Polymer composition and molded products formed thereof

Abstract

The present invention provides a polymer composition including a first base polymer (A) containing at least a thermoplastic polymer, a second base polymer (B) containing at least a thermoplastic polymer and not having compatibility with the first base polymer (A), and an additive (C) containing at least a substance not having compatibility with any of the first base polymer (A) and the second base polymer (B), the additive (C) being in the form of liquid or slurry at the lower of a pyrolysis temperature of the first base polymer (A) and a pyrolysis temperature of the second base polymer (B). (A), (B) and (C) are phase-separated from each other, and interfaces each located between two of phases of (A), (B) and (C) contacting each other form three-dimensional continuous parallel interfaces.

Claims

1. A polymer composition comprising: a first base polymer (A) containing at least a thermoplastic polymer chosen from among addition polymers, condensation polymers, and thermoplastic precursors; a second base polymer (B) containing at least a thermoplastic polymer chosen from among addition polymers, condensation polymers, and thermoplastic precursors and not having compatibility with the first base polymer (A); and an additive (C) comprising a thermoplastic polymer chosen from among addition polymers, condensation polymers, and thermoplastic precursors, and containing at least a substance not having compatibility with any of the first base polymer (A) and the second base polymer (B), the additive (C) being in the form of liquid or slurry at the lower of a pyrolysis temperature of the first base polymer (A) and a pyrolysis temperature of the second base polymer (B), wherein (A), (B) and (C) are phase-separated from each other, and interfaces each located between two of phases of (A), (B) and (C) contacting each other form three-dimensional continuous parallel interfaces, said three-dimensional continuous parallel interfaces referring to each of the opposite sides of a layer which separates two regions in a gyroid structure, said gyroid structure referring to an interconnected structure in which a continuous layer periodically extends throughout a space, dividing the space into two regions, wherein components (A), (B) and (C) form a parallel layer having a gyroid structure, and (A) and (B) occupy two respective regions separated by (C), wherein said continuous parallel interfaces include an interface between (B) and (C) and an interface between (A) and (C) of a layer formed of (C), and an interface between (A) and (B) wherein the interfaces , , and are parallel with each other, and three-dimensionally and continuously extend throughout space wherein at least one of (A) and (B) is a polyolefin, a polystyrene, a polyester, a polyamide, polycarbonate, polyurethane, and an unsaturated polyester resin precursor or a phenol resin precursor; and additive (C) is polydifluoroethylene, tetrafluoroethylene-ethylene copolymer, tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer, polystyrene, styrene oligomer, polyethylene glycol, polypropylene glycol, a polyvinyl butyral, a poly(vinyl alcohol-vinyl acetate) copolymer, polyvinyl acetate or saponified polyvinyl acetate.

2. The polymer composition of claim 1, wherein (C) further comprises at least one selected from the group consisting of oils, insecticides, pheromones, repellents, attractants, adhesives, surfactants, release agents, antibacterial agents, antifungal agents, flame resistant agents, lubricating agents, low-friction agents, reinforcing materials, electro-conductive agents, heat transfer agents, anti-corrosion agents, and electrolytic solutions.

3. A molded product comprising the polymer composition of claim 2, wherein the electro-conductive agent is a thermoplastic and highly electrically conductive composition.

4. The polymer composition of claim 1, wherein at least one of (A), (B) and (C) is a gas barrier thermoplastic resin.

5. The polymer composition of claim 4, wherein the gas barrier thermoplastic resin is at least one of vinyl alcohol-vinyl acetate copolymer, polyvinylidene chloride, thermoplastic polyacrylonitrile, and polyamides.

6. The polymer composition of claim 1, wherein at least one of (A), (B) and (C) is a thermoplastic adhesive.

7. The polymer composition of claim 6, wherein the thermoplastic adhesive is an adhesive for at least one of ceramic, metal, wood, and plastic.

8. A molded soil release composite product which is a multilayer structure of the polymer composition of claim 6 and a fluoropolymer molded product.

9. The polymer composition of claim 1, wherein at least one of (A), (B) and (C) is one of polyolefin resins, modified polyolefin resins, and polymer blends containing at least one of polyolefin resins and modified polyolefin resins.

10. The polymer composition of claim 1, wherein at least one of (A), (B) and (C) is one of fluoropolymers, modified fluoropolymers, and polymer blends containing at least one of fluoropolymers and modified fluoropolymers.

