoplastic resin composition can be used as a material for a soluble material for three-dimensional modeling for a support material, and the thermoplastic resin composition has a high dissolution rate in neutral water, can be quickly removed from a three-dimensional object precursor without using a strong alkaline aqueous solution, is less colored, and has excellent appearance quality.

< soluble Material for three-dimensional Molding >

The soluble material for three-dimensional modeling of the present embodiment is the thermoplastic resin composition described above.

The method for producing the soluble material for three-dimensional modeling is not particularly limited, and the soluble material can be produced by a known method. Examples of the method for producing the soluble material for three-dimensional modeling include a method in which the raw materials such as the thermoplastic resin composition are kneaded by a kneader such as a batch kneader or a twin-screw extruder.

< method for producing three-dimensional object >

[ procedure for obtaining a three-dimensional object precursor having a three-dimensional object and a support Material ]

[ support material removal step of contacting the three-dimensional object precursor with neutral water to remove the support material ]

[ neutral Water ]

< support Material >

With respect to the above embodiments, the present specification further discloses the following compositions and methods of manufacture.

A method for producing a thermoplastic resin composition containing a thermoplastic resin having dicarboxylic acid monomer units A derived from a dicarboxylic acid component, wherein the proportion of aromatic dicarboxylic acid monomer units a derived from an aromatic dicarboxylic acid component a having a sulfonic acid group and/or a sulfonate group in the dicarboxylic acid monomer units A is 10 mol% or more, the method comprising a step of mixing an organic salt compound represented by the following general formula (I).

(R¹-SO₃ ^-)_nXⁿ⁺(I)

<2>According to<1>The method for producing a thermoplastic resin composition, wherein the sulfonate group is preferably-SO₃M³(wherein, M³The counter ion representing the sulfonic acid group constituting the sulfonate group is preferably at least one or more selected from the group consisting of sodium ion, potassium ion, lithium ion, calcium ion, magnesium ion, ammonium ion, barium ion, and zinc ion, more preferably at least one or more selected from the group consisting of sodium ion, potassium ion, lithium ion, magnesium ion, and ammonium ion, even more preferably at least one or more selected from the group consisting of sodium ion and potassium ion, and even more preferably sodium ion).

<3> the method for producing a thermoplastic resin composition according to <1> or <2>, wherein the aromatic dicarboxylic acid component a is preferably at least one or more selected from the group consisting of 5-sulfoisophthalic acid, 2-sulfoterephthalic acid and 4-sulfo-2, 6-naphthalenedicarboxylic acid, more preferably at least one or more selected from the group consisting of 5-sulfoisophthalic acid and 2-sulfoterephthalic acid, and even more preferably 5-sulfoisophthalic acid.

<4> the method for producing a thermoplastic resin composition according to any one of <1> to <3>, wherein the proportion of the dicarboxylic acid monomer unit a in the dicarboxylic acid monomer unit A is 10 mol% or more, preferably 16 mol% or more, more preferably 20 mol% or more, further preferably 23 mol% or more, preferably 90 mol% or less, more preferably 80 mol% or less, further preferably 70 mol% or less, further preferably 65 mol% or less, preferably 10 to 90 mol%, more preferably 16 to 80 mol%, further preferably 20 to 70 mol%, further preferably 23 to 65 mol%.

<5> the method for producing a thermoplastic resin composition according to any one of <1> to <4>, wherein the total of the content of the sulfonic acid group and the content of the sulfonate group in the thermoplastic resin is preferably 0.5mmol/g or more, more preferably 0.6mmol/g or more, further preferably 0.7mmol/g or more, preferably 3.0mmol/g or less, more preferably 1.5mmol/g or less, further preferably 1.0mmol/g or less, preferably 0.5 to 3.0mmol/g, more preferably 0.6 to 1.5mmol/g, further preferably 0.7 to 1.0 mmol/g.

