阅读说明：本技术 树脂成型体、轮胎、汽车用部件和树脂组合物 (Resin molded body, tire, automobile part, and resin composition ) 是由 堀田文 盐野纱彩 樽谷泰典 西室阳一 于 2020-05-27 设计创作，主要内容包括：本发明提供树脂成型体、轮胎和汽车用部件,其实现韧性和耐冲击性之间的优异平衡,并且还具有优异的伸长性。本发明还提供可以制造它们的树脂组合物。该树脂组合物包括：包含共轭二烯单元、非共轭烯烃单元、和芳香族乙烯基单元并且其丁烯单元的含量为0mol％的共聚物；和聚酰胺系树脂。(The present invention provides a resin molded body, a tire, and an automobile part, which achieve an excellent balance between toughness and impact resistance and also have excellent elongation. The present invention also provides resin compositions from which they can be made. The resin composition comprises: a copolymer which comprises a conjugated diene unit, a non-conjugated olefin unit, and an aromatic vinyl unit and has a butene unit content of 0 mol%; and a polyamide resin.)

1. A resin composition comprising a copolymer and a polyamide-based resin, the copolymer comprising conjugated diene units, non-conjugated olefin units and aromatic vinyl units and having a butene unit content of 0 mol%.

2. The resin composition according to claim 1, wherein the content of the copolymer is 1 to 81 mass% of the total mass of the copolymer and the polyamide-based resin.

3. The resin composition according to claim 1 or 2, wherein in the copolymer, the content of the conjugated diene unit is 5 to 70 mol%, the content of the non-conjugated olefin unit is 25 to 95 mol%, and the content of the aromatic vinyl unit is 2 to 30 mol%.

4. The resin composition according to any one of claims 1 to 3, wherein the copolymer has a melting point of 30 to 130 ℃ as measured with a Differential Scanning Calorimeter (DSC).

5. The resin composition according to any one of claims 1 to 4, wherein the copolymer has a weight average molecular weight in terms of polystyrene of 50,000 to 2,000,000.

6. The resin composition according to any one of claims 1 to 5, wherein the copolymer has a crystallinity of 0.5 to 50%.

7. The resin composition according to any one of claims 1 to 6, wherein the non-conjugated olefin unit is a non-cyclic non-conjugated olefin unit.

8. The resin composition of claim 7, wherein the acyclic nonconjugated olefin unit consists only of ethylene units.

9. The resin composition according to any one of claims 1 to 8, wherein the aromatic vinyl unit comprises a styrene unit.

10. The resin composition according to any one of claims 1 to 9, wherein the conjugated diene unit comprises at least one selected from the group consisting of a 1, 3-butadiene unit and an isoprene unit.

11. The resin composition according to any one of claims 1 to 10, further comprising an anti-aging agent.

12. The resin composition according to any one of claims 1 to 11, further comprising a compatibilizer.

13. The resin composition according to claim 12, wherein the compatibilizer is a modified copolymer in which a polymer is modified with maleic acid, and the polymer to be modified is at least one selected from the group consisting of styrene-isobutylene-styrene block copolymer (SIBS), styrene-butadiene-styrene block copolymer (SBS), styrene-ethylene/butylene-styrene block copolymer (SEBS), and styrene-ethylene/propylene block copolymer (SEPS).

14. The resin composition according to claim 12 or 13, wherein the content of the compatibilizer is 0.5 to 20 parts by mass with respect to 100 parts by mass of the total of the copolymer and the polyamide resin.

15. The resin composition according to any one of claims 11 to 14, wherein the antioxidant comprises an antioxidant containing 2 or more phenyl groups having a branched alkyl group.

16. A resin molded article using the resin composition according to any one of claims 1 to 15.

17. A tire using the resin composition described in any one of claims 1 to 15.

18. An automobile part using the resin composition according to any one of claims 1 to 15.

Technical Field

The invention relates to a resin molded body, a tire, an automobile part and a resin composition.

Background

Heretofore, various resin molded articles have been produced using olefin-based resins, polyamide-based resins, and the like, which are excellent in impact resistance and chemical resistance.

For example, from the viewpoint of obtaining a polypropylene-based resin composition suitable for use as a coating-free resin molding material having scratch resistance and impact resistance compatibility, there has been disclosed a polypropylene-based resin composition comprising 75 to 90% by weight of a polypropylene resin, 7 to 15% by weight of a hydrogenated styrene/butadiene/styrene copolymer elastomer (a) having a styrene content of 18 to 42% by weight, and 3 to 10% by weight of a hydrogenated styrene/butadiene/styrene copolymer elastomer (B) having a styrene content of 12 to 15% by weight (see PTL 1, for example).

From the viewpoint of obtaining a resin article having high impact resistance and transparency, a resin composition comprising a multipolymer, wherein the multipolymer comprises conjugated diene units, non-conjugated olefin units and aromatic vinyl units and wherein the content of the aromatic vinyl units is 50 mol% or more and less than 100 mol% of the entire multipolymer has been disclosed (for example, see PTL 2).

Reference list

Patent document

PTL 1：JP 2012-246366A

PTL 2：WO2017/065300A1

Disclosure of Invention

Problems to be solved by the invention

However, although improvement of impact resistance is studied therein, the resin molded bodies described in PTLs 1 and 2 are insufficient in toughness.

An object of the present invention is to provide a resin molded body, a tire, and an automobile part, which achieve an excellent balance between toughness and impact resistance and also have excellent elongation (elongation), and also to provide a resin composition capable of producing these, and the present invention solves the problem of achieving the object.

Means for solving the problems

<1> a resin composition comprising a copolymer and a polyamide-based resin, the copolymer comprising conjugated diene units, non-conjugated olefin units and aromatic vinyl units and having a butene unit content of 0 mol%.

<2> the resin composition <1>, wherein the content of the copolymer is 1 to 81 mass% of the total mass of the copolymer and the polyamide resin.

<3> the resin composition according to <1> or <2>, wherein in the copolymer, the content of the conjugated diene unit is 5 to 70 mol%, the content of the non-conjugated olefin unit is 25 to 95 mol%, and the content of the aromatic vinyl unit is 2 to 30 mol%.

<4> the resin composition according to any one of <1> to <3>, wherein the copolymer has a melting point of 30-130 ℃ as measured by a Differential Scanning Calorimeter (DSC).

<5> the resin composition according to any one of <1> to <4>, wherein the copolymer has a weight average molecular weight in terms of polystyrene of 50,000 to 800,000.

<6> the resin composition according to any one of <1> to <5>, wherein the copolymer has a crystallinity of 0.5 to 50%.

<7> the resin composition according to any one of <1> to <6>, wherein the non-conjugated olefin unit is a non-cyclic non-conjugated olefin unit.

<8> the resin composition <7>, wherein the acyclic nonconjugated olefin unit is composed of only an ethylene unit.

<9> the resin composition according to any one of <1> to <8>, wherein the aromatic vinyl unit comprises a styrene unit.

<10> the resin composition according to any one of <1> to <9>, wherein the conjugated diene unit comprises at least one selected from the group consisting of a 1, 3-butadiene unit and an isoprene unit.

<11> the resin composition according to any one of <1> to <10>, which further comprises an antioxidant.

<12> the resin composition according to any one of <1> to <11>, which further comprises a compatibilizer.

<13> the resin composition according to <12>, wherein the compatibilizer is a modified copolymer in which a polymer is modified with maleic acid, and the polymer to be modified is at least one selected from the group consisting of styrene-isobutylene-styrene block copolymer (SIBS), styrene-butadiene-styrene block copolymer (SBS), styrene-ethylene/butylene-styrene block copolymer (SEBS), and styrene-ethylene/propylene block copolymer (SEPS).

<14> the resin composition <12> or <13>, wherein the content of the compatibilizer is 0.5 to 20 parts by mass with respect to 100 parts by mass of the total of the copolymer and the polyamide resin.

<15> the resin composition according to any one of <11> to <14>, wherein the antioxidant comprises an antioxidant containing 2 or more phenyl groups having a branched alkyl group.

<16> a resin molded article using the resin composition <1> to <15 >.

<17> a tire using the resin composition of any one of <1> to <15 >.

<18> an automobile part using the resin composition <1> to <15 >.

ADVANTAGEOUS EFFECTS OF INVENTION

According to the present invention, it is possible to provide a resin molded body, a tire, and an automobile part which achieve an excellent balance between toughness and impact resistance and also have excellent elongation, and also provide a resin composition capable of producing these.

Drawings

Fig. 1 is an AFM image of the surface of the resin molded body of example 2.

Fig. 2 is an AFM image of the surface of the resin molded body of example 3.

Fig. 3 is an AFM image of the surface of the resin molded body of example 4.

Fig. 4 is an AFM image of the surface of the resin molded body of example 5.

Fig. 5 is an AFM image of the surface of the resin molded body of example 6.

Fig. 6 is an AFM image of the surface of the resin molded body of example 7.

Fig. 7 is an AFM image of the surface of the resin molded body of example 8.

Fig. 8 is an AFM image of the surface of the resin molded body of comparative example 2.

Fig. 9 is an AFM image of the surface of the resin molded body of example 9.

Fig. 10 is an AFM image of the surface of the resin molded body of example 10.

Fig. 11 is an AFM image of the surface of the resin molded body of example 11.