11. A separator for condensers or capacitors, wherein the separator is formed of a film or a fiber containing the polymer composition of claim 10.

12. A molded product comprising the polymer composition of claim 1 as a part thereof.

13. The molded product of claim 12, wherein the molded product is formed by extrusion molding or injection molding.

14. The molded product of claim 13, wherein (C) further comprises at least one of edible oils, adhesives and anti-corrosion agents, and the molded product is formed in the shape of a film.

15. The molded product of claim 12, wherein at least one of (A), (B) and (C) is a substance having an electrical resistance of 10.sup.15cm or more.

16. The molded product of claim 15, wherein the molded product is a filter including a melt blown nonwoven fabric or a multilayer structure of a melt blown nonwoven fabric.

17. A molded product obtained by diluting the polymer composition of claim 1 with one of (A), (B) and polymers having compatibility with (A) or (B), and molding the dilution of the polymer composition.

18. The molded product of claim 17, comprising a film made of (C) and having a thickness from 0.001 m to 2 m on a surface thereof.

19. A fluid having fluidity, wherein the fluid contains a mixture of the polymer composition of claim 1 in the form of powder and a liquid.

20. An ink comprising the polymer composition of claim 1.

21. A paint comprising the polymer composition of claim 1.

22. The polymer composition of claim 1, wherein the polyolefin is one of a polyethylene, polypropylene, polymethacrylate, polyisoprene, or polybutene, the polyester is one of polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate or polylactic acid, and the polyamide is one of nylon 6, nylon 66 or nylon 12.

Description

EXAMPLES

Example 1

Soil Release Molded Product

(1) Three components, i.e., 34 vol % of a thermoplastic PVDF (vinylidene fluoride-hexafluoropropylene copolymer) manufactured by DAIKIN INDUSTRIES, ltd. as (A), 36 vol % of PVDF (vinylidene fluoride) manufactured by DAIKIN INDUSTRIES, ltd. as (B), and 30 vol % of MOWITAL B30T manufactured by KURARAY CO., LTD., which is an adhesive polymer for glass, as (C), were fed at constant feed rates from hoppers of a high-speed rotation twin-screw kneading extruder. (A), (B) and (C), any two of which are phase-separated, were molten and kneaded, followed by extrusion into the shape of a strand, at a screw rotational speed of 1,200 rpm, at a maximum temperature of 320 C., which is lower than or equal to the pyrolysis temperatures of (A) and (B), and at a die temperature of 300 C. The strand was quenched in a water bath at 40 C. and was then cut, thereby obtaining compound pellets of a three-dimensional continuous parallel interface structure composition of Example 1.

(2) A cross-section in an extrusion direction and another cross-section perpendicular thereto of the pellet, on which the fluorine component was stained with a metal, were observed using a SEM. As a result, a parallel multilayer structure was found, and therefore, it was confirmed that a three-dimensional continuous parallel interface structure was formed.

(3) The compound was extruded and laminated through a T-die at 320 C. onto a PVDF (vinylidene fluoride-hexafluoropropylene copolymer) sheet having a thickness of 50 m manufactured by DAIKIN INDUSTRIES, ltd., thereby producing a multilayer sheet as a molded product of Example 1.

(4) The multilayer sheet and a glass plate which is 3 mm in thickness and 20 cm per side and whose surface had been cleaned, were stacked on each other, followed by hot pressing at 320 C., to produce a PVDF-glass multilayer structure of Example 1.

(5) A PVDF surface of the PVDF-glass multilayer structure exhibited excellent water and oil repellent properties, which are possessed by PVDF itself. One ml of 15% hexane dilution of a soil component (carbon black: 16.7%, beef fat hardened oil: 20.8%, and liquid paraffin: 62.5%) was dropped onto a sample, which was then allowed to stand for one or more hours at room temperature to remove hexane by air drying, thereby attaching a spot-like soil. A wipe-off property test was conducted using a KAKEN (Japan Synthetic Textile Inspection Institute Foundation) type wipe-off property tester. As a result, the multilayer sheet of Example 1 exhibited an excellent soil release property, i.e., the quantity of the remainders of the hydrophilic soil and the lipophilic soil was small, as compared to a PP sheet (control). Moreover, the PVDF surface of this product had a thickness of as large as 42 m and therefore exhibited excellent durability which enables the product to endure long-time use.