<6> the method for producing a thermoplastic resin composition according to any one of <1> to <5>, wherein the dicarboxylic acid monomer units B having a dicarboxylic acid component derived from a dicarboxylic acid component having no hydrophilic group, the dicarboxylic acid component B from which the dicarboxylic acid monomer units B are derived is preferably at least one or more selected from the group consisting of aromatic dicarboxylic acids, aliphatic dicarboxylic acids and alicyclic dicarboxylic acids, more preferably at least one or more selected from the group consisting of terephthalic acid, isophthalic acid, 2, 5-furandicarboxylic acid, 2, 6-naphthalenedicarboxylic acid, 1, 4-cyclohexanedicarboxylic acid and 1, 3-adamantanedicarboxylic acid, still more preferably at least one or more selected from the group consisting of terephthalic acid, 2, 5-furandicarboxylic acid and 2, 6-naphthalenedicarboxylic acid, and still more preferably 2, 6-naphthalenedicarboxylic acid.

<7> the method for producing a thermoplastic resin composition according to any one of <1> to <6>, wherein the ratio of the amount of the substance of the dicarboxylic acid monomer unit a in the thermoplastic resin to the total amount of the substances of all the monomer units in the thermoplastic resin is preferably 5 mol% or more, more preferably 8 mol% or more, further preferably 10 mol% or more, preferably 45 mol% or less, more preferably 35 mol% or less, further preferably 30 mol% or less, preferably 5 to 45 mol%, more preferably 8 to 40 mol%, and further preferably 10 to 35 mol%.

<8> the method for producing a thermoplastic resin composition according to any one of <1> to <7>, wherein the ratio of the amount of the substance of the dicarboxylic acid monomer units B in the thermoplastic resin to the total amount of the substances of all the monomer units in the thermoplastic resin is preferably 5 mol% or more, more preferably 15 mol% or more, further preferably 20 mol% or more, preferably 45 mol% or less, more preferably 42 mol% or less, further preferably 40 mol% or less, preferably 5 to 45 mol%, more preferably 15 to 42 mol%, and further preferably 20 to 40 mol%.

<9> the method for producing a thermoplastic resin composition according to any one of <1> to <8>, wherein the thermoplastic resin is preferably at least one selected from the group consisting of polyester resins, polyamide resins, acrylic resins, polyvinyl alcohol resins, polyvinyl pyrrolidone resins, ester amide resins, and polyurethane resins, and more preferably at least one selected from the group consisting of polyester resins and polyamide resins.

<10> the method for producing a thermoplastic resin composition according to any one of <1> to <9>, wherein the polyester resin is represented by the following general formulae (II) and (III).

(in the general formula (III), p2 represents the number of polymerization degrees of ethylene 2, 6-naphthalate, q2 represents the number of polymerization degrees of ethylene 5-sulfoisophthalate, r2 represents the number of polymerization degrees of a condensate of bisphenoxyethanolfluorene and 2, 6-naphthalenedicarboxylic acid, and s2 represents the number of polymerization degrees of a condensate of bisphenoxyethanolfluorene and 5-sulfoisophthalic acid, wherein the condensate of ethylene 2, 6-naphthalate, ethylene 5-sulfoisophthalate, bisphenoxyethanolfluorene and 2, 6-naphthalenedicarboxylic acid, and bisphenoxyethanolfluorene and 5-sulfoisophthalic acid is block-bonded and/or randomly-bonded, more preferably randomly-bonded.)

<11> the method for producing a thermoplastic resin composition according to any one of <1> to <10>, wherein the polyamide resin is represented by the following general formulae (IV) to (IX).

(in the general formula (IV), p3 and q3 each represent a number of degrees of polymerization, and each polymerization is a block bond and/or a random bond, more preferably a random bond.)

(in the above general formula (V), p4 and q4 each represent a number of degrees of polymerization, and each polymerization is a block bond and/or a random bond, more preferably a random bond.)

(in the above general formula (VI), p5 and q5 each represent a number of degrees of polymerization, and each polymerization is a block bond and/or a random bond, more preferably a random bond.)

(in the general formula (VII), p6 and q6 each represent a number of degrees of polymerization, and each polymerization is a block bond and/or a random bond, more preferably a random bond.)

(in the above general formula (VIII), p7 and q7 each represent a number of degrees of polymerization, and each polymerization is a block bond and/or a random bond, more preferably a random bond.)

(in the general formula (IX), p8 and q8 each represent a number of degrees of polymerization, and each polymerization is a block bond and/or a random bond, more preferably a random bond.)

<12> the method for producing a thermoplastic resin composition according to any one of <1> to <11>, wherein the weight average molecular weight of the thermoplastic resin is preferably 3000 or more, more preferably 10000 or more, further preferably 16000 or more, preferably 70000 or less, more preferably 50000 or less, further preferably 40000 or less, and further preferably 35000 or less.