Fig. 12 is an AFM image of the surface of the resin molded body of example 12.

Fig. 13 is an AFM image of the surface of the resin molded body of example 13.

Detailed Description

< resin composition >

The resin composition of the present invention comprises a copolymer and a polyamide resin, wherein the copolymer comprises a conjugated diene unit, a non-conjugated olefin unit and an aromatic vinyl unit, and the content of a butene unit is 0 mol%.

The resin composition may further contain components such as an antioxidant, a filler, a crosslinking agent, and an ultraviolet absorber.

Olefin-based resins and polyamide-based resins (PA resins) are widely used as automobile parts because of their excellent properties. In particular, they are often used as exterior parts such as bumpers. The polyamide-based resin has low impact resistance due to its high glass transition temperature (Tg). Therefore, heretofore, a PP/SEBS system to which a hydrogenated styrene-ethylene/butylene-styrene copolymer (SEBS) is added as in PTL 1 has been used as a rubber component. However, SEBS has low toughness, and thus further improvement is required. PTL 2 discloses a resin composition capable of containing a copolymer having high impact resistance and transparency and together with various resins, but specific embodiments of the resin composition containing the copolymer and the resin have not been sufficiently studied.

Even a resin molded article having high impact resistance tends to have low toughness when having high impact resistance at low temperature, that is, low-temperature impact resistance and toughness are contradictory characteristics with respect to the resin molded article.

In contrast, the resin molded article of the present invention realizes an excellent balance between toughness and impact resistance because the resin composition has the above-described constitution. Further, another characteristic of the resin molded product of the present invention is excellent elongation.

[ copolymer ]

The copolymer contains a conjugated diene unit, a non-conjugated olefin unit and an aromatic vinyl unit and has a content of a butene unit of 0 mol% (hereinafter, this may be referred to as "copolymer in the present invention").

In the hydrogenated styrene-butadiene-styrene copolymer elastomer used in PTL 1, a hydrogenated styrene-ethylene/butylene-styrene copolymer (SEBS) containing a butylene unit is used. In the copolymer in the present invention, the content of butene unit is 0 mol%, that is, the copolymer in the present invention does not contain SEBS.

The copolymer in the present invention contains a conjugated diene unit and has elasticity, and thus functions as a rubber component.

In the case where the copolymer in the present invention contains only three units of a conjugated diene unit, a non-conjugated olefin unit and an aromatic vinyl unit, the copolymer in the present invention may be referred to as a "terpolymer". "ternary" means that the copolymer contains three different structural units. In the case where the copolymer further contains any one or more units in addition to the three units of the conjugated diene unit, the non-conjugated olefin unit and the aromatic vinyl unit, the copolymer is referred to as "quaternary" and "pentabasic" depending on the number of the structural units. Therefore, the copolymer in the present invention is a multipolymer comprising at least three units of a conjugated diene unit, a non-conjugated olefin unit and an aromatic vinyl unit.

Since the copolymer contains a non-conjugated olefin unit, when the resin molded body is largely deformed, a crystalline component derived from the non-conjugated olefin unit is broken, and thus the copolymer can release energy as melting energy. As a result, the resin molded body can realize high toughness. Further, since the copolymer contains conjugated diene units, the glass transition temperature (Tg) thereof is low, and therefore the copolymer can attain high low-temperature impact resistance.

The copolymer in the present invention contains at least a conjugated diene unit, a non-conjugated olefin unit and an aromatic vinyl unit, and may be composed of only a conjugated diene unit, a non-conjugated olefin unit and an aromatic vinyl unit, or may further contain any other monomer unit other than a butene unit.

(conjugated diene Unit)

The conjugated diene unit is a structural unit derived from a conjugated diene compound as a monomer.

The conjugated diene compound referred to herein means a diene compound of a conjugated system. The conjugated diene compound preferably has 4 to 8 carbon atoms. Specifically, examples of such conjugated diene compounds include 1, 3-butadiene, isoprene, 1, 3-pentadiene, 2, 3-dimethyl-1, 3-butadiene, and myrcene. One or two or more of the conjugated diene compounds may be used alone or in combination.

From the viewpoint of improving the balance between toughness and impact resistance of the resin molded body, the conjugated diene compound as a monomer of the copolymer preferably contains at least one selected from 1, 3-butadiene and isoprene, and more preferably consists of at least one selected only from the group consisting of 1, 3-butadiene and isoprene, and even more preferably is only 1, 3-butadiene.

In other words, the conjugated diene unit in the copolymer preferably contains at least one selected from the group consisting of a 1, 3-butadiene unit and an isoprene unit, and more preferably consists of at least one selected only from a 1, 3-butadiene unit and an isoprene unit, and even more preferably is only a 1, 3-butadiene unit.

The content of the conjugated diene unit in the copolymer is preferably 5 mol% or more, more preferably 7 mol% or more, even more preferably 8 mol% or more, and preferably 70 mol% or less, more preferably 60 mol% or less, even more preferably 50 mol% or less.

When the content of the conjugated diene unit is 5 mol% or more of the whole copolymer, a resin molded article excellent in impact resistance can be obtained, and when the content is 70 mol% or less, a resin molded article excellent in toughness can be obtained.

The content of the conjugated diene unit is preferably within a range of 5 to 55 mol%, more preferably within a range of 7 to 50 mol% of the entire copolymer, from the viewpoint of improving the balance between toughness and impact resistance of the resin molded product.

(nonconjugated olefin Unit)

The non-conjugated olefin unit is a structural unit derived from a non-conjugated olefin compound as a monomer.

Herein, the non-conjugated olefin compound means an aliphatic unsaturated hydrocarbon, which is a compound having at least one carbon-carbon double bond. The non-conjugated olefin compound preferably has 2 to 10 carbon atoms. Specifically, examples of the non-conjugated olefin compound include α -olefins such as ethylene, propylene, 1-pentene, 1-hexene, 1-heptene and 1-octene; and heteroatom-substituted olefinic compounds, such as vinyl pivalate, 1-phenylthioethane, N-vinylpyrrolidone. The non-conjugated olefin compound may be used alone or in combination of two or more thereof.

From the viewpoint of improving the balance between toughness and impact resistance of the resin molded article, the non-conjugated olefin compound as a monomer of the copolymer is preferably a non-cyclic non-conjugated olefin compound, and the non-cyclic non-conjugated olefin compound is preferably an α -olefin, more preferably an α -olefin containing ethylene, and particularly preferably only ethylene.

In other words, the non-conjugated olefin unit in the copolymer is preferably a non-cyclic non-conjugated olefin unit, and the non-cyclic non-conjugated olefin unit is more preferably an α -olefin unit, even more preferably an α -olefin unit containing an ethylene unit, and particularly preferably composed of only an ethylene unit.

The content of the non-conjugated olefin unit in the copolymer is preferably 25 mol% or more, more preferably 40 mol% or more, even more preferably 42 mol% or more, further more preferably 45 mol% or more, and preferably 95 mol% or less, more preferably 90 mol% or less, even more preferably 87 mol% or less.

When the content of the non-conjugated olefin unit is 25 mol% or more of the entire copolymer, the content of the conjugated diene unit or the aromatic vinyl unit is reduced accordingly, thereby improving the impact resistance of the resin molded article. When the content of the non-conjugated olefin unit is 95 mol% or less, the content of the conjugated diene unit or the aromatic vinyl unit is increased accordingly, thereby improving the toughness of the resin molded article.

The content of the non-conjugated olefin unit is preferably in the range of 25 to 98 mol%, more preferably in the range of 40 to 95 mol%, even more preferably in the range of 42 to 90 mol%, and still more preferably in the range of 45 to 87 mol% of the whole copolymer.

(aromatic vinyl Unit)

The aromatic vinyl unit is a structural unit derived from an aromatic vinyl compound as a monomer.

Containing such an aromatic vinyl unit, the copolymer can avoid excessive crystallization derived from the non-conjugated olefin unit therein, and therefore can achieve high toughness of the resin molded body while improving its rigidity with little decrease in elasticity.

Here, the aromatic vinyl compound is an aromatic compound substituted with at least a vinyl group, and is not included in the conjugated diene compound. The aromatic vinyl compound preferably has 8 to 10 carbon atoms. Examples of such aromatic vinyl compounds include styrene, o-methylstyrene, m-methylstyrene, p-methylstyrene, o, p-dimethylstyrene, o-ethylstyrene, m-ethylstyrene, and p-ethylstyrene. The aromatic vinyl compound may be used alone or in combination of two or more thereof.

From the viewpoint of improving the balance between toughness and impact resistance of the resin molded article, the aromatic vinyl compound as a monomer of the copolymer preferably contains styrene, and more preferably consists only of styrene. In other words, the aromatic vinyl unit in the copolymer preferably contains a styrene unit, and more preferably consists only of a styrene unit.

The aromatic ring in the aromatic vinyl unit is not included in the main chain of the copolymer as long as it is not bonded to the adjacent unit.

The content of the aromatic vinyl unit in the copolymer is preferably 2 mol% or more, more preferably 3 mol% or more, and preferably 30 mol% or less, more preferably 25 mol% or less. When the content of the aromatic vinyl unit is 2 mol% or more, the resin molded article may be excellent in impact resistance. When the content of the aromatic vinyl unit is 30 mol% or less, the effect due to the conjugated diene unit and the non-conjugated olefin unit is remarkable. The content of the aromatic vinyl unit is preferably in the range of 2 to 30 mol%, more preferably in the range of 2 to 25 mol%, and even more preferably in the range of 3 to 25 mol% of the whole copolymer.

