Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Mixing of two or more solid polymers; mixing of solid...
Reexamination Certificate
2002-11-26
2004-08-31
Nutter, Nathan M. (Department: 1711)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Mixing of two or more solid polymers; mixing of solid...
C525S222000, C525S232000, C525S240000, C525S241000, C428S500000
Reexamination Certificate
active
06784250
ABSTRACT:
TECHNICAL FIELD
The present invention relates to a resin composition used for calender formation, a molded article molded by calender formation with the use of the resin composition, material for a polyolefin-based leather tone product and a leather tone product provided by laminating the material on a substrate.
BACKGROUND ART
A molded article provided by calender formation method is broadly used for farming supplies, parts for home electric appliances/OA equipment, interior or exterior parts in automobiles, parts for residence/building materials, medical application products, foods supplies, packaging supplies in the form of tapes, sheets, films, leathers, etc.
Among the materials that may be used for these applications, soft vinyl chloride resin is broadly used due at least in part to its excellent characteristic such as superior flexibility and deformation recoverability. However, it is known that the vinyl chloride resin generates harmful substance such as hydrogen chloride gas or dioxin during burning process therefore the development of a substitute resin has long been desired. As a substitute resin, a molded article obtained by calender molding a resin composition comprising a specific &agr;-olefin/polyene copolymer and an olefin polymer is disclosed in Japanese Patent Application Laid-Open No. Hei 5-202237. However, the stereoregularity of this resin is as high as 98% and the flexibility of this resin was inferior. Recently, an olefin-based polymer produced by the use of metallocene catalyst, for example, a copolymer of ethylene and &agr;-olefin has been proposed as a substrate resin. However, this copolymer in soft type has a shortcoming of causing sticking components. This resin is also not satisfactory because of poor transparency and poor surface characteristics.
Therefore, the first object of the present invention is to provide a resin composition for calendering and a molded article obtained by calender molding the resin composition which is environmentally friendly, superior in tackiness, softness and transparency and has excellent molding properties.
A leather tone product made by laminating the resin with a cloth, a lumber, a plastic, etc., is preferably used as epidermis materials in applications such as automobile interior materials, furniture, bags, wearing apparels. Polyvinyl chloride-based resin has been employed broadly because of its excellent characteristics such as superior flexibility, and deformation-recovering ability. However, a problem with disposal is that PVC resin generates hydrogen chloride gas or dioxin during incineration. Moreover, concern that a plasticizer used for plasticization of PVC have environmental consequences such as mimicking human hormone. Accordingly, intense development of polyolefin-based resin as alternate material for the polyvinyl chloride-based resin is attempted recently. However, for polyolefin-based resin such as conventional polyethylene or polypropylene, it is necessary to copolymerize or to blend a rubber component in order to obtain the desired flexibility. This blending may lead to tackiness caused by a low molecular weight component and a copolymerization component, and may lead to transparency or texture (the feel) degradation.
Therefore, to improve the foregoing problems in the leather tone product, the second object of the present invention is to provide a material for polyolefin-based leather tone product having excellent molding ability, easiness in recycling, a little risk of generating toxic gases such as hydrogen chloride gas or dioxin during disposal or incineration, environmental friendliness, little tackiness, superiority in softness, transparency and texture, and to provide a leather tone product obtained by laminating the material on a substrate.
DISCLOSURE OF THE INVENTION
The present invention was completed by zealously investigating and finding that a specific resin composition comprising specific propylene polymer and olefin-based polymer achieves the first and the second objects of the invention. Accordingly, the present invention provides a resin composition used for calender formation, a molded article molded by calender formation with the use of the resin composition, a material for a polyolefin-based leather tone product and a leather tone product provided by laminating the material on a substrate as the following:
[1] A resin composition for calender formation comprising [I] a propylene polymer in an amount of 1 to 99 mass %, and [II] an olefin-based polymer in an amount of 99 to 1 mass %, wherein [I] the propylene polymer satisfies the following requirements of:
(1) a meso pentad fraction (mmmm) is from 0.2 to 0.6: and
(2) a racemic pentad fraction (rrrr) and (1−mmmm) satisfy the following relation:
[
rrrr
/(1
−mmmm
)]≦0.1.
[2] The resin composition for calender formation as defined in the item [1], wherein [I] the propylene polymer satisfies the following requirement of:
(3) an intrinsic viscosity [&eegr;] measured at 135° C. in tetralin is from 1.0 to 3.0 deciliter/g.
[3] The resin composition for calender formation as defined in the item [1] or the item [2], wherein [I] the propylene polymer satisfies the following requirement of:
(4) an amount of a component which is eluted at 25° C. or lower through temperature rise chromatography (W 25) is from 20 to 100 mass %.
[4] The resin composition for calender formation according to any one of the items [1], [2] or [3], wherein [I] the propylene polymer is polymerized by the use of a metallocene catalyst containing a promoter and a transition metallic compound in which a cross-linking structure is formed via two cross-linking groups.
[5] The molded article provided by calender molding the resin composition for calender formation according to any one of the items [1], [2], [3] or [4].
[6] A material for polyolefin-based leather tone product containing a polyolefin resin layer comprising the resin composition for calender formation according to any one of the items [1], [2], [3] or [4].
[7] A leather tone product provided by laminating the material for polyolefin-based leather tone product according to the item [6] on a substrate.
THE MOST PREFERRED EMBODIMENT TO CARRY OUT THE INVENTION
The present invention provides a resin composition for calender formation comprising [I] a specific propylene polymer in an amount of 1 to 99 mass % and [II] an olefin-based polymer in an amount of 99 to 1 mass %, a molded resin molded by calender formation with the use of the resin composition, material for a polyolefin-based leather tone product including a polyolefin resin layer with the use of the resin composition and a leather tone product provided by laminating the material on a substrate. The present invention shall be explained below in further details.
Resin Composition
The [I] specific propylene polymer employed for the present invention satisfies the following requirements of:
(1) a meso pentad fraction (mmmm) is from 0.2 to 0.6: and
(2) a racemic pentad fraction (rrrr) and (1−mmmm) satisfy the following relation:
[
rrrr
/(1
−mmmm
)]≦0.1.
Although the present invention requires that the propylene polymer satisfies (1) and (2) above, the meso pentad fraction (mmmm) is desirable to be 0.3-0.6 and more desirable to be 0.4-0.5. Additionally, the relation between the racemic pentad fraction (rrrr) and (1−mmmm) is desirable to be [rrrr/(1−mmmm)]≦0.08, more desirable to be [rrrr/(1−mmmm)]≦0.06 and the most desirable to be [rrrr/(1−mmmm)]≦0.05.
When [I] the propylene polymer satisfies the foregoing relation, the obtained calender molded article and the material for polyolefin-based leather tone product will be well balan
Idemitsu Petrochemical Co. Ltd.
Nutter Nathan M.
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