Resin composition, masterbatch pellets, and molded resin composition product and method for producing the same

Abstract

Provided are a resin composition and masterbatch pellets, which enable a molded resin composition product to improve both flexural modulus and Izod impact strength, and a molded resin composition product having both improved flexural modulus and improved Izod impact strength, and a method for producing the same. The resin composition includes 45 to 95 mass % of an olefin polymer, 1 to 50 mass % of fibrous basic magnesium sulfate, 0.00001 to 0.8 mass % of spherical silica particles, and 0.1 to 10 mass % of a lubricant. Also, the masterbatch pellets are for production of the resin composition by kneading the masterbatch pellets with a diluent containing olefin polymer, and the masterbatch pellets contain 10 to 50 mass % of an olefin polymer, 35 to 80 mass % of fibrous basic magnesium sulfate, 0.00005 to 5.0 mass % of spherical silica particles, and 0.5 to 10 mass % of a lubricant.

Claims

1. A resin composition, comprising: 45 to 95 mass % of an olefin polymer; 1 to 50 mass % of fibrous basic magnesium sulfate; 0.00001 to 0.8 mass % of spherical silica particles having an average particle diameter of 5 to 100 nm; and 0.1 to 10 mass % of a lubricant based on a total mass of the resin composition, wherein a mass ratio of fibrous basic magnesium sulfate to the spherical silica particles is 14.93/0.000015 to 14.82/0.74, and a mass ratio of the spherical silica particles to the lubricant is 0.000015/0.45 to 0.74/0.44.

2. The resin composition according to claim 1, wherein said lubricant is a metal salt of a fatty acid.

3. The resin composition according to claim 2, wherein said lubricant is at least one member selected from the group consisting of magnesium stearate, calcium stearate, and aluminum stearate.

4. The resin composition according to claim 2, wherein said spherical silica particles have a sphericity of 0.7 or more.

5. A molded resin composition product which is a molded product of the resin composition according to claim 1.

6. A molded resin composition product which is a molded product of the resin composition according to claim 2.

7. A molded resin composition product which is a molded product of the resin composition according to claim 3.

8. A molded resin composition product which is a molded product of the resin composition according to claim 4.

9. A method for producing a molded resin composition product, comprising molding the resin composition according to claim 1 into a molded resin composition product.

10. A method for producing a molded resin composition product, comprising molding the resin composition according to claim 2 into a molded resin composition product.

11. A method for producing a molded resin composition product, comprising molding the resin composition according to claim 3 into a molded resin composition product.

12. A method for producing a molded resin composition product, comprising molding the resin composition according to claim 4 into a molded resin composition product.

Description

EXAMPLE

(1) The present invention will be specifically described based on the following examples, but these examples do not limit the object of the present invention, and the present invention is not limited to these examples.

1. Evaluation of Properties

(2) Properties of test samples are evaluated by the following method.

(3) Notching: notching machine (IMC-AOCA, made by Imoto machinery Co. LTD.)

(4) Izod impact strength: measured by a Pendulum impact testing machine (impact testing machine No. 511, made by MYS-TESTER Company Limited) in conformity to JIS-K7110.

(5) Flexural modulus (FM): measured by a Motorized test stand (MX-500N, made by IMADA CO., LTD.), three point bending test in conformity to JIS-K7171

(6) MFR: measured by a Melt indexer (F-F01 type, made by Toyo Seiki Seisaku-sho, Ltd.) at a temperature of 230° C. under a load of 2.16 kg in conformity to ASTM-D1238

2. Example 1

(7) (1) Production of the Masterbatch (Hereinafter, Referred to as MB) Pellets

(8) 30 mass parts of a polypropylene resin [block copolymer, MFR: 47 g/10 min.], 70 mass parts of fibrous basic magnesium sulfate (MOS-HIGE® A-1, average major axis: 15 μm, average minor axis: 0.5 μm, made by Ube Material Industries, Ltd.), 0.007 mass parts of spherical silica particles (ADMANANO, average particle diameter 10 nm (measured by a scanning electron microscope (SEM)), made by Admatechs Company Limited), and 2.1 mass parts of magnesium stearate were blended. After the obtained mixture was kneaded, MB pellets were produced.