Example 2

Electret-Treated Filter

(6) Three components, i.e., 44 vol % of an LDPE, NOVATEC (MFR: 2) manufactured by Japan Polyethylene Corporation, as (A), 46 vol % of a PP, Prime Polypro (MFR: 3) manufactured by Prime Polymer Co., Ltd., as (B), and 10 vol % of an insulating material, PSt polymer (MFR: 30) manufactured by PS-Japan Corporation, as (C), were fed at constant feed rates from hoppers of a high-speed rotation twin-screw kneading extruder. (A), (B) and (C), any two of which are phase-separated, were molten and kneaded, followed by extrusion into the shape of a strand, at a screw rotational speed of 1,200 rpm, at a maximum temperature of 230 C., which is lower than the pyrolysis temperature 350 C. of the PP polymer

(7) (B), and at a die temperature of 190 C. The strand was quenched in a water bath at 40 C. and was then cut, thereby obtaining a compound of a three-dimensional continuous parallel interface structure composition of Example 2.

(8) A melt blown nonwoven fabric was produced using the compound. In this case, (A), (B) and (C) were decomposed by heating at a spinning temperature of 380 C., thereby reducing the molecular weights thereof, followed by an electret treatment, to obtain a melt blown nonwoven fabric of Example 2. It is known that, when a fabric which has been electret-treated so as to improve the dust collecting effect is exposed under a high humidity condition, isolated charge moves and therefore the effect of the electret treatment efficacy is reduced. After the melt blown nonwoven fabric was allowed to stand for 24 hours at 20 C. and 80 RH %, the dust collecting rate thereof was reduced by 12 %, which is smaller than about 20 % for typical PP melt blown nonwoven fabrics. Thus, the melt blown nonwoven fabric maintained the dust collecting effect at an excellent level.

(9) A cross-section in an extrusion direction and another cross-section perpendicular thereto of the compound pellet, on which the PSt component was stained with a metal, were observed using a SEM. As a result, a parallel multilayer structure was found, and therefore, it was confirmed that a three-dimensional continuous parallel interface structure was formed.

Example 3

Anti-Corrosion Film

(10) Three components, i.e., 36 vol % of an LDPE, NOVATEC (MFR: 0.9) manufactured by Japan Polyethylene Corporation, as (A), 34 vol % of a modified HDPE (MFR: 5) as (B), and 30 vol % of an anti-corrosion agent, sodium nitrite (melting temperature: 271 C.), as (C), were fed at constant feed rates from hoppers of a high-speed rotation twin-screw kneading extruder. (A), (B) and (C), any two of which are phase-separated, were molten and kneaded, followed by extrusion, at a screw rotational speed of 1,000 rpm, at a maximum temperature of 290 C., which is lower than the pyrolysis temperatures of (A) and (B), and at a die temperature of 270 C. The extrudate was cut using a hot cutter, followed by quenching in air, thereby obtaining an anti-corrosion masterbatch of a three-dimensional continuous parallel interface structure composition of Example 3. During production of the masterbatch, molten sodium nitrite did not blow out from the nozzle. Moreover, the pellet was not sticky. Although the pellet was slightly colored, there was not a problem with process ability.

(11) The masterbatch pellet was boiled in water at a bath ratio of 100:1 for 20 min to remove the sodium nitrite. Thereafter, a cross-section in an extrusion direction and another cross-section perpendicular thereto were observed using a SEM. As a result, a parallel multilayer structure was found, and therefore, it was confirmed that a three-dimensional continuous parallel interface structure was formed.

(12) Three w % of the masterbatch was diluted with 97 w % of an LDPE, NOVATEC (MFR: 0.9) manufactured by Japan Polyethylene Corporation. The diluted masterbatch was used to produce an anti-corrosion PE inflation film having a thickness of 100 m and a width of 20 cm of Example 3 by a commonly used method. This film contained about 0.9 g/m.sup.2 of sodium nitrite and was substantially transparent and colorless.

(13) The anti-corrosion properties of the anti-corrosion PE film and a commercially available PE film were compared under a condition suited to film in conformity with JIS Z 1535 5.4 volatile corrosion inhibitor treated paper. Occurrence of corrosion was not found in test pieces of the film of Example 3, and was found in test pieces of the commercially available film (control).