The number of kinds of monomers of the copolymer is not particularly limited as long as the copolymer contains a conjugated diene unit, a non-conjugated olefin unit and an aromatic vinyl unit and does not contain a butene unit. Although the copolymer may have any other structural unit (other than the butene unit) other than the conjugated diene unit, the non-conjugated olefin unit and the aromatic vinyl unit, from the viewpoint of obtaining the desired effect, the content of the other structural unit is preferably 30 mol% or less, more preferably 20 mol% or less, even more preferably 10 mol% or less of the entire copolymer, and particularly preferably, the copolymer does not contain any other structural unit, that is, the content of the other structural unit therein is 0 mol%.

From the viewpoint of improving the balance between toughness and impact resistance of the resin molded article, the copolymer is preferably a polymer obtained by polymerizing at least using, as monomers, only one conjugated diene compound, only one non-conjugated olefin compound, and only one aromatic vinyl compound.

In other words, the copolymer is preferably a copolymer comprising only one conjugated diene unit, only one non-conjugated olefin unit, and only one aromatic vinyl unit, more preferably a terpolymer composed of only one conjugated diene unit, only one non-conjugated olefin unit, and only one aromatic vinyl unit, and even more preferably a terpolymer composed of only 1, 3-butadiene units, ethylene units, and styrene units. Herein, conjugated diene units of different bonding modes are included in "only one conjugated diene unit".

In the copolymer, from the viewpoint of improving the balance between toughness and impact resistance of the resin molded article, it is preferable that the content of the conjugated diene unit is 5 to 70 mol%, the content of the non-conjugated diene unit is 25 to 95 mol%, and the content of the aromatic vinyl unit is 2 to 30 mol%.

The weight average molecular weight (Mw) of the copolymer in terms of polystyrene is preferably 50,000 to 2,000,000, more preferably 100,000 to 2,000,000, and even more preferably 150,000 to 1,000,000. When the Mw of the copolymer is 50,000 or more, the resin molded article can sufficiently secure impact resistance. When Mw is 2,000,000 or less, workability of the resin composition is hardly deteriorated.

The number average molecular weight (Mn) of the copolymer in terms of polystyrene is preferably 30,000 to 1,500,000, more preferably 50,000 to 1,200,000, and even more preferably 60,000 to 1,000,000. When the Mn of the copolymer is 30,000 or more, the resin molded article can sufficiently secure impact resistance. When Mn is 1,500,000 or less, workability of the resin composition is hardly deteriorated.

The copolymer preferably has a molecular weight distribution [ Mw/Mn (weight average molecular weight/number average molecular weight) ] of 1.00 to 4.00, more preferably 1.30 to 3.70, and even more preferably 1.50 to 3.50. When the molecular weight distribution of the copolymer is 4.00 or less, the copolymer can secure sufficiently uniform physical properties.

The weight average molecular weight (Mw), number average molecular weight (Mn), and molecular weight distribution (Mw/Mn) of the copolymer can be determined in Gel Permeation Chromatography (GPC) using polystyrene as a standard substance.

The copolymer preferably has an endothermic peak energy at 0 to 120 ℃ as measured by a Differential Scanning Calorimeter (DSC) of 10 to 150J/g, more preferably 30 to 120J/g. When the endothermic peak energy of the copolymer is 10J/g or more, the crystallinity of the copolymer is high, thereby further improving the toughness. When the endothermic peak energy of the copolymer is 150J/g or less, the workability of the resin composition is improved.

The endothermic peak energy of the copolymer can be measured using a differential scanning calorimeter in accordance with JIS K7121-1987, for example, by heating the copolymer from-150 ℃ to 150 ℃ at a temperature rising rate of 10 ℃/min.

The melting point of the copolymer as measured by a Differential Scanning Calorimeter (DSC) is preferably 30 to 130 ℃, more preferably 35 to 120 ℃, even more preferably 40 to 110 ℃. When the melting point of the copolymer is 30 ℃ or higher, the crystallinity of the copolymer is high, and the toughness of the resin molded product is further improved. When the melting point of the copolymer is 130 ℃ or lower, the workability of the resin composition is improved.

The melting point of the copolymer can be measured by a differential scanning calorimeter in accordance with JIS K7121-1987.

The glass transition temperature (Tg) of the copolymer as measured by a Differential Scanning Calorimeter (DSC) is preferably 0 ℃ or less, more preferably-130 to-10 ℃, even more preferably-120 to-15 ℃. When the glass transition temperature of the copolymer is 0 ℃ or lower, the impact resistance of the resin molded article can be further improved.

The glass transition temperature of the copolymer can be measured by a differential scanning calorimeter in accordance with JIS K7121-1987.

The crystallinity of the copolymer is preferably 0.5 to 50%, more preferably 3 to 45%, even more preferably 5 to 45%. When the crystallinity of the copolymer is 0.5% or more, the toughness of the resin molded article can be further improved while sufficiently ensuring the crystallinity of the copolymer due to the non-conjugated olefin unit therein. When the crystallinity of the copolymer is 50% or less, workability in kneading of the resin composition is improved, and also extrusion processability thereof is improved.

With respect to the crystallinity of the copolymer, the crystalline melting energy of polyethylene of 100% crystalline component and the melting peak energy of the copolymer were measured, and the crystallinity of the copolymer was calculated from the energy ratio of polyethylene to copolymer. The melting peak energy can be measured with a differential scanning calorimeter.

For the copolymer, it is preferable that its main chain is composed of only a non-cyclic structure. This can further improve the impact resistance of the resin molded article.

In order to confirm whether or not the main chain of the copolymer has a cyclic structure, NMR was used as a main measurement means. Specifically, in the case where a peak derived from a cyclic structure present in the main chain (for example, a peak appearing at 10ppm to 24ppm for a three-membered ring to a five-membered ring) is not observed, it indicates that the main chain of the copolymer is composed of only a non-cyclic structure.

In the present invention, the main chain of the Polymer means a linear molecular chain formed by pendently bonding all other molecular chains (long molecular chains or short molecular chains or both) thereto [ see section 1.34 of "gloss of Basic terminals in Polymer Science IUPAC Recommendations 1996", Pure appl. chem.,68,2287-2311(1996) ].

The acyclic structure means a linear structure or a branched structure.

The copolymer is produced through a polymerization step using a conjugated diene compound, a non-conjugated olefin compound and an aromatic vinyl compound as monomers, and optionally a coupling step, a washing step and any other steps.

Here, in the production of the copolymer, it is preferable that the non-conjugated olefin compound and the aromatic vinyl compound are first separately added to a reactor and polymerized in the presence of a polymerization catalyst without adding the conjugated diene compound thereto. In particular, in the case of using the catalyst composition described below, the conjugated diene compound has higher reactivity than the non-conjugated olefin compound and the aromatic vinyl compound, and therefore, it would be difficult to polymerize at least one selected from the group consisting of the non-conjugated olefin compound and the aromatic vinyl compound in the presence of the conjugated diene compound. In addition, in view of the characteristics of the catalyst, it is also difficult to polymerize a conjugated diene compound in advance and then polymerize a non-conjugated olefin compound and an aromatic vinyl compound by addition polymerization.

As the polymerization method, any method such as solution polymerization, suspension polymerization, liquid-phase bulk polymerization, emulsion polymerization, gas-phase polymerization or solid-phase polymerization can be used. In the case where a solvent is used for the polymerization, the solvent may be any solvent that is inert in the polymerization. Examples of the solvent include toluene, cyclohexane and n-hexane.

The polymerization step may be a single-stage reaction or a multistage reaction of two or more stages.

The single-stage polymerization step is a step of polymerizing all the monomers to be polymerized (i.e., all the conjugated diene compound, the non-conjugated olefin compound, the aromatic vinyl compound and any other monomer) at once, preferably all the conjugated diene compound, the non-conjugated olefin compound and the aromatic vinyl compound at once.

The multistage polymerization process comprises the following steps: first a part or all of one or both monomers are reacted to form a polymer (first polymerization stage), then the remaining kind of monomers not yet added in the first polymerization stage and the remaining part of monomers added in the first polymerization stage are added thereto and polymerized in more than one stage (second polymerization stage to final polymerization stage). In particular, in the production of the copolymer, the polymerization step is preferably carried out in a multistage polymerization.

In the polymerization step, the polymerization reaction is preferably carried out in an atmosphere of an inert gas, preferably nitrogen or argon. The polymerization temperature of the polymerization reaction is not particularly limited, but is, for example, preferably in the range of-100 ℃ to 200 ℃ and may be around room temperature. In order to sufficiently introduce the conjugated diene compound into the polymerization reaction system, the polymerization pressure is preferably in the range of 0.1 to 10.0 MPa.

The polymerization reaction time is also not particularly limited, and is, for example, preferably in the range of 1 second to 10 days. The time can be appropriately selected depending on the conditions such as the kind of the polymerization catalyst and the polymerization temperature.

In the polymerization step of the conjugated diene compound, a polymerization terminator such as methanol, ethanol or isopropanol may be used to terminate the polymerization.