<13> the method for producing a thermoplastic resin composition according to any one of <1> to <12>, wherein the glass transition temperature (Tg) of the thermoplastic resin is 50 ℃ or more, preferably 60 ℃ or more, more preferably 70 ℃ or more, further preferably 80 ℃ or more, and 250 ℃ or less, preferably 220 ℃ or less, more preferably 180 ℃ or less, further preferably 160 ℃ or less, further preferably 140 ℃ or less, and further preferably 120 ℃ or less.

<14> the method for producing a thermoplastic resin composition according to any one of <1> to <13>, wherein the content of the thermoplastic resin in the thermoplastic resin composition is preferably 70% by mass or more, more preferably 80% by mass or more, preferably 95% by mass or less, more preferably 90% by mass or less.

<15>According to<1>～<14>The method for producing a thermoplastic resin composition according to any of the above methods, wherein in the general formula (I), Xⁿ⁺Represents a sodium ion, a potassium ion, a lithium ion, an ammonium ion, a phosphonium ion, a magnesium ion, a calcium ion, a barium ion, a zinc ion or a phosphonium ion, preferably a sodium ion, a potassium ion, a lithium ion, a magnesium ion, an ammonium ion or a phosphonium ion, more preferably a sodium ion, a lithium ion, an ammonium ion or a phosphonium ion, further preferably a lithium ion or a phosphonium ion, further preferably a phosphonium ion, and among the phosphonium ions, a tetraalkylphosphonium ion is preferred, and a tetrabutylphosphonium ion is more preferred.

<16> the method for producing a thermoplastic resin composition according to any one of <1> to <15>, wherein the thermoplastic resin is the polyester resin, and the polyester resin is produced by a two-stage process, wherein in a first stage, an alkyl ester of the dicarboxylic acid component B such as dimethyl ester of the dicarboxylic acid component a having a sulfonate group, dimethyl terephthalate and the like and the diol C are heated at normal pressure in the presence of a transesterification catalyst to cause transesterification, and in a second stage, a reaction product obtained by the normal pressure reaction is heated at reduced pressure in the presence of a polymerization catalyst to cause polycondensation until a desired weight average molecular weight is reached, and these reactions are carried out in the presence of the organic salt compound.

<17> the method for producing a thermoplastic resin composition according to any one of <1> to <16>, wherein the organic salt compound is added at a timing of producing the polyester resin, preferably during a normal pressure reaction, and more preferably immediately before a reduced pressure reaction is started.

<18>According to<1>～<17>The method for producing a thermoplastic resin composition according to any of the above methods, wherein the addition of the organic salt compound is preferably performed with an alkylsulfonic acid ion (R) of the organic salt compound¹-SO₃ ^-) The amount of the substance(s) to be added is 0.005 or more, more preferably 0.01 or more, still more preferably 0.02 or more, still more preferably 0.03 or more, yet more preferably 0.35 or less, still more preferably 0.25 or less, and yet more preferably 0.2 or less, based on the total amount of the substance(s) having a sulfonic acid group and the substance(s) having a sulfonate group in the thermoplastic resin (the amount of the substance(s) having an alkylsulfonic acid ion in the organic salt compound/the total amount of the substance(s) having a sulfonic acid group and the substance(s) having a sulfonate group in the thermoplastic resin).

<19> a soluble material for three-dimensional modeling, which comprises the thermoplastic resin composition obtained by the method for producing a thermoplastic resin composition according to any one of <1> to <18 >.

<20> the soluble material for three-dimensional modeling according to <19>, wherein the glass transition temperature of the soluble material for three-dimensional modeling is more preferably 60 ℃ or higher, still more preferably 70 ℃ or higher, still more preferably 80 ℃ or higher, preferably 250 ℃ or lower, still more preferably 220 ℃ or lower, and still more preferably 200 ℃ or lower.

<21> the dissolvable material for three-dimensional modeling according to <19> or <20>, wherein the dissolvable material for three-dimensional modeling is preferably in the form of a thread.

<22> the soluble material for three-dimensional modeling according to any one of <19> to <21>, wherein the diameter of the filament is preferably 0.5mm or more, more preferably 1.0mm or more, preferably 3.0mm or less, more preferably 2.0mm or less, and further preferably 1.8mm or less.