Example 4

Gas Barrier Film

(14) Three components, i.e., i.e., 46 vol % of an LDPE, NOVATEC (MFR: 0.9) manufactured by Japan Polyethylene Corporation, as (A), 44 vol % of a modified HDPE (MFR: 5) as (B), and 10 vol % of a gas barrier resin, EVAL (melting point: about 170 C., ethylene content: 38%) manufactured by KURARAY CO., LTD., as (C), were fed at constant feed rates from hoppers of a high-speed rotation twin-screw kneading extruder. (A), (B) and (C), any two of which are phase-separated, were molten and kneaded, followed by extrusion, at a screw rotational speed of 1,000 rpm, at a maximum temperature of 210 C., which is lower than the pyrolysis temperatures of (A) and (B), and at a die temperature of 200 C. The extrudate was cut using a hot cutter, followed by quenching in air, thereby obtaining a gas barrier compound of a three-dimensional continuous parallel interface structure composition of Example 4. A cross-section in an extrusion direction and another cross-section perpendicular thereto of the compound pellet, on which EVAL was stained with a metal, were observed using a SEM. As a result, a parallel multilayer structure was found, and therefore, it was confirmed that a three-dimensional continuous parallel interface structure was formed.

(15) The compound was used to produce an inflation film of Example 4 having a thickness of 25 m by a commonly used method. This film exhibited an oxygen gas transmission rate (23 C., 0% RH) of 0.5 ml.Math.25 /m.sup.2.Math.24hr.Math.Atm. The oxygen gas transmission rate of 100% EVAL is 0.4. Therefore, although the absolute value was slightly smaller, substantially the same excellent oxygen gas barrier property was exhibited. Film made of 100% EVAL is disadvantageously more expensive than PE, has a narrower temperature range satisfying a film production condition, and is more easily gelated by a long-time operation. Typically, EVAL is used along with PE or the like in the form of a multilayer film, which is also aimed to reduce the cost. On the other hand, the compound of Example 4 can be handled under a production condition similar to that of typical PE, and is economical since the content of expensive EVAL used therein can be reduced.

Example 5

Separator

(16) Two components, i.e., 44 vol % of a modified PP, Prime Polypro (MFR: 30) manufactured by Prime Polymer Co., Ltd., as (A) and 46 vol % of a PP (MFR: 30) as (B), were fed at constant feed rates from hoppers of a high-speed rotation twin-screw kneading extruder, and 10 vol % of propylene carbonate (electrolyte solvent) as (C) was fed by side-injection at a constant feed rate. (A), (B) and (C), any two of which are phase-separated, were molten and kneaded, followed by extrusion into the shape of a strand, at a screw rotational speed of 1,200 rpm, at a maximum temperature of 230 C., which is lower than the pyrolysis temperatures of (A) and (B), and at a die temperature of 190 C. The strand was quenched in a water bath at 40 C. and was then cut, thereby obtaining PP-compound pellets of a three-dimensional continuous parallel interface structure composition of Example 5. A cross-section in an extrusion direction and another cross-section perpendicular thereto of the pellet were observed using a SEM. As a result, a parallel multilayer structure was found, and therefore, it was confirmed that a three-dimensional continuous parallel interface structure was formed.

(17) A spunbond of Example 5 having a basis weight of 20 g/m.sup.2 was produced using the compound at spinning temperature of 230 C. by a commonly used method. In this spunbond, solvent was exposed on a fiber surface, and therefore, a capacitor in which the spunbond was used as a separator allowed electrolytic solution to be easily loaded without contamination of bubbles, resulting in a reduction in variations in capacitor capacity due to contamination of bubbles.

Example 6

Electrical Conductivity Polymer

(18) Three components, i.e., 44 vol % of a modified PP, Prime Polypro (MFR: 30) manufactured by Prime Polymer Co., Ltd., as (A), 46 vol % of a PP (MFR: 30) as (B), and 10 vol % of SnCu-based (401) lead-free solder powder manufactured by Yamanishi Kinzoku Kabushiki Kaisha as (C), were fed at constant feed rates from hoppers of a high-speed rotation twin-screw kneading extruder. (A), (B) and (C), any two of which are phase-separated, were molten and kneaded, followed by extrusion into the shape of a strand, at a screw rotational speed of 1,200 rpm, at a maximum temperature of 230 C., which is lower than the pyrolysis temperatures of (A) and (B), and at a die temperature of 190 C. The extrudate was quenched in a water bath at 40 C., thereby producing an electrically conductive PP strand of Example 6 having a diameter of 1 mm. The electrical resistance of the strand was of the order of 10.sup.5 cm, i.e., exhibited electrical conductivity similar to those of metals.