(9) (2) Dilution of MB Pellets and Molding of the Test Sample

(10) The MB pellets produced in paragraph (1) and a polypropylene resin [block copolymer, MFR: 47 g/10 min.] were mixed so that a mass ratio of the polypropylene resin to the fibrous basic magnesium sulfate is a mass ratio of 85:15. The mixture was directly molded at a temperature of 230° C. by an electric injection molding machine (C. Mobile 0813, made by Shinko Sellbic Co., Ltd.) to prepare a test sample for evaluation of the physical properties.

3. Example 2

(11) A test sample for evaluation of physical properties was prepared in the same manner as in Example 1 except that the amount of the spherical silica particles was 0.070 mass parts for the Production of MB pellets in Example 1(1).

4. Example 3

(12) A test sample for evaluation of physical properties was prepared in the same manner as in Example 1 except that the amount of the spherical silica particles was 0.700 mass parts for the Production of MB pellets in Example 1(1).

5. Example 4

(13) A test sample for evaluation of physical properties was prepared in the same manner as in Example 1 except that the amount of the spherical silica particles was 3.500 mass parts for the Production of MB pellets in Example 1(1).

6. Example 5

(14) A test sample for evaluation of physical properties was prepared in the same manner as in Example 1 except that the amount of the spherical silica particles was 0.00007 mass parts for the Production of MB pellets in Example 1(1).

7. Example 6

(15) A test sample for evaluation of physical properties was prepared in the same manner as in Example 1 except that the amount of the spherical silica particles was 0.00035 mass parts for the Production of MB pellets in Example 1(1).

8. Example 7

(16) A test sample for evaluation of physical properties was prepared in the same manner as in Example 1 except that the amount of the spherical silica particles was 0.0007 mass parts for the Production of MB pellets in Example 1(1).

9. Example 8

(17) A test sample for evaluation of physical properties was prepared in the same manner as in Example 1 except that the amount of the spherical silica particles was 0.0035 mass parts for the Production of MB pellets in Example 1(1).

10. Example 9

(18) A test sample for evaluation of physical properties was prepared in the same manner as in Example 1 except that the amounts of polypropylene resin, fibrous basic magnesium sulfate, spherical silica particles and magnesium stearate were 40 mass parts, 60 mass parts, 0.600 mass parts and 1.80 mass parts, respectively, for the Production of MB pellets in Example 1(1).

11. Example 10

(19) (1) Production of Resin Composition

(20) 85 mass parts of a polypropylene resin [block copolymer, MFR: 47 g/10 min.], 15 mass parts of fibrous basic magnesium sulfate (MOS-HIGE® A-1, average major axis: 15 μm, average minor axis: 0.5 μm, made by Ube Material Industries, Ltd.), 0.015 mass parts of spherical silica particles (ADMANANO, average diameter: 10 nm (measured by a scanning electron microscope (SEM)), made by Admatechs Company Limited), and 0.45 mass parts of magnesium stearate were blended. After the obtained mixture was kneaded, the resin composition pellets were produced.

(21) (2) Molding of Test Sample

(22) The resin composition pellets were injection-molded at a temperature of 230° C. by an electric injection molding machine (C. Mobile 0813, made by Shinko Sellbic Co., Ltd.) to prepare a test sample for evaluation of the physical properties.

12. Comparative Example 1

(23) A test sample for evaluation of physical properties was prepared in the same manner as in Example 10 except that the spherical silica particles was not added for the Production of Resin Composition Pellets in Example 10(1).

13. Comparative Example 2

(24) A test sample for evaluation of physical properties was prepared in the same manner as in Example 10 except that the magnesium stearate was not added for the Production of Resin Composition Pellets in Example 10(1).

14. Comparative Example 3

(25) A test sample for evaluation of physical properties was prepared in the same manner as in Example 10 except that the spherical silica particles and the magnesium stearate were not added for the Production of Resin Composition Pellets in Example 10(1).

15. Comparative Example 4

(26) A test sample for evaluation of physical properties was prepared in the same manner as in Example 1 except that the spherical silica particles was not added for the Production of MB Pellets in Example 1(1).