<23> a method for manufacturing a three-dimensional object by a thermal fusion deposition method, comprising: obtaining a three-dimensional object precursor having a three-dimensional object and a support material; and a support material removing step of removing the support material by bringing the three-dimensional object precursor into contact with neutral water, wherein the support material is the soluble material for three-dimensional modeling according to any one of <19> to <22 >.

<24> the method of <23>, wherein the molding material as the material of the three-dimensional object is preferably a thermoplastic resin such as an ABS resin, a PP resin, an ASA resin, a PS resin, a HIPS resin, a PVC resin, a polylactic acid resin, a polycarbonate resin, a polyamide resin, a polyetherimide resin, a polyetheretherketone resin, and a polyphenylsulfone resin, more preferably at least one selected from the group consisting of an ABS resin, a polylactic acid resin, a polycarbonate resin, and a polyamide resin, and still more preferably at least one selected from the group consisting of an ABS resin, a polycarbonate resin, and a polyamide resin.

<25> the method of producing a three-dimensional object according to <23> or <24>, wherein the glass transition temperature of the support material used in the step of obtaining the three-dimensional object precursor is preferably (the glass transition temperature of the modeling material used is-20 ℃) to (the glass transition temperature of the modeling material used is +20 ℃), and more preferably (the glass transition temperature of the modeling material used is-15 ℃) to (the glass transition temperature of the modeling material used is +15 ℃).

<26> the method of manufacturing a three-dimensional object according to any one of <23> to <25>, which comprises a support material removing step of immersing the three-dimensional object precursor in neutral water to dissolve and remove the support material.

<27> the method for producing a three-dimensional object according to any one of <23> to <26>, wherein the neutral water contains a water-soluble organic solvent.

<28> the method for producing a three-dimensional object according to any one of <23> to <27>, wherein the water-soluble organic solvent is preferably a lower alcohol such as methanol, ethanol, or 2-propanol, a glycol ether such as propylene glycol monomethyl ether, ethylene glycol monoethyl ether, ethylene glycol mono-t-butyl ether, or diethylene glycol monobutyl ether, or a ketone such as acetone or methyl ethyl ketone.

<29> the method of manufacturing a three-dimensional object according to any one of <23> to <28>, wherein a content of the water-soluble organic solvent in the neutral water is preferably 0.1% by mass or more, more preferably 0.5% by mass or more, further preferably 1% by mass or more, further preferably 3% by mass or more, and preferably 50% by mass or less, more preferably 40% by mass or less, further preferably 30% by mass or less, and further preferably 20% by mass or less.

<30> the method of manufacturing a three-dimensional object according to any one of <23> to <29>, wherein the amount of the neutral water used is preferably 10 times by mass or more, more preferably 20 times by mass or more, preferably 10000 times by mass or less, more preferably 5000 times by mass or less, further preferably 1000 times by mass or less, and further preferably 100 times by mass or less with respect to the supporting material.

<31> the method for producing a three-dimensional object according to any one of <23> to <30>, wherein the time for bringing the soluble material for three-dimensional modeling into contact with neutral water is preferably 5 minutes or longer, preferably 180 minutes or shorter, more preferably 120 minutes or shorter, and still more preferably 90 minutes or shorter.

<32> the method for producing a three-dimensional object according to any one of <23> to <31>, wherein the temperature of neutral water brought into contact with the soluble material for three-dimensional modeling is preferably 15 ℃ or higher, more preferably 25 ℃ or higher, further preferably 30 ℃ or higher, further preferably 40 ℃ or higher, preferably 85 ℃ or lower, more preferably 70 ℃ or lower, and further preferably 60 ℃ or lower.

<33> a thermoplastic resin composition comprising a thermoplastic resin having a sulfonic acid group and/or a sulfonate group, and an organic salt compound represented by the following general formula (I).

(R¹-SO₃ ^-)_nXⁿ⁺(I)

<34>According to<33>The thermoplastic resin composition, wherein, the sulfonate group is preferably-SO₃M³(wherein, M³The counter ion representing the sulfonic acid group constituting the sulfonate group is preferably at least one or more selected from the group consisting of sodium ion, potassium ion, lithium ion, calcium ion, magnesium ion, ammonium ion, barium ion, and zinc ion, more preferably at least one or more selected from the group consisting of sodium ion, potassium ion, lithium ion, magnesium ion, and ammonium ion, even more preferably at least one or more selected from the group consisting of sodium ion and potassium ion, and even more preferably sodium ion).