The polymerization step is preferably carried out in a multistage polymerization. More preferably, the polymerization process comprises the following steps: the polymerization method includes a first process of mixing a first monomer raw material containing at least an aromatic vinyl compound with a polymerization catalyst to prepare a polymerization mixture, and a second process of adding a second monomer raw material containing at least one selected from the group consisting of a conjugated diene compound, a non-conjugated olefin compound, and an aromatic vinyl compound to the polymerization mixture, wherein, more preferably, the first monomer raw material does not contain the conjugated diene compound, and the second monomer raw material contains the conjugated diene compound.

The first monomer raw material to be used in the first step may contain a non-conjugated olefin compound together with an aromatic vinyl compound. The first monomer raw material may contain all of the aromatic vinyl compound to be used or may contain a part thereof. The non-conjugated olefin compound is contained in at least any one of the first monomer raw material and the second monomer raw material.

Preferably, the first procedure is carried out in a reactor under an atmosphere of an inert gas, preferably nitrogen or argon. The temperature (reaction temperature) in the first step is not particularly limited, and is preferably in the range of-100 ℃ to 200 ℃ or may be around room temperature, for example. The pressure in the first step is also not particularly limited, but is preferably in the range of 0.1 to 10.0MPa in order to sufficiently introduce the aromatic vinyl compound into the polymerization reaction system. The time (reaction time) taken in the first step can be appropriately selected depending on the conditions such as the kind of the polymerization catalyst and the reaction temperature. In the case where the reaction temperature is 25 ℃ to 80 ℃, the reaction time is preferably in the range of 5 minutes to 500 minutes.

In the first step, as a polymerization method for obtaining a polymerization mixture, any method such as solution polymerization, suspension polymerization, liquid-phase bulk polymerization, emulsion polymerization, gas-phase polymerization, and solid-phase polymerization can be employed. In the case of using a solvent for the polymerization reaction, the solvent may be any solvent inert in the polymerization reaction, and examples thereof include toluene, cyclohexane, and n-hexane.

The second monomer raw material used in the second step is preferably only a conjugated diene compound, or a conjugated diene compound and a non-conjugated olefin compound, or a conjugated diene compound and an aromatic vinyl compound, or a conjugated diene compound, a non-conjugated olefin compound and an aromatic vinyl compound.

In the case where the second monomer raw material contains at least one selected from the group consisting of a non-conjugated olefin compound and an aromatic vinyl compound in addition to the conjugated diene compound, these monomer raw materials may be mixed together with a solvent in advance and then introduced into the polymerization mixture, or each monomer raw material may be introduced therein in a separate state. These monomer raw materials may be added simultaneously or sequentially.

In the second step, although the method of introducing the second monomer raw material into the polymerization mixture is not particularly limited, it is preferable to continuously add the monomer raw materials to the polymerization mixture while controlling the flow rate of each monomer raw material (in a so-called metering mode). Here, in the case of using a monomer raw material which is a gas under the conditions of the polymerization reaction system (for example, ethylene or the like which is a non-conjugated olefin compound under the conditions of room temperature and atmospheric pressure), it may be introduced into the polymerization reaction system under a predetermined pressure.

Preferably, the second procedure is carried out in an atmosphere of inert gas, preferably nitrogen or argon, within the reactor. The temperature (reaction temperature) in the second step is not particularly limited, and is preferably in the range of-100 ℃ to 200 ℃ or may be around room temperature, for example. As the reaction temperature increases, the selectivity of cis-1, 4 bonds in the conjugated diene units decreases. The pressure in the second step is also not particularly limited, but is preferably in the range of 0.1 to 10.0MPa in order to sufficiently introduce the monomer such as the conjugated diene compound into the polymerization reaction system. The time (reaction time) taken for the second step is not particularly limited and may be appropriately selected depending on conditions such as the kind of the polymerization catalyst and the reaction temperature. For example, the time is preferably in the range of 0.1 hour to 10 days.

In the second process, a polymerization terminator such as methanol, ethanol or isopropanol may be used to terminate the polymerization reaction.

Preferably, the step of polymerizing the conjugated diene compound, the non-conjugated olefin compound, and the aromatic vinyl compound includes a step of polymerizing each monomer in the presence of at least one catalyst component selected from the following components (a) to (F). In the polymerization step, at least one of the following components (a) to (F) is preferably used, and more preferably two or more of the following components (a) to (F) are combined and used as a catalyst composition.

A component (A): a rare earth element compound or a reaction product of the rare earth element compound and a Lewis base.

A component (B): an organometallic compound.

A component (C): an aluminoxane.

A component (D): an ionic compound.

A component (E): a halogen compound.

A component (F): a compound having a cyclopentadiene skeleton selected from substituted or unsubstituted cyclopentadiene (a compound having a cyclopentadienyl group), substituted or unsubstituted indene (a compound having an indenyl group), and substituted or unsubstituted fluorene (a compound having a fluorenyl group).

The above-mentioned components (A) to (F) can be used in the polymerization process by referring to, for example, WO 2018/092733A.

The coupling step is a step of modifying (coupling) at least a part (for example, an end) of a polymer chain of the copolymer obtained in the polymerization step to perform a reaction.

In the coupling step, the coupling reaction is preferably carried out when the polymerization reaction reaches 100%.

The coupling agent used for the coupling reaction is not particularly limited and may be appropriately selected depending on the intended purpose. Examples thereof include tin-containing compounds such as bis (1-octadecyl maleate) dioctyltin (IV); isocyanate compounds such as 4,4' -diphenylmethane diisocyanate; and alkoxysilane compounds such as glycidylpropyltrimethoxysilane. These may be used alone or in combination of two or more thereof.

Among them, bis (1-octadecyl maleate) dioctyltin (IV) is preferable from the viewpoint of reaction efficiency and low gel formation.

The coupling reaction can increase the number average molecular weight (Mn) of the multipolymer.

The washing step is a step of washing the copolymer obtained in the polymerization step.

The medium used for the washing process is not particularly limited and may be appropriately selected depending on the intended purpose. Examples thereof include methanol, ethanol, and 2-propanol. When a catalyst derived from a lewis acid is used as the polymerization catalyst, in particular, an acid (for example, hydrochloric acid, sulfuric acid, and nitric acid) may be added to such a solvent and used. The amount of the acid added is preferably 15 mol% or less with respect to the solvent. When the addition amount is 15 mol% or less, the acid may hardly remain in the copolymer, thereby not causing any adverse effect on the reaction at the kneading and vulcanization of the resin composition.

In the washing step, the amount of the catalyst remaining in the copolymer can be appropriately reduced.

Although not particularly limited, the content of the copolymer is preferably 1% by mass or more, more preferably 5% by mass or more, even more preferably 10% by mass or more, and preferably 81% by mass or less, more preferably 75% by mass or less, even more preferably 65% by mass or less, further more preferably 50% by mass or less of the total mass of the copolymer and the polyamide-based resin in the present invention.

When the content of the copolymer is 1% by mass or more of the total mass of the copolymer and the polyamide resin in the present invention, the copolymer can sufficiently exhibit its effect to sufficiently ensure the impact resistance of the resin molded article. When the content of the copolymer is 81 mass% or less of the total mass of the copolymer and the polyamide resin in the present invention, the resin molded article can sufficiently secure toughness.

Preferably, the copolymer is dispersed in the polyamide-based resin as a plurality of fine particles (dispersed phase particles having a diameter of submicron or micrometer scale). The copolymer is not miscible with the polyamide resin and can be present as a dispersed phase in the polyamide resin. In this way, since the copolymer is dispersed as dispersed phase particles in the polyamide-based resin, the resin composition can form a resin molded body having excellent toughness and impact resistance.

[ Polyamide resin ]

The resin composition contains a polyamide resin.

The polyamide-based resin is a resin having an amide bond (-NHCO-) in the main chain, and may be thermosetting or thermoplastic. Preferably, the polyamide-based resin used in the present invention is not miscible with the above-mentioned copolymer.

The polyamide-series resin includes aliphatic polyamides such as polycaproamide (nylon-6), poly- ω -aminoheptanoic acid (nylon-7), poly- ω -aminononanoic acid (nylon-9), polyundecanolactam (nylon-11), polylaurolactam (nylon-12), polyethylene adipamide (nylon-2, 6), polybutylene adipamide (nylon-4, 6), polyhexamethylene adipamide (nylon-6, 6), polyhexamethylene sebacamide (nylon-6, 10), polyhexamethylene dodecanodiamide (nylon-6, 12), polyhexamethylene adipamide (nylon-8, 6), and polyhexamethylene sebacamide (nylon-10, 8); and crystalline aromatic polyamides obtained by polycondensation of aromatic amines such as m-xylylenediamine and p-xylylenediamine and dicarboxylic acids such as adipic acid, suberic acid, sebacic acid, cyclohexanedicarboxylic acid, terephthalic acid and isophthalic acid, or derivatives thereof.

Among them, nylon-6, 6 and nylon-12 are preferable, and nylon-6 (also referred to as polyamide 6) is more preferable.

The number average molecular weight (Mn) of the polyamide resin in terms of polystyrene is preferably 5,000 to 10,000,000, more preferably 7,000 to 1,000,000, and even more preferably 10,000 to 1,000,000, from the viewpoint of improving the low-temperature impact resistance of the resin molded article.