16. Comparative Example 5

(27) A test sample for evaluation of physical properties was prepared in the same manner as in Example 1 except that the amount of the spherical silica particles was 7.000 mass parts for the Production of MB pellets in Example 1(1).

17. Comparative Example 6

(28) A test sample for evaluation of physical properties was prepared in the same manner as in Example 1 except that the amount of the spherical silica particles was 21.00 mass parts for the Production of MB pellets in Example 1(1).

18. Comparative Example 7

(29) A test sample for evaluation of physical properties was prepared in the same manner as in Example 1 except that the spherical silica particles and the magnesium stearate were not added for the Production of MB Pellets in Example 1 (1).

19. Comparative Example 8

(30) A test sample for evaluation of physical properties was prepared in the same manner as in Example 1 except that the magnesium stearate was not added for the Production of MB Pellets in Example 1(1).

20. Comparative Example 9

(31) A test sample for evaluation of physical properties was prepared in the same manner as in Example 2 except that the magnesium stearate was not added for the Production of MB Pellets in Example 2(1).

21. Comparative Example 10

(32) A test sample for evaluation of physical properties was prepared in the same manner as in Example 3 except that the magnesium stearate was not added for the Production of MB Pellets in Example 3(1).

(33) The following Table summarizes the results of the above-mentioned Examples and Comparative Examples. In the Table, “PP” denotes polypropylene resin, “MOS” denotes fibrous basic magnesium sulfate, “SiO.sub.2” denotes spherical silica particles, “StMg” denotes a lubricant, “MB components” denotes a composition of a masterbatch, “Izod” in “Properties of Resin Composition” denotes an Izod impact strength, and “FM” denotes a flexural modulus.

(34) TABLE-US-00001 TABLE 1 Properties of Resin Composition Conponents (total Resin MB Components (total 100 mass %) 100 mass %) Composition PP MOS SiO.sub.2 StMg PP MOS SiO.sub.2 StMg Izod FM (mass %) (mass %) (mass %) (mass %) (mass %) (mass %) (mass %) (mass %) (kJ/m.sup.2) (Mpa) Example 5 29.38 68.56 0.00007 2.06 84.62 14.93 0.000015 0.45 5.1 2860 Example 6 29.38 68.56 0.00034 2.06 84.62 14.93 0.000075 0.45 6.2 3240 Example 7 29.38 68.56 0.00069 2.06 84.62 14.93 0.00015 0.45 6.1 3250 Example 8 29.38 68.56 0.0034 2.06 84.62 14.93 0.00075 0.45 5.5 3160 Example 1 29.38 68.56 0.0069 2.06 84.62 14.93 0.0015 0.45 6.6 3300 Example 2 29.36 68.51 0.069 2.06 84.61 14.93 0.015 0.45 5.3 3160 Example 3 29.18 68.09 0.68 2.04 84.49 14.91 0.15 0.45 5.5 3060 Example 4 28.41 66.29 3.31 1.99 83.99 14.82 0.74 0.44 5.7 2890 Example 9 39.09 58.59 0.59 1.76 84.49 14.91 0.15 0.45 7.1 3070 Example 10 — — — — 84.49 14.91 0.15 0.45 4.6 2850 Comparative — — — — 84.62 14.93 — 0.45 4.2 2730 Example 1 Comparative — — — — 84.87 14.98 0.15 — 2.9 2890 Example 2 Comparative — — — — 85.00 15.00 — — 2.4 2740 Example 3 Comparative 29.38 68.56 — 2.06 84.62 14.93 — 0.45 3.9 3040 Example 4 Comparative 27.50 64.16 6.42 1.92 83.37 14.71 1.47 0.44 4.0 2710 Example 5 Comparative 24.37 56.86 17.06 1.71 80.99 14.29 4.29 0.43 4.0 2500 Example 6 Comparative 30.00 70.00 — — 85.00 15.00 — — 2.2 2450 Example 7 Comparative 30.00 70.00 0.0070 — 85.00 15.00 0.0015 — 3.0 2620 Example 8 Comparative 29.98 69.95 0.070 84.99 15.00 0.015 — 2.8 2860 Example 9 Comparative 29.79 69.51 0.70 84.87 14.98 0.15 — 2.1 3200 Example 10