<35> the thermoplastic resin composition according to <33> or <34>, which comprises dicarboxylic acid monomer units A derived from a dicarboxylic acid component, wherein the proportion of aromatic dicarboxylic acid monomer units a derived from an aromatic dicarboxylic acid component a having a sulfonic acid group and/or a sulfonate group in the dicarboxylic acid monomer units A is 10 mol% or more.

<36> the thermoplastic resin composition according to any one of <33> to <35>, wherein the aromatic dicarboxylic acid component a is preferably at least one or more selected from the group consisting of 5-sulfoisophthalic acid, 2-sulfoterephthalic acid and 4-sulfo-2, 6-naphthalenedicarboxylic acid, more preferably at least one or more selected from the group consisting of 5-sulfoisophthalic acid and 2-sulfoterephthalic acid, and even more preferably 5-sulfoisophthalic acid.

<37> the thermoplastic resin composition according to any one of <33> to <35>, wherein the proportion of the dicarboxylic acid monomer unit a in the dicarboxylic acid monomer unit A is 10 mol% or more, preferably 16 mol% or more, more preferably 20 mol% or more, further preferably 23 mol% or more, preferably 90 mol% or less, more preferably 80 mol% or less, further preferably 70 mol% or less, further preferably 65 mol% or less, preferably 10 to 90 mol%, more preferably 16 to 80 mol%, further preferably 20 to 70 mol%, further preferably 23 to 65 mol%.

<38> the thermoplastic resin composition according to any one of <33> to <37>, wherein the total of the content of the sulfonic acid group and the content of the sulfonate group in the thermoplastic resin is preferably 0.5mmol/g or more, more preferably 0.6mmol/g or more, further preferably 0.7mmol/g or more, preferably 3.0mmol/g or less, more preferably 1.5mmol/g or less, further preferably 1.0mmol/g or less, preferably 0.5 to 3.0mmol/g, more preferably 0.6 to 1.5mmol/g, further preferably 0.7 to 1.0 mmol/g.

<39> the thermoplastic resin composition according to any one of <33> to <38>, wherein the dicarboxylic acid monomer units B having a dicarboxylic acid component derived from a dicarboxylic acid component having no hydrophilic group, the dicarboxylic acid component B from which the dicarboxylic acid monomer units B are derived is preferably at least one or more selected from the group consisting of aromatic dicarboxylic acids, aliphatic dicarboxylic acids, and alicyclic dicarboxylic acids, more preferably at least one or more selected from the group consisting of terephthalic acid, isophthalic acid, 2, 5-furandicarboxylic acid, 2, 6-naphthalenedicarboxylic acid, 1, 4-cyclohexanedicarboxylic acid, and 1, 3-adamantanedicarboxylic acid, further preferably at least one or more selected from the group consisting of terephthalic acid, 2, 5-furandicarboxylic acid, and 2, 6-naphthalenedicarboxylic acid, and further preferably 2, 6-naphthalenedicarboxylic acid.

<40> the thermoplastic resin composition according to any one of <33> to <39>, wherein the ratio of the amount of the substance of the dicarboxylic acid monomer unit a in the thermoplastic resin to the total amount of the substances of all the monomer units in the thermoplastic resin is preferably 5 mol% or more, more preferably 8 mol% or more, further preferably 10 mol% or more, preferably 45 mol% or less, more preferably 35 mol% or less, further preferably 30 mol% or less, preferably 5 to 45 mol%, more preferably 8 to 40 mol%, and further preferably 10 to 35 mol%.

<41> the thermoplastic resin composition according to any one of <33> to <40>, wherein the ratio of the amount of the substance of the dicarboxylic acid monomer units B in the thermoplastic resin to the total amount of the substances of all the monomer units in the thermoplastic resin is preferably 5 mol% or more, more preferably 15 mol% or more, further preferably 20 mol% or more, preferably 45 mol% or less, more preferably 42 mol% or less, further preferably 40 mol% or less, preferably 5 to 45 mol%, more preferably 15 to 42 mol%, and further preferably 20 to 40 mol%.