When Mn of the polyamide-based resin is 5,000 or more, low-temperature impact resistance of the resin molded body may be excellent, and when Mn is 10,000,000 or less, toughness of the resin molded body may be excellent.

The polyamide-based resin preferably has a relatively high viscosity from the viewpoint of miscibility with the copolymer in the present invention.

The above polyamide-series resin includes UBESTA (e.g., 3014U, 3020U) and Ube Nylon (injection 1022B, injection 1030B) manufactured by Ube Industries, ltd.; and VESTAMID (e.g., L1600, L1700) manufactured by Daicel-Evonik ltd.

The content of the polyamide-based resin is preferably 19% by mass or more, more preferably 25% by mass or more, even more preferably 35% by mass or more, further more preferably 50% by mass or more, and preferably 99% by mass or less, more preferably 95% by mass or less, even more preferably 90% by mass or less of the total mass of the copolymer and the polyamide-based resin in the present invention.

When the content of the polyamide-based resin is 19% by mass or more of the total mass of the copolymer and the polyamide-based resin in the present invention, the copolymer can sufficiently exhibit the effect to sufficiently secure the impact resistance of the resin molded article. When the content of the copolymer is 99% by mass or less of the total mass of the copolymer and the polyamide resin in the present invention, the resin molded article can sufficiently secure toughness.

(anti-aging agent)

From the viewpoint of further improving the impact resistance and toughness of the resin molded article, the resin composition preferably contains an antioxidant. It is also preferable that the resin composition contains an antioxidant to prevent gelation of the conjugated diene unit at high temperature when the resin composition is melt-kneaded.

Examples of the antioxidant include amine-ketone compounds, imidazole compounds, amine compounds, phenol compounds, sulfur compounds and phosphorus compounds.

Particularly preferably, the resin composition comprises an antioxidant comprising at least 2 phenyl groups having a branched alkyl group. The dispersibility of the copolymer and the polyamide-based resin in the present invention can be made better by using an antioxidant comprising at least 2 phenyl groups having a branched alkyl group. In addition, the antioxidant comprising at least 2 phenyl groups having branched alkyl groups can prevent gelation of the copolymer when the copolymer of the present invention and the polyamide-based resin are mixed at high temperature.

More specifically, the antioxidant preferably has a structure represented by the following formula (1) or (2).

In the formulae (1) and (2), R¹～R⁸、R¹¹～R¹⁸And R²¹～R²⁴Each represents a hydrogen atom, a straight-chain alkyl group, a cyclic alkyl group or a branched-chain alkyl group, and R¹～R⁸At least one of (1), and R¹¹～R¹⁸And R²¹～R²⁴At least one of which is a branched alkyl group. R¹～R⁸、R¹¹～R¹⁸And R²¹～R²⁴Each may be the same or different from each other. R⁹Represents a hydrocarbon group. A. the¹And A²Each represents a linking group. E represents a trivalent heteroatom.

The straight-chain alkyl group preferably has 1 to 12 carbon atoms, more preferably 1 to 8, even more preferably 1 to 5, and further more preferably 1 to 3 carbon atoms. Specifically, examples of the group include methyl, ethyl, n-propyl, n-butyl, n-pentyl, n-hexyl, n-heptyl, n-octyl, n-nonyl, n-decyl and n-dodecyl groups. The straight-chain alkyl group may further have a substituent such as a halogen atom.

Among the above, the linear alkyl group is preferably an unsubstituted linear alkyl group, and more preferably a methyl group, an ethyl group or an n-propyl group.

The cyclic alkyl group preferably has 5 to 12 carbon atoms, more preferably 6 to 12, and even more preferably 6 to 8 carbon atoms. Specifically, examples of the group include cyclopentyl, cyclohexyl, and cyclooctyl. The cyclic alkyl group may further have a substituent such as an alkyl group having 1 to 3 carbon atoms, and a halogen atom.

Among the above, the cyclic alkyl group is preferably an unsubstituted cyclic alkyl group, and more preferably a cyclohexyl group.

The branched alkyl group preferably has 3 to 12 carbon atoms, more preferably 3 to 8, even more preferably 4 to 8, and further more preferably 4 to 6 carbon atoms. Specifically, examples of the group include isopropyl group, 2-butyl group, tert-pentyl group, 2-hexyl group, 2-heptyl group, -2-octyl group and 2-dodecyl group. The branched alkyl group may further have a substituent such as a halogen atom.

Among the above, the branched alkyl group is preferably an unsubstituted branched alkyl group, more preferably an isopropyl group, a 2-butyl group, a tert-butyl group or a tert-pentyl group, and even more preferably a tert-butyl group or a tert-pentyl group.

From R⁹Examples of the hydrocarbon groups represented include alkyl groups, alkenyl groups, and alkynyl groups.

The alkyl group includes the above R¹～R⁸And other listed straight chain, cyclic and branched alkyl groups, and their preferred ranges are also the same as the latter.

Preferably, the alkenyl group and the alkynyl group each have 2 to 8 carbon atoms, and examples thereof include a vinyl group.

From A¹And A²The linking group includes a divalent hydrocarbon group having 1 to 6 carbon atoms, which may contain a divalent or higher hetero atom. The hydrocarbon of the hydrocarbon group may be a saturated hydrocarbon or an unsaturated hydrocarbon. Among them, the linking group is preferably a saturated hydrocarbon group, and preferably has 1 to 5 carbon atoms, more preferably 1 to 4 carbon atoms.

Examples of divalent or higher heteroatoms include oxygen atoms and sulfur atoms.

The linking group may further have a substituent such as a halogen atom, a methyl group or an ethyl group.

The trivalent hetero atom represented by E includes a sulfur atom and a phosphorus atom, and among them, a phosphorus atom is preferable.

In the formula (1), R¹～R⁴At least one of (1) and R⁵～R⁸Each of which has a branched alkyl group. In formula (2), preferably, selected from the group consisting of R¹¹～R¹⁴A group Ra selected from R¹⁵～R¹⁸And a group selected from R²¹～R²⁴At least two of the groups Rc in (a) each have a branched alkyl group.

The phenyl group having a branched alkyl group preferably has a plurality of branched alkyl groups.

Wherein R is¹～R⁴At least two of R⁵～R⁸At least two of R¹¹～R¹⁴At least two of (1), and R¹⁵～R¹⁸At least two of which are each preferably branched alkyl.

Preferably, formula (1) is the following structure:

R¹and R⁸Each is a branched alkyl group; r²、R⁴、R⁵And R⁷Is a hydrogen atom; r³And R⁶Each is a branched alkyl or straight chain alkyl; r⁹Is an unsaturated hydrocarbon group; and A is¹Is a divalent saturated hydrocarbon group.

More preferably, formula (1) is the following structure:

R¹and R⁸Each is an unsubstituted branched alkyl group having 3 to 6 carbon atoms; r²、R⁴、R⁵And R⁷Is a hydrogen atom; r³And R⁶Each being an unsubstituted branched alkyl group having 4 to 5 carbon atoms or an unsubstituted straight alkyl group having 1 to 3 carbon atoms; r⁹Is an unsaturated vinyl group; and A is¹Is a methylene group substituted with an alkyl group, or an unsubstituted methylene group.

Preferably, formula (2) is the following structure:

R¹¹、R¹³、R¹⁶、R¹⁸and R²¹Each is a branched alkyl group; r¹²、R¹⁴、R¹⁵、R¹⁷、R²²And R²³Is a hydrogen atom; r²⁴Is a straight chain alkyl group; a. the²Is a divalent saturated hydrocarbon group containing an oxygen atom; and E is a sulfur atom or a phosphorus atom.

More preferably, formula (2) is the following structure:

R¹¹、R¹³、R¹⁶、R¹⁸and R²¹Each is an unsubstituted branched alkyl group having 3 to 5 carbon atoms; r¹²、R¹⁴、R¹⁵、R¹⁷、R²²And R²³Is a hydrogen atom; r²⁴Is an unsubstituted straight-chain alkyl group having 1 to 3 carbon atoms; a. the²Is an unsubstituted alkyleneoxy group (-OR-, wherein R is an unsubstituted alkylene group having 2 to 5 carbon atoms) having 2 to 5 carbon atoms; and E is a phosphorus atom.

More preferably, the compound having the structure of formula (1) is a compound having a structure represented by the following formula (3) or (4).

More preferably, the compound having the structure of formula (2) is a compound having a structure represented by the following formula (5).

Among the above, the antioxidant comprising at least 2 phenyl groups having a branched alkyl group is even more preferably a compound having a structure represented by the above formula (4) or (5).

For an antioxidant comprising at least two phenyl groups having a branched alkyl group, one or two or more of the compounds having the above structure may be used alone or in combination.

The content of the antioxidant in the resin composition is preferably 0.1 to 5 parts by mass, more preferably 0.5 to 3 parts by mass, based on 100 parts by mass of the total of the copolymer and the polyamide resin in the present invention.

[ compatibilizers ]

From the viewpoint of improving the dispersibility of the copolymer and the polyamide resin in the present invention, the resin composition preferably further contains a compatibilizer.

The compatibilizer includes modified copolymers of styrene-isobutylene-styrene block copolymer (SIBS), styrene-butadiene-styrene block copolymer (SBS), styrene-ethylene/butylene-styrene block copolymer (SEBS; polystyrene-hydrogenated polybutadiene-polystyrene block copolymer), and styrene-ethylene/propylene block copolymer (SEPS; polystyrene-hydrogenated polyisoprene-polystyrene block copolymer), each of which is modified with maleic acid. In the present invention, at least one selected from these modified copolymers is preferable.