(19) The strand was cut into electrically conductive PP-compound pellets of a three-dimensional continuous parallel interface structure composition of Example 6. A cross-section in an extrusion direction and another cross-section perpendicular thereto of the pellet containing the tin component were observed using a SEM. As a result, a parallel multilayer structure was found, and therefore, it was confirmed that a three-dimensional continuous parallel interface structure was formed.

(20) A rectangular plate having a thickness of 3 mm was produced using the pellet by injection molding with a commonly used method. The electrical resistance of the plate was of the order of 10.sup.5 cm, i.e., exhibited electrical conductivity similar to those of metals.

Example 7

Powder Catalyst for Powder Coating

(21) Three components, i.e., 42 vol % of a curing agent for novolac phenolic resins, Type PR51530 manufactured by SUMITOMO BAKELITE Co., Ltd., as (A), 38 vol % of PR54869 as (B), and 20 vol % of an imidazole-based curing catalyst, C11ZCN (melting point: about 50 C.) manufactured by SHIKOKU CHEMICALS CORPORATION, as (C), were fed at constant feed rates from hoppers of a high-speed rotation twin-screw kneading extruder. (A), (B) and (C), any two of which are phase-separated, were molten and kneaded, followed by extrusion into the shape of a strand, at a screw rotational speed of 1,200 rpm, at a maximum temperature of 110 C., which is lower than or equal to the pyrolysis temperatures of (A) and (B), and at a die temperature of 100 C. The extrudate was cut using a hot cutter, followed by quenching in air, thereby obtaining masterbatch pellets of a cross-linking catalyst for powder coating of Example 7. A cross-section in an extrusion direction and another cross-section perpendicular thereto of the pellet, which imidazole was stained with a metal, were observed using a SEM. As a result, a parallel multilayer structure was found, and therefore, it was confirmed that a three-dimensional continuous parallel interface structure was formed. Next, the masterbatch was pulverized using a hammer mill and the pulverized masterbatch was classified according to the diameter (10 to 40 m), thereby producing a powder catalyst of Example 7.

(22) Two w % of the powder catalyst of this example, 38 w % of a powder of a curing agent for novolac phenolic resins, Type PRHF3 manufactured by SUMITOMO BAKELITE Co., Ltd., and 60 w % of a powder of a bisphenol-A epoxy resin, 1003F manufactured by Japan Epoxy Resins, Co., Ltd., containing 40 w % of titanium oxide, were uniformly applied to a zinc phosphate-treated cold-rolled steel having a thickness of 0.8 mm by electrostatic coating, followed by baking at 140 C. for 20 min, thereby forming a coating having a dry film thickness of 60 m.

(23) As a comparative example, 0.4 w % of a powder of a curing catalyst C11ZCN in place of the powder catalyst of this example, and other coating components, i.e., 39 w % of a powder of a curing agent for novolac phenolic resins, Type PRHF3 manufactured by SUMITOMO BAKELITE Co., Ltd., and 60.6 w % of a powder of a bisphenol-A epoxy resin, 1003F manufactured by Japan Epoxy Resins, Co., Ltd., containing 40 w % of titanium oxide, were dry-blended, and were uniformly applied to a zinc phosphate-treated cold-rolled steel having a thickness of 0.8 mm by electrostatic coating, followed by baking at 140 C. for 20 min, thereby forming a coating having a dry film thickness of 60 m. The impact strength (load: 500 g, drop height: 50 cm) of the coating of the comparative example was visually compared with that of the powder coating employing the powder catalyst of this example. As a result, the comparative example was clearly poorer than the embodiment example.

Example 8

Easy Release Film

(24) Two components, i.e., 33 vol % of an LDPE, NOVATEC (MFR: 5) manufactured by Japan Polyethylene Corporation, as (A) and 37 vol % of a PP, Prime Polypro (MFR: 5) manufactured by Prime Polymer Co., Ltd., as (B), were fed at constant feed rates from hoppers of a high-speed rotation twin-screw kneading extruder, and additionally, 30 vol % of a supernatant separated from unsalted butter molten by heating at 60 C. as (C) was fed by side-injection at a constant feed rate at an intermediate point of the extruder using a plunger pump. (A), (B) and (C), any two of which are phase-separated, were molten and kneaded, followed by extrusion into the shape of a strand, at a screw rotational speed of 1,200 rpm, at a maximum temperature of 200 C., which is lower than the pyrolysis temperatures of (A) and (B), and at a die temperature of 190 C. The strand was quenched in a water bath at 40 C. and was then cut, thereby obtaining translucent and colorless masterbatch pellets of a three-dimensional continuous parallel interface structure composition of Example 8. During production of the masterbatch, the butter did not blow out from the nozzle. Moreover, the pellet was not sticky and there was not a problem with process ability.