<42> the thermoplastic resin composition according to any one of <33> to <41>, wherein the thermoplastic resin is preferably at least one selected from the group consisting of polyester resins, polyamide resins, acrylic resins, polyvinyl alcohol resins, polyvinyl pyrrolidone resins, ester amide resins, and polyurethane resins, and more preferably at least one selected from the group consisting of polyester resins and polyamide resins.

<43> the thermoplastic resin composition according to any one of <33> to <42>, wherein the polyester resin is a polyester resin having the dicarboxylic acid monomer unit A and a diol monomer unit.

<44> the thermoplastic resin composition according to any one of <33> to <43>, wherein a ratio of the amount of the substance of the dicarboxylic acid monomer unit a in the polyester resin to a total amount of the substances of all the monomer units of the polyester resin is preferably 10 mol% or more, more preferably 20 mol% or more, preferably 70 mol% or less, more preferably 65 mol% or less, further preferably 60 mol% or less, further preferably 40 mol% or less, and further preferably 27 mol% or less.

<45> the thermoplastic resin composition according to any one of <33> to <44>, wherein a ratio of the amount of the substance of the dicarboxylic acid monomer units B in the polyester resin to a total amount of the substances of all the monomer units in the polyester resin is preferably 30 mol% or more, more preferably 35 mol% or more, further preferably 40 mol% or more, further preferably 65 mol% or more, further preferably 73 mol% or more, preferably 90 mol% or less, and more preferably 80 mol% or less.

<46> the thermoplastic resin composition according to any one of <33> to <45>, wherein the polyester resin is represented by the following general formulae (II) and (III).

(in the general formula (III), p2 represents the number of polymerization degrees of ethylene 2, 6-naphthalate, q2 represents the number of polymerization degrees of ethylene 5-sulfoisophthalate, r2 represents the number of polymerization degrees of a condensate of bisphenoxyethanolfluorene and 2, 6-naphthalenedicarboxylic acid, and s2 represents the number of polymerization degrees of a condensate of bisphenoxyethanolfluorene and 5-sulfoisophthalic acid, wherein the condensate of ethylene 2, 6-naphthalate, ethylene 5-sulfoisophthalate, bisphenoxyethanolfluorene and 2, 6-naphthalenedicarboxylic acid, and bisphenoxyethanolfluorene and 5-sulfoisophthalic acid is block-bonded and/or randomly-bonded, more preferably randomly-bonded.)

<47> the thermoplastic resin composition according to any one of <33> to <46>, wherein the polyamide resin has the dicarboxylic acid monomer unit A and the diamine monomer unit.

<48> the thermoplastic resin composition according to any one of <33> to <47>, wherein the ratio of the amount of the substance of the dicarboxylic acid monomer unit a in the polyamide resin to the total amount of the substances of all the monomer units of the polyamide resin is 2.5 mol% or more, preferably 4 mol% or more, more preferably 6 mol% or more, further preferably 8 mol% or more, further preferably 10 mol% or more, and 40 mol% or less, preferably 35 mol% or less, more preferably 31 mol% or less, further preferably 25 mol% or less, further preferably 20 mol% or less, further preferably 15 mol% or less, further preferably 10 mol% or less, and further preferably 8 mol% or less.

<49> the thermoplastic resin composition according to any one of <33> to <48>, wherein the ratio of the amount of the substance of the dicarboxylic acid monomer unit B in the polyamide resin to the total amount of the substances of all the monomer units in the polyamide resin is preferably 10 mol% or more, more preferably 20 mol% or more, further preferably 30 mol% or more, further preferably 35 mol% or more, further preferably 40 mol% or more, further preferably 42 mol% or more, preferably 47.5 mol% or less, further preferably 45 mol% or less, further preferably 42 mol% or less, further preferably 40 mol% or less.

<50> the thermoplastic resin composition according to any one of <33> to <49>, wherein the polyamide resin is represented by the following general formulae (IV) to (IX).

(in the general formula (IV), p3 and q3 each represent a number of degrees of polymerization, and each polymerization is a block bond and/or a random bond, more preferably a random bond.)

(in the above general formula (V), p4 and q4 each represent a number of degrees of polymerization, and each polymerization is a block bond and/or a random bond, more preferably a random bond.)

(in the above general formula (VI), p5 and q5 each represent a number of degrees of polymerization, and each polymerization is a block bond and/or a random bond, more preferably a random bond.)

(in the general formula (VII), p6 and q6 each represent a number of degrees of polymerization, and each polymerization is a block bond and/or a random bond, more preferably a random bond.)