The content of the compatibilizer in the resin composition is preferably 0.5 to 20 parts by mass, more preferably 2 to 10 parts by mass, based on 100 parts by mass of the total of the copolymer and the polyamide resin in the present invention.

[ Components ]

The resin composition may contain compounding agents generally used in the rubber industry, for example, an elastomer component, any other resin component than the polyamide-based resin, a crosslinking agent, a softening agent, stearic acid, zinc oxide, and a crosslinking accelerator, as long as they are appropriately selected within a range not deviating from the object of the present invention.

(elastomer component)

The elastomer component includes any other rubber component and thermoplastic elastomer other than the copolymer in the present invention.

(1) Rubber component

Examples of the other rubber component other than the copolymer in the invention include diene rubbers.

The diene rubber includes Natural Rubber (NR) and synthetic diene rubber.

Specifically, the synthetic diene rubber includes polyisoprene rubber (IR), polybutadiene rubber (BR), styrene-butadiene copolymer rubber (SBR), Chloroprene Rubber (CR), halogenated butyl rubber, and acrylonitrile-butadiene rubber (NBR).

One or more kinds of diene rubbers may be used alone or in combination. The diene rubber may be modified.

The rubber component may contain a non-diene rubber.

(2) Thermoplastic elastomer

Examples of the thermoplastic elastomer include styrene-based elastomers, olefin-based elastomers, ester-based elastomers, polyurethane-based elastomers, amide-based elastomers, and hard vinyl chloride-based elastomers. In the present invention, a single one or two or more of these elastomers may be used.

(resin component)

The resin composition of the present invention may contain any other resin component than the polyamide-based resin. Examples of other resin components suitable for use in the present invention include thermoplastic resins and thermosetting resins other than polyamide-based resins.

(Filler)

The resin composition may contain a filler.

The filler contained in the resin composition can improve characteristics such as abrasion resistance of the resin molded article.

The filler is not particularly limited, and for example, a reinforcing filler capable of reinforcing the resin composition may be used. Examples of the reinforcing filler include silica, carbon black, talc, fibers, calcium carbonate, titanium oxide, graphite, metal powder, clay, mica, glass flake, calcium titanate, alumina, Eval and water-absorbing polymer gel. One or two or more of these may be used alone or in combination. Among them, silica, carbon black, talc, fiber and calcium carbonate are more preferable.

[ carbon Black ]

Without particular limitation, the carbon black may be appropriately selected depending on the intended purpose. For example, FEF, SRF, HAF, ISAF or SAF grade carbon black is preferred, and HAF, ISAF or SAF grade carbon black is more preferred.

[ silica ]

The silica is not particularly limited, and general grade silica as well as special silica prepared by surface treatment with a silane coupling agent or the like may be used according to the intended purpose. As the silica, for example, wet silica is preferably used.

[ fibers ]

The fibers are not particularly limited, and glass fibers, cellulose fibers, carbon fibers, metal fibers, aramid fibers, and gypsum fibers may be selected according to the intended purpose. Among them, glass fiber, carbon fiber, aramid fiber and cellulose fiber are more preferable.

(crosslinking agent)

Without particular limitation, in general, peroxides, sulfur, oximes, amines, and ultraviolet curing agents may be used as the crosslinking agent.

The copolymer in the present invention contains conjugated diene units and can therefore be crosslinked (vulcanized) with sulfur. Examples of sulfur include powdered sulfur, precipitated sulfur, colloidal sulfur, surface-treated sulfur, and insoluble sulfur.

< method for producing resin composition >

The resin composition can be produced by: the copolymer of the present invention, the polyamide resin, and other various components such as an antioxidant are blended, and then kneaded with a kneader such as a Banbury mixer, a roll, an internal mixer, a single-screw extruder, or a twin-screw extruder.

Preferably, in the production of the resin composition, the components in the resin composition are each blended in an amount shown by the content of each component in the resin composition.

The mixing of the components may be carried out all in one stage, or may be carried out in two or more stages.

In the case where the resin composition is extruded by melt extrusion using an extrusion compounder, the extruded resin composition may be directly pelletized into pellets, or strands (strand) may be first formed and then the strands may be pelletized into pellets. The shape of the pellets may be any common shape such as cylindrical, prismatic and spherical.

< resin molded article >

The resin molded article of the present invention is formed using the resin composition of the present invention.

For example, the pelletized resin composition can be molded by injection molding or extrusion molding to obtain a resin molded article.

The resin composition may be crosslinked with the above-mentioned crosslinking agent, or may be crosslinked by electron beam crosslinking or microwave irradiation without using such a crosslinking agent, to obtain a resin molded article.

Having a diene portion, the resin molded body of the present invention can be etched and plated like ABS (acrylonitrile butadiene styrene) resin. The plating conditions are not particularly limited, and the resin molded body may be plated in a known plating method (electroless plating or electroplating). In the plating, various functionalities such as conductivity, electromagnetic wave shielding property and design property can be imparted to the resin molded body, and thus various added values can be imparted.

As for injection molding, not only a usual molding method but also any other molding method such as injection compression molding, injection press molding, gas assist injection molding, foam molding, insert molding, in-mold coating molding, adiabatic runner molding, rapid heating cooling molding, two-color molding, multi-color molding, sandwich molding or ultrahigh speed injection molding can be used to obtain a molded article. For the forming, either a cold runner system or a hot runner system may be selected.

In extrusion molding, various profile extrusion molded articles, sheets and films can be obtained. For forming sheets and films, inflation, calendering or casting methods may also be employed.

The resin molded body can be further stretched.

The resin molded article of the present invention preferably has a microstructure of a so-called "sea-island" structure in which fine particles (dispersed phase particles) of the copolymer are dispersed in the polyamide-based resin. Such a structure can be confirmed, for example, by observing the resin molded body with an optical microscope, a scanning electron microscope, or an atomic force microscope.

The resin molded article of the present invention is excellent in toughness and impact resistance, and therefore can be applied to various products. For example, it is suitable for tires and automobile parts (e.g., automobile seats, automobile batteries (e.g., lithium ion batteries), weather strips, hoses, vibration-proof rubbers, cables, and sealants).

The resin composition of the present invention is suitable for use in conveyor belts, crawler belts, vibration-proof rubbers, hoses, resin piping, sound-absorbing materials, bedding, precision parts for office machines (OA rollers), bicycle frames, golf balls, tennis rackets, golf clubs, resin additives, filters, adhesives, pressure-sensitive adhesives, inks, medical machines (medical catheters, bags, microneedles, rubber sleeves, artificial organs, caps, packages, syringe gaskets, stoppers, artificial legs, and prostheses), cosmetics (UV powders, puffs, containers, waxes, shampoos, and hair conditioners), detergents, building materials (flooring materials, vibration control rubbers, vibration-isolating rubbers, building films, sound-absorbing materials, waterproof sheets, heat-insulating materials, caulking materials, and sealant materials), packaging materials, liquid crystal materials, organic EL materials, organic semiconductor materials, electronic materials, and the like, Electronic equipment, communication equipment, aircraft components, mechanical components, electronic components, agricultural materials, electric wires, cables, fibers (wearable chassis), household goods (toothbrushes, shoe soles, glasses, baits, binoculars, toys, dust masks, garden watering hoses), robot components, optical components, road materials (asphalt, guard rails, utility poles, signs), protective devices (shoes, protective vests), exterior components of electrical appliances, OA exterior components, shoe soles, and sealants.

In the above, OA means office automation, UV means ultraviolet ray, and EL means electroluminescence.

Examples

The present invention is described in more detail below by referring to examples, but it should be construed that the examples are illustrative of the present invention and not limitative of the present invention in any way.

Example 1, comparative example 1

< preparation of resin composition >

Resin compositions were prepared according to the formulations in table 2.

The details of the components in table 2 are as follows.

Polyamide resin (PA resin) 1: polyamide 6, trade name "UBE Nylon (registered trademark) injection 1022B" manufactured by Ube Industries, Ltd "

Polymer 1: polymer produced according to the following production method

Polymer 101: hydrogenated styrene-based thermoplastic elastomer (SEBS) having a crystallinity degree of "gauge-Tech (registered trademark) H1062" manufactured by Asahi Kasei corp., ltd: 0 percent.

Compatibilizer 1: a trade name "Tough-Tech (registered trademark) M1913" manufactured by Asahi Kasei Corp.

Anti-aging agent 1:2, 2' -methylenebis (4-ethyl-6-tert-butylphenol), "Nocrac (registered trademark) NS-5" manufactured by Ouchi Shinko Chemical Industrial Co., Ltd "

[ Process for producing Polymer 1]

1. Synthesis method of Polymer 1 (copolymer in the invention)

52g of styrene and 762g of toluene were placed in a completely dry 2000-mL pressure-resistant stainless steel reactor.