(25) The absence of the stickiness of the pellet means that the viscous liquid butter not having compatibility with the base polymer is only about 0.1 m in thickness on the pellet surface. This means that a butter layer inside the pellet also has a thickness of about 0.1 m or so, and that a fine structure is quasi-stably formed inside the pellet. A cross-section in an extrusion direction and another cross-section perpendicular thereto of the pellet were washed with cyclohexane and were then observed by a SEM. As a result, a parallel multilayer structure was found, and therefore, it was confirmed that a three-dimensional continuous parallel interface structure was formed.

(26) Five vol % of the masterbatch and 95 vol % of an LDPE, NOVATEC (MFR: 5) manufactured by Japan Polyethylene Corporation, were fed at constant feed rates. The mixture was extruded through a T-die into a laminate having a thickness of 10 m, which was then laid on an aluminum foil-polypropylene laminated film having a thickness of 15 m at 200 C., thereby producing a multilayer film of Example 8.

(27) The multilayer film was cooled with liquid nitrogen and was then fractured. A resultant cross-section of the multilayer film was observed by a SEM. As a result, it was confirmed that a butter layer having a thickness of 0.13 m was formed on the polyethylene layer of the multilayer film.

(28) A pouch of 18 cm wide and 20 cm deep was created from this multilayer film by heat sealing, where the polyethylene layer of the multilayer film faces the inside of the pouch. One hundred gram of commercially available pre-cooked curry heated to 60 C. was poured into the pouch, and immediately thereafter, the pouch was turned upside down to allow the curry to spontaneously flow out. Thereafter, curry residue was weighed. The amount of the curry residue was 1.8 g.

(29) For comparison, a pouch was created from a multilayer film which did not contain the masterbatch. In the case of this pouch, the amount of curry residue was 8.1 g. Therefore, the multilayer film of this example exhibits an excellent release property.

(30) The result of SEM observation showed that continuous parallel interfaces did not exist in a cross-section of the multilayer film. This fact indicates that the three-dimensional continuous parallel interface structure which had been formed in the masterbatch was disrupted in the film, and was changed to a discontinuous polyblend which is typically observed.

Comparative Example

(31) As is similar to Example 8, 70 vol % of a PP, Prime Polypro (MFR: 50), and 30 vol % of a supernatant separated from unsalted butter molten by heating at 60 C. as a liquid additive, were fed by side-injection at constant feed rates at an intermediate point of the extruder using a plunger pump. As a result, the butter was phase-separated from the PP, and blew out from the nozzle, and therefore, the mixture was not successfully extruded into the shape of a strand.

Example 9

Hydrophilic Nonwoven Fabric

(32) As is similar to Example 8, two components, i.e., 34 vol % of an LDPE, NOVATEC (MFR: 5) manufactured by Japan Polyethylene Corporation, as (A) and 36 vol % of a PP, Prime Polypro (MFR: 5) manufactured by Prime Polymer Co., Ltd., as (B), were fed at constant feed rates from hoppers of a high-speed rotation twin-screw kneading extruder, and additionally, 30 vol % of a molten surfactant glycerol monostearate as a liquid additive (C) was fed by side-injection at a constant feed rate at an intermediate point of the extruder using a plunger pump. (A), (B) and (C), any two of which are phase-separated, were molten and kneaded, followed by extrusion, at a screw rotational speed of 1,200 rpm, at a maximum temperature of 200 C., which is lower than the pyrolysis temperatures of (A) and (B), and at a die temperature of 190 C. The extrudate was cut using a hot cutter, followed by quenching in air, thereby obtaining masterbatch pellets of a three-dimensional continuous parallel interface structure composition of Example 9. During production of the masterbatch, the molten glycerol monostearate did not blow out from the nozzle. Moreover, the pellet was not sticky and there was not a problem with process ability.