(in the above general formula (VIII), p7 and q7 each represent a number of degrees of polymerization, and each polymerization is a block bond and/or a random bond, more preferably a random bond.)

(in the general formula (IX), p8 and q8 each represent a number of degrees of polymerization, and each polymerization is a block bond and/or a random bond, more preferably a random bond.)

<51> the thermoplastic resin composition according to any one of <33> to <50>, wherein the weight average molecular weight of the thermoplastic resin is preferably 3000 or more, more preferably 10000 or more, further preferably 16000 or more, preferably 70000 or less, more preferably 50000 or less, further preferably 40000 or less, and further preferably 35000 or less.

<52> the thermoplastic resin composition according to any one of <33> to <51>, wherein the glass transition temperature (Tg) of the thermoplastic resin is 50 ℃ or more, preferably 60 ℃ or more, more preferably 70 ℃ or more, further preferably 80 ℃ or more, and 250 ℃ or less, preferably 220 ℃ or less, more preferably 180 ℃ or less, further preferably 160 ℃ or less, further preferably 140 ℃ or less, and further preferably 120 ℃ or less.

<53> the thermoplastic resin composition according to any one of <33> to <52>, wherein the content of the thermoplastic resin in the thermoplastic resin composition is preferably 70% by mass or more, more preferably 80% by mass or more, preferably 95% by mass or less, more preferably 90% by mass or less.

<54>According to<33>～<53>The thermoplastic resin composition according to any one of the above-mentioned general formula (I), wherein X isⁿ⁺Represents a sodium ion, a potassium ion, a lithium ion, an ammonium ion, a phosphonium ion, a magnesium ion, a calcium ion, a barium ion, a zinc ion or a phosphonium ion, preferably a sodium ion, a potassium ion, a lithium ion, a magnesium ion, an ammonium ion or a phosphonium ion, more preferably a sodium ion, a lithium ion, an ammonium ion or a phosphonium ion, further preferably a lithium ion or a phosphonium ion, further preferably a phosphonium ion, among phosphonium ions, a tetraalkylphosphonium ion is preferred, and a tetrabutylphosphonium ion is more preferred.

<55> the thermoplastic resin composition according to any one of <33> to <54>, wherein the mass ratio of the organic salt compound to the thermoplastic resin is preferably 0.5 or more, more preferably 2 or more, further preferably 6 or more, preferably 30 or less, more preferably 20 or less, further preferably 15 or less.

<56>According to<33>～<55>The thermoplastic resin composition of, wherein the alkylsulfonic acid ion (R) of the organic salt compound¹-SO₃ ^-) The ratio of the amount of substance(s) of (a) to the total amount of substance(s) of the sulfonic acid group(s) and the sulfonate group(s) of the thermoplastic resin (of the organic salt compound)The amount of the substance of the alkylsulfonic acid ion/the total amount of the substance of the sulfonic acid group and the substance of the sulfonate group of the thermoplastic resin) is preferably 0.005 or more, more preferably 0.01 or more, still more preferably 0.02 or more, yet more preferably 0.03 or more, preferably 0.35 or less, still more preferably 0.25 or less, and still more preferably 0.2 or less.

<57> the thermoplastic resin composition according to any one of <33> to <56>, wherein in the thermoplastic resin composition, the dicarboxylic acid monomer unit a is preferably 10 to 30 mol%, the dicarboxylic acid monomer unit B is preferably 20 to 40 mol%, the diol monomer unit is preferably 40 to 60 mol%, and the organic salt compound is preferably 0.05 to 2 mol%, with respect to the total ratio of the dicarboxylic acid monomer unit a, the dicarboxylic acid monomer unit B, the diol monomer unit, and the organic salt compound to the mass amounts of all the monomer units of the thermoplastic resin.

<58> a soluble material for three-dimensional modeling, which comprises the thermoplastic resin composition according to any one of <33> to <57 >.

<59> the soluble material for three-dimensional modeling according to <58>, wherein the glass transition temperature of the soluble material for three-dimensional modeling is more preferably 60 ℃ or higher, still more preferably 70 ℃ or higher, still more preferably 80 ℃ or higher, preferably 250 ℃ or lower, still more preferably 220 ℃ or lower, and still more preferably 200 ℃ or lower.