In a glove box under nitrogen atmosphere, mono (bis (1, 3-tert-butyldimethylsilyl) indenyl) bis (dimethylsilyl) amide) gadolinium complex 1,3- [ (t-Bu) Me₂Si]₂C₉H₅Gd[N(SiHMe₂)₂]0.031mmol, and dimethylanilinium tetrakis (pentafluorophenyl) borate [ Me₂NHPhB(C₆F₅)₄]0.031mmol was put into a glass container, and 21g of toluene was added thereto to prepare a catalyst solution. The catalyst solution was added to the previous pressure resistant stainless steel reactor and heated to 60 ℃. "t-Bu" means t-butyl, "Me" means methyl, and "Ph" means phenyl (the same applies to the process for producing polymers 2 and 3).

Next, ethylene was introduced into a pressure-resistant stainless steel reactor at a pressure of 1.0MPa, and copolymerization was carried out at 75 ℃ for a total of 9 hours. As for 1, 3-butadiene, 108g of a toluene solution containing 27g of 1, 3-butadiene was continuously added at a rate of 0.6 mL/min.

Next, 1mL of a 5 mass% isopropanol solution of 2,2' -methylene-bis (4-ethyl-6-tert-butylphenol) (NS-5) was added to a pressure-resistant stainless steel reactor to terminate the reaction.

Next, the copolymer was isolated using a large amount of methanol, and vacuum-dried at 50 ℃, thereby obtaining polymer 1.

Physical properties of the obtained polymer 1 are shown in Table 1.

TABLE 1

	Polymer 1
		Weight average molecular weight (Mw) (. times.10)3)	403
Number average molecular weight (Mn) (. times.10)3)	156
		Peak Top molecular weight (Mp) (. times.10)3)	248
Molecular weight distribution (Mw/Mn)	2.6
		Content of ethylene Unit (mol%)	85
Content of butadiene Unit (mol%)	8
		Content of styrene Unit (mol%)	7
Melting Point (. degree.C.)	49
		Degree of crystallinity (%)	13.1

Polymer 1 in which¹³No peak was observed at 10 to 24ppm in the C-NMR spectrum, and it was confirmed that the main chain of the polymer 1 synthesized herein was composed of only a non-cyclic structure.

These physical properties were measured according to the following methods.

[ measuring method of physical Properties of Polymer ]

(1) Number average molecular weight (Mn), weight average molecular weight (Mw), peak top molecular weight (Mp) and molecular weight distribution (Mw/Mn)

The gel permeation chromatography [ GPC: HLC-8121GPC/HT manufactured by Tosoh Corporation, having 2 GMHs manufactured by Tosoh Corporation_HR-H (S) HT column, and detector for differential Refractometer (RI)]The number average molecular weight (Mn), weight average molecular weight (Mw), peak top molecular weight (Mp), and molecular weight distribution (Mw/Mn) of the copolymer in terms of polystyrene were determined based on monodisperse polystyrene. The measurement temperature was 40 ℃.

(2) Content of ethylene unit, butadiene unit and styrene unit

By¹The content (mol%) of ethylene units, butadiene units and styrene units in the copolymer was determined by integrating the ratio of peaks in an H-NMR spectrum (100 ℃ C., d-tetrachloroethane standard: 6 ppm).

In the polymer 1, the total of the content of ethylene units, the content of butadiene units and the content of styrene units was 100 mol%, and the content of butene units thereof was 0 mol%.

(3) Melting Point

The melting point of the copolymer was measured with a differential scanning calorimeter (DSC, "DSC Q2000" manufactured by TA Instruments Japan Inc.) in accordance with JIS K7121-1987.

(4) Degree of crystallinity

The crystalline melting energy of polyethylene in 100% crystalline component and the melting peak energy of the resulting copolymer at 0 to 120 ℃ are measured, and the crystallinity is calculated from the energy ratio of polyethylene to copolymer. The melting peak energy was measured with a differential scanning calorimeter (DSC, "DSC Q2000" manufactured by TAInstructions Japan Inc.).

(5) Confirmation of the backbone Structure

Measuring synthetic copolymers¹³C-NMR spectrum.

< production of resin molded article >

The components were blended at 180 ℃ and 50rpm for 5 minutes according to the formulation in table 2 and using 90-cc laboptomill (manufactured by Toyo Seiki Kogyo co., ltd.). The obtained resin composition was pressed at 180 ℃ for 5 minutes using a mold having a thickness of 2mm, and then rapidly cooled for 5 minutes, thereby obtaining a resin molded body of 150mm × 150mm × 2 mm.

A test piece for charpy test (resin molded article) for evaluating impact resistance was produced as follows.

The resin compositions prepared according to the formulations in table 2 were molded into test pieces having dimensions of 10mm × 80mm × 4mm using a 15-ton injection molding machine (Roboshot manufactured by Fanuc Corporation) at an injection speed of 30 mm/sec, a cylinder temperature of 200 ℃ and a mold temperature of 40 ℃, and then the resulting test pieces were notched into test pieces for charpy test using a notching machine.

< evaluation >

(1) Toughness of

Elongation at break (% GL) and stress at break (MPa) of the resin molded body were measured, and toughness of the resin molded body was calculated as "(elongation at break × stress at break)/2". The calculated value in comparative example 1 was referred to as 100, and the calculated value in example 1 was indexed based on the former. The toughness index obtained is shown in Table 2.

A test piece for tensile test (JIS-K7127, test piece type 1B size) was sampled from the resin molded body, and the strength thereof was measured at a rate of 100 mm/min in the tensile test, and the measurement was stopped when the resin molded body was broken, and the elongation at this time was referred to as the elongation at break, and the strength at this time was referred to as the breaking stress.

As the measuring device, a universal tester ("Tensilon RTC-1310A" manufactured by A & D Corporation) was used.

(2) Impact resistance

Samples of the resin molded body placed in an environment of-30 ℃ and samples of the resin molded body placed in an environment of 30 ℃ were analyzed to measure charpy notched impact values thereof in accordance with ISO 179. The measured value of the impact resistance at 30 ℃ in comparative example 1 was referred to as 100, and the measured value at 30 ℃ in example 1, the measured value at-30 ℃ in example 1, and the measured value at-30 ℃ in comparative example 1 were each indexed based on the former. The impact resistance index obtained is shown in Table 2.

(3) Balance between toughness and impact resistance

In example 1 and comparative example 1, the sum of the toughness index and the impact resistance index at 30 ℃ and the sum of the toughness index and the impact resistance index at-30 ℃ were calculated, respectively, and are shown in Table 2. The larger the numerical value is, the more excellent the balance between toughness and impact resistance of the resin molded article is.

TABLE 2

As is apparent from table 2, the resin molded body obtained from the system (comparative example 1) in which SEBS (polymer 101) and polyamide-based resin (PA resin 1) were used together as usual is not excellent in the balance between toughness and impact resistance.

On the other hand, the resin molded body of example had a toughness index of more than 2.5 times as compared with the index in comparative example 1, had high toughness, and had a significantly larger balance index of toughness and impact resistance at 30 ℃ and-30 ℃ than comparative example 1, that is, the resin molded body of example 1 was excellent in the balance between toughness and impact resistance.

As in the above, applying a resin molded body having high toughness and a good balance between toughness and impact resistance to a tire and a bumper can obtain a tire and a bumper excellent in both impact resistance and toughness even in cold climates.

Examples 2 to 8 and comparative example 2

< preparation of resin composition >

Resin compositions were prepared according to the formulations in table 4.

The details of the components in table 4 are as follows.

Polyamide resin (PA resin) 1: polyamide 6, trade name "UBE Nylon (registered trademark) injection 1022B" manufactured by Ube Industries, Ltd "

Polyamide resin (PA resin) 2: polyamide 6, available under the trade name "UBE Nylon (registered trademark) injection 1030B" from Ube Industries, Ltd "

Polymer 2: a polymer produced according to the following production method.

BR: butadiene rubber (trade name "UBEPOL BR150L1 manufactured by Ube Industries, ltd.) compatibilizer 1: a trade name "Tough-Tech (registered trademark) M1913" manufactured by Asahi Kasei Corp.

Anti-aging agent 1:2, 2' -methylenebis (4-ethyl-6-tert-butylphenol), "Nocrac (registered trademark) NS-5" manufactured by Ouchi Shinko Chemical Industrial Co., Ltd "

[ Synthesis method of Polymer 2]

91g of styrene and 379g of toluene were placed in a completely dry 2000-mL pressure-resistant stainless steel reactor.

In a glove box under nitrogen atmosphere, mono (bis (1, 3-tert-butyldimethylsilyl) indenyl) bis (dimethylsilyl) amide) gadolinium complex 1,3- [ (t-Bu) Me₂Si]₂C₉H₅Gd[N(SiHMe₂)₂]0.1mmol of dimethylanilinium tetrakis (pentafluorophenyl) borate [ Me₂NHPhB(C₆F₅)₄]0.1mmol, and 0.2mmol of triisobutylaluminum were put in a glass vessel, and 63mL of toluene was added thereto to prepare a catalyst solution. The catalyst solution was added to the previous pressure resistant stainless steel reactor and heated to 60 ℃.

Next, ethylene was introduced into a pressure-resistant stainless steel reactor at a pressure of 1.5MPa, and copolymerization was carried out at 75 ℃ for a total of 3 hours. As for 1, 3-butadiene, 280g of a toluene solution containing 70g of 1, 3-butadiene was continuously added at a rate of 1.5 to 1.6 mL/min.

Next, 1mL of a 5 mass% isopropanol solution of 2,2' -methylene-bis (4-ethyl-6-tert-butylphenol) (NS-5) was added to a pressure-resistant stainless steel reactor to terminate the reaction.