(33) The masterbatch pellet was boiled in water at a bath ratio of 100:1 for 20 min to remove the glycerol monostearate. Thereafter, a cross-section in an extrusion direction and another cross-section perpendicular thereto were observed using a SEM. As a result, a parallel multilayer structure was found, and therefore, it was confirmed that a three-dimensional continuous parallel interface structure was formed.

(34) Six parts by weight of the masterbatch was diluted with 94 parts by weight of a PP, Prime Polypro (MFR: 15) manufactured by Prime Polymer Co., Ltd. The dilution was used to produce a spunbond of Example 9 having a basis weight of 30 g/m.sup.2 by melting and spinning with a commonly used method. When 1 ml of distilled water was dropped onto the spunbond using a pipette, the spunbond instantaneously absorbed the water, which indicates satisfactory hydrophilicity. The spunbond had a fiber diameter of about 20 m. The glycerol monostearate content of the PP fiber is not more than 1 w %, and the thickness of the liquid additive containing the remaining 2 w % of glycerol monostearate which is considered to exist on the fiber surface, is calculated as about 0.1 m.

Example 10

Anti-Corrosion Film

(35) As is similar to Example 8, three components, i.e., 36 vol % of an LDPE, NOVATEC (MFR: 0.9) manufactured by Japan Polyethylene Corporation, as (A), 34 vol % of a PP, Prime Polypro (MFR: 5) manufactured by Prime Polymer Co., Ltd., as (B), and 30 vol % of an anti-corrosion agent DICHAN (dicyclohexylamine nitrite) as a liquid additive (C), were fed at constant feed rates from hoppers of a high-speed rotation twin-screw kneading extruder. (A), (B) and (C), any two of which are phase-separated, were molten and kneaded, followed by extrusion, at a screw rotational speed of 1,000 rpm, at a maximum temperature of 160 C., which is lower than the pyrolysis temperatures of (A) and (B), and at a die temperature of 150 C. The extrudate was cut using a hot cutter, followed by quenching in air, thereby obtaining anti-corrosion masterbatch pellets of a three-dimensional continuous parallel interface structure composition of Example 10. During production of the masterbatch, the molten DICHAN did not blow out from the nozzle. Moreover, the pellet was not sticky. Although the pellet was colored to light brown, there was not a problem with process ability.

(36) The masterbatch pellet was boiled in water at a bath ratio of 100:1 for 20 min to remove the DICHAN. Thereafter, a cross-section in an extrusion direction and another cross-section perpendicular thereto were observed using a SEM. As a result, a parallel multilayer structure was found, and therefore, it was confirmed that a three-dimensional continuous parallel interface structure was formed.

(37) Six parts by weight of the masterbatch was diluted with 94 parts by weight of an LDPE, NOVATEC (MFR: 0.9) manufactured by Japan Polyethylene Corporation. The dilution was used to produce an anti-corrosion inflation film of Example 10 having a thickness of 100 m and a width of 20 cm by a commonly used method. Although this film contained about 1.8 g/m.sup.2 of DAICHAN, the film was substantially colorless and slightly translucent. DAICHAN exhibits its anti-corrosion capability when it is contained in air at a concentration of 5 mg/L or more. This film was used to produce a cylindrical anti-corrosion pouch of Example 10 which was 20 cm wide and 30 cm long. The pouch had a maximum air capacity of about 3 L. The weight of the film used to produce the pouch was 8 g/pouch, and the DICHAN content was 144 mg/pouch. When about 10 W % of the DICHAN contained in the pouch vaporizes, the DICHAN concentration reaches a level which allows a sufficient anti-corrosion property. Therefore, it was demonstrated that the anti-corrosion property can be maintained for a sufficient long time.

(38) The aforementioned embodiments and examples are only for the purpose of illustrating the present invention. The present invention is not limited to these examples. The base polymers (A) and (B) may be a polymer blend of a plurality of thermoplastic polymers. For example, in Example 2, a blend of two LDPEs having different molecular weights may be used as (A), and a blend of two PPs having different molecular weights may be used as (B). Although polymers of the same type are blended in this example, polymers of different types may be blended.

INDUSTRIAL APPLICABILITY

(39) The polymer composition of the present invention quasi-stably contains a large amount of a substance which does not compatibility with a matrix polymer, and therefore, is useful for, for example, production of molded products having various properties, such as interface activation properties, release properties, anti-corrosion properties and the like.