<60> the dissolvable material for three-dimensional modeling according to <58> or <59>, wherein the dissolvable material for three-dimensional modeling is preferably in the form of a thread.

<61> the soluble material for three-dimensional modeling according to any one of <58> to <60>, wherein the diameter of the filament is preferably 0.5mm or more, more preferably 1.0mm or more, preferably 3.0mm or less, more preferably 2.0mm or less, and further preferably 1.8mm or less.

<62> a method for manufacturing a three-dimensional object by a thermal fusion deposition method, comprising: obtaining a three-dimensional object precursor having a three-dimensional object and a support material; and a support material removing step of removing the support material by bringing the three-dimensional object precursor into contact with neutral water, wherein the support material is the soluble material for three-dimensional modeling according to any one of <58> to <61>

<63> the method of <62>, wherein the molding material as the material of the three-dimensional object is preferably a thermoplastic resin such as an ABS resin, a PP resin, an ASA resin, a PS resin, a HIPS resin, a PVC resin, a polylactic acid resin, a polycarbonate resin, a polyamide resin, a polyetherimide resin, a polyetheretherketone resin, and a polyphenylsulfone resin, more preferably at least one selected from the group consisting of an ABS resin, a polylactic acid resin, a polycarbonate resin, and a polyamide resin, and still more preferably at least one selected from the group consisting of an ABS resin, a polycarbonate resin, and a polyamide resin.

<64> the method of producing a three-dimensional object according to <62> or <63>, wherein the glass transition temperature of the support material used in the step of obtaining the three-dimensional object precursor is preferably (glass transition temperature of the modeling material used-20 ℃) to (glass transition temperature of the modeling material used +20 ℃), and more preferably (glass transition temperature of the modeling material used-15 ℃) to (glass transition temperature of the modeling material used +15 ℃).

<65> the method of manufacturing a three-dimensional object according to any one of <62> to <63>, comprising a support material removing step of immersing the three-dimensional object precursor in neutral water to dissolve and remove the support material.

<66> the method for producing a three-dimensional object according to any one of <62> to <63>, wherein the neutral water contains a water-soluble organic solvent.

<67> the method of producing a three-dimensional object according to any one of <62> to <66>, wherein the water-soluble organic solvent is preferably a lower alcohol such as methanol, ethanol, or 2-propanol, a glycol ether such as propylene glycol monomethyl ether, ethylene glycol monoethyl ether, ethylene glycol mono-t-butyl ether, or diethylene glycol monobutyl ether, or a ketone such as acetone or methyl ethyl ketone.

<66> the method of manufacturing a three-dimensional object according to any one of <62> to <65>, wherein a content of the water-soluble organic solvent in the neutral water is preferably 0.1% by mass or more, more preferably 0.5% by mass or more, further preferably 1% by mass or more, further preferably 3% by mass or more, and preferably 50% by mass or less, preferably 40% by mass or less, preferably 30% by mass or less, and preferably 20% by mass or less.

<67> the method of manufacturing a three-dimensional object according to any one of <62> to <66>, wherein the amount of the neutral water used is preferably 10 times by mass or more, more preferably 20 times by mass or more, preferably 10000 times by mass or less, more preferably 5000 times by mass or less, further preferably 1000 times by mass or less, and further preferably 100 times by mass or less with respect to the supporting material.

<66> the method of producing a three-dimensional object according to any one of <62> to <65>, wherein the time for bringing the soluble material for three-dimensional modeling into contact with neutral water is preferably 5 minutes or longer, preferably 180 minutes or shorter, more preferably 120 minutes or shorter, and still more preferably 90 minutes or shorter.

<67> the method of manufacturing a three-dimensional object according to any one of <62> to <66>, wherein the temperature of neutral water brought into contact with the soluble material for three-dimensional modeling is preferably 15 ℃ or higher, more preferably 25 ℃ or higher, further preferably 30 ℃ or higher, further preferably 40 ℃ or higher, preferably 85 ℃ or lower, more preferably 70 ℃ or lower, and further preferably 60 ℃ or lower.

<68> a support material for supporting a three-dimensional object when the three-dimensional object is produced by a 3D printer using a thermal fusion deposition method, wherein a raw material of the support material is the soluble material for three-dimensional modeling according to any one of <58> to <61 >.

<69> <33> to <57>, as a soluble material for three-dimensional modeling.

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Method for producing thermoplastic resin composition

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