Next, the copolymer was isolated using a large amount of methanol, and vacuum-dried at 50 ℃, thereby obtaining polymer 2.

Physical properties of the obtained polymer 2 are shown in Table 3. The physical properties of the polymer 2 were measured according to the above "[ measuring method of physical properties of polymer ]".

TABLE 3

	Polymer 2
		Weight average molecular weight (Mw) (. times.10)3)	457
Number average molecular weight (Mn) (. times.10)3)	184
		Peak Top molecular weight (Mp) (. times.10)3)	330
Molecular weight distribution (Mw/Mn)	2.5
		Content of ethylene Unit (mol%)	69
Content of butadiene Unit (mol%)	26
		Content of styrene Unit (mol%)	5
Melting Point (C degree)	80
		Degree of crystallinity (%)	16.4

In the polymer 2, the total of the content of ethylene units, the content of butadiene units and the content of styrene units was 100 mol%, and the content of butene units thereof was 0 mol%. Polymer 2 therein¹³No peak was observed at 10 to 24ppm in the C-NMR spectrum, and it was confirmed that the main chain of the polymer 2 synthesized herein was composed of only a non-cyclic structure.

< production of resin molded article >

According to the formulation in Table 4 and using an extruder (single-rotating twin-screw extruder, Omega 30H (phi 30, L/D60, manufactured by Steer Japan) and a feeder (gravimetric single-screw feeder KS60), the components were blended at a feed rate of 9kg/H and a mixing temperature of 25 ℃ and then, the mixture was extruded as a strand of phi 3mm, these were cooled and cut into pellets, the resulting resin composition was pressed at 250 ℃ for 5 minutes using a die having a thickness of 2mm and then rapidly cooled for 5 minutes, thereby obtaining a resin molded body of 150mm X2 mm.

< evaluation >

The surfaces of the resin molded bodies of examples 2 to 8 and comparative example 2 were subjected to shape measurement using an atomic force microscope (AFM, SPM-9700HT, manufactured by Shimadzu Corporation). The measurement conditions are as follows.

(measurement conditions)

Phase scanning range: 20 μm.times.20 μm

Scanning speed: 0.5Hz

Pixel number: 512X 512

Cantilever used: OMCL-AC160TS-R3 (resonant frequency: 300kHz, spring constant 26N/m) manufactured by Olympus Corporation

TABLE 4

FIGS. 1 to 8 show atomic force microscope images (in the range of 20 μm. times.20 μm) of the surfaces of the resin molded bodies of examples 2 to 8 and comparative example 2, respectively. In all examples in which the polymer 2 was mixed with a polyamide-based resin, the polymer dispersibility was good. In examples 5, 6 and 8 using the polyamide-based resin 2, the polymer dispersion was better than that of comparative example 2 in which butadiene rubber and a polyamide-based resin were mixed. In examples 5, 6 and 8, the dispersibility was better than in examples 2 to 4 and 7 using the polyamide resin 1. The polyamide resin 2 is characterized by having a higher viscosity than that of the polyamide resin 1, and therefore, it is presumed that the viscosity of the polyamide resin and the amount of the compatibilizer have a certain influence on the polymer dispersibility.

Examples 9 to 13 and comparative example 3

< preparation of resin composition >

Resin compositions were prepared according to the formulations in table 6.

The details of the components in table 6 are as follows.

Polyamide resin (PA resin) 2: polyamide 6, available under the trade name "UBE Nylon (registered trademark) injection 1030B" from Ube Industries, Ltd "

Polymer 1: a polymer produced according to the above production method.

Polymer 2: a polymer produced according to the above production method.

Polymer 3: a polymer produced according to the following production method.

Compatibilizer 1: a trade name "Tough-Tech (registered trademark) M1913" manufactured by Asahi Kasei Corp.

Compatibilizer 2: a trade name "Tough-Tech (registered trademark) M1943" manufactured by Asahi Kasei Corp.

Anti-aging agent 2: "SUMILIZER (registered trademark) GS (F)" manufactured by Sumitomo Chemical Co., Ltd "

Anti-aging agent 3: "SUMILIZER (registered trademark) GP" manufactured by Sumitomo Chemical Co., Ltd "

[ Process for producing Polymer 3]

91g of styrene and 379g of toluene were placed in a completely dry 2000-mL pressure-resistant stainless steel reactor.

In a glove box under nitrogen atmosphere, mono (bis (1, 3-tert-butyldimethylsilyl) indenyl) bis (dimethylsilyl) amide) gadolinium complex 1,3- [ (t-Bu) Me₂Si]₂C₉H₅Gd[N(SiHMe₂)₂]0.1mmol of dimethylanilinium tetrakis (pentafluorophenyl) borate [ Me₂NHPhB(C₆F₅)₄]0.1mmol and 0.3mmol of triisobutylaluminum were put in a glass vessel, and 63mL of toluene was added thereto to prepare a catalyst solution. The catalyst solution was added to the previous pressure resistant stainless steel reactor and heated to 60 ℃.

Next, ethylene was introduced into a pressure-resistant stainless steel reactor under a pressure of 1 to 1.5MPa, and copolymerization was carried out at 85 ℃ for a total of 4 hours. As for 1, 3-butadiene, 280g of a toluene solution containing 70g of 1, 3-butadiene was continuously added at a rate of 1.1 to 1.2 mL/min.

Next, 1mL of a 5 mass% isopropanol solution of 2,2' -methylene-bis (4-ethyl-6-tert-butylphenol) (NS-5) was added to a pressure-resistant stainless steel reactor to terminate the reaction.

Next, the copolymer was isolated using a large amount of methanol, and vacuum-dried at 50 ℃, thereby obtaining polymer 3.

Physical properties of the obtained polymer 3 are shown in Table 5. The physical properties of the polymer 3 were measured according to the above "[ measuring method of physical properties of polymer ]".

TABLE 5

	Polymer 3
		Weight average molecular weight (Mw) (. times.10)3)	513
Number average molecular weight (Mn) (. times.10)3)	163
		Peak Top molecular weight (Mp) (. times.10)3)	299
Molecular weight distribution (Mw/Mn)	3.2
		Content of ethylene Unit (mol%)	66
Content of butadiene Unit (mol%)	29
		Content of styrene Unit (mol%)	5
Melting Point (. degree.C.)	80
		Degree of crystallinity (%)	18.5

The content of ethylene units, the content of butadiene units and the content of styrene units in the polymer 3The total is 100 mol%, and the content of butene units thereof is 0 mol%. Polymer 3 at which¹³No peak was observed at 10 to 24ppm in the C-NMR spectrum, and it was confirmed that the main chain of the polymer 3 synthesized herein was composed of only a non-cyclic structure.

< production of resin molded article >

The components were blended at a feeding speed of 9kg/H and a mixing temperature of 25 ℃ in accordance with the formulation in table 6 and using an extruder (single-rotating twin-screw extruder, Omega 30H (Φ 30, L/D60, manufactured by Steer Japan) and a feeder (gravimetric single-screw feeder KS60), and subsequently, the mixture was extruded as a strand of Φ 3mm, these were cooled and cut into pellets, the resulting resin composition was pressed at 250 ℃ for 5 minutes using a die having a thickness of 2mm, and then rapidly cooled for 5 minutes, thereby obtaining a resin molded body of 150mm × 150mm × 2 mm.

In comparative example 3, the polyamide resin 2 was pressed at 250 ℃ for 5 minutes using a mold having a thickness of 2mm, and then rapidly cooled for 5 minutes, thereby obtaining a resin molded body of 150mm × 150mm × 2 mm.

< evaluation >

(1) Atomic Force Microscope (AFM) observation

The surfaces of the resin molded bodies of examples 9 to 13 were subjected to shape measurement using an atomic force microscope (SPM-9700HT, manufactured by Shimadzu Corporation). The measurement conditions were the same as described above.

(2) Tensile strength and elongation at break

The resin molded bodies of examples 9 to 11 and comparative example 3 were molded into No.3 dumbbell test pieces in accordance with JIS K6251: 2017.

Tensile strength (Tb) was measured using a tensile tester (manufactured by Instron Corporation) based on JIS K6251: 2017. The test piece was elongated 100% at 25 ℃ and the maximum tension required to break the test piece was measured.

With respect to the elongation at break (Eb), a test piece was pulled at a speed of 100 mm/min at 25 ℃, the length of the test piece at break was measured, and the length at this time with respect to the length before pulling (100%) was calculated.

The results of measuring the tensile strength and elongation at break of the resin molded articles of examples 9 to 11 and comparative example 3 are shown in Table 6.

TABLE 6

FIGS. 9 to 13 show Atomic Force Microscope (AFM) images of the surfaces of the resin molded bodies of examples 9 to 13, respectively. In examples 9 to 13, since a proper amount of a compatibilizer was added and a resin having a relatively high viscosity was used, the polymer was almost uniformly dispersed in the polyamide-based resin as a fine dispersion phase therein.

As shown in Table 6, the resin molded articles of examples 9 to 11 had slightly lower tensile strength than the resin molded article of comparative example 3, but they all had greatly increased elongation at break. Specifically, it can be said that a resin molded body formed from a resin composition containing the polymer of the present invention and a polyamide resin is excellent not only in toughness and impact resistance as shown in table 2, but also in elongation.