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
1997-10-27
2003-12-02
Wilson, Donald R. (Department: 1713)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Mixing of two or more solid polymers; mixing of solid...
C525S176000, C525S177000, C525S178000, C525S183000, C525S184000
Reexamination Certificate
active
06657008
ABSTRACT:
TECHNICAL FIELD
The present invention relates to a flame retardant resin composition, and more specifically, it relates to a syndiotactic polystyrenic resin composition having an excellent stiffness, heat resistance, impact resistance and water resistance as well as a high flame retardancy which can suitably be used as industrial materials such as electric and electronic materials, industrial structure materials, automobile parts, appliance parts and mechanical parts.
BACKGROUND ART
A styrenic polymer (hereinafter abbreviated to “SPS” sometimes) having a syndiotactic configuration is excellent in heat resistance, chemical resistance, water resistance, acid resistance and alkali resistance, but it is poor in impact resistance. For this reason, the application range of the styrenic polymer as a material has heretofore been limited. On the other hand, a polymer such as a polyamide having a polar group is excellent in moldability and heat resistance, but it is hygroscopic. When the polyamide absorbs water, the physical properties of the polyamide change, and they also noticeably deteriorate due to the presence of an acid or an alkali. Accordingly, it has been desired to overcome such drawbacks.
In order to solve these problems, the formation of an alloy of the SPS and the polyamide has been suggested (Japanese Patent Application Laid-open No. 25795/1987). However, the alloy of the SPS and the polyamide is poor in flame retardancy, and therefore it cannot be used as a material which requires the flame retardancy. In recent years, the flame retardancy has been required in many fields, and the development of the flame retardant alloy has been desired. However, in the case that a flame retardant is added to the alloy comprising the SPS and the polyamide alone, it cannot be achieved to impart the flame retardancy to the alloy, keeping up mechanical properties such as toughness.
Under such circumstances, the present invention has been intended, and an object of the present invention is to provide a resin composition maintaining excellent characteristics of the SPS and having a high flame retardancy.
DISCLOSURE OF THE INVENTION
The present inventors have intensively researched, and as a result, it has been found that the above-mentioned object can be achieved by a composition obtained by adding a flame retardant to a resin composition comprising an SPS, a thermoplastic resin having a reactive polar group and a specific compatibilizing agent in a predetermined ratio, or a composition obtained by further blending a specific rubbery elastomer and/or a specific core shell type particulate elastomer with the above-mentioned composition. The present invention has been completed on the basis of such a knowledge.
That is to say, the first aspect of the present invention is directed to a flame retardant resin composition which comprises (a) a styrenic polymer having a syndiotactic configuration, (b) a thermoplastic resin having a reactive polar group, preferably a polyamide, (c) a compatibilizing agent having compatibility with the component (a) and a polar group capable of reacting with the component (b), (d) a flame retardant and (e) a flame retardant auxiliary, a weight ratio of the component (a)/the component (b) being less than 1.5, the amount of the component (c) being in the range of 0.5 to 10% by weight with respect to 100% by weight of the total of the components (a), (b) and (c), the amount of the component (d) being 10 parts by weight or more and the amount of the component (e) being 3 parts by weight or more with respect to 100 parts by weight of the total of the components (a), (b) and (c).
The second aspect of the present invention is directed to a flame retardant resin composition which comprises the above-mentioned flame retardant resin composition, (f) a rubbery elastomer having a polar group capable of reacting with the component (b) and a portion compatible with the component (a) and/or (g) a core shell type particulate elastomer having a siloxane.
The third aspect of the present invention is directed to a flame retardant resin composition which comprises the above-mentioned flame retardant resin composition comprising the components (a), (b), (c), (d), (e), (f) and (g), and (h) an inorganic filler.
BEST MODE FOR CARRYING OUT THE INVENTION
A resin composition of the present invention, as described above, comprises (a) a styrenic polymer having a syndiotactic configuration, (b) a thermoplastic resin having a reactive polar group, (c) a compatibilizing agent having compatibility with the component (a) and a polar group capable of reacting with the component (b), (d) a flame retardant and (e) a flame retardant auxiliary.
In the styrenic polymer having the syndiotactic configuration which can be used as the component (a), the syndiotactic configuration means that its stereochemical structure has a syndiotactic configuration, i.e., a steric structure in which phenyl groups and substituted phenyl groups which are side chains are located alternately in opposite directions on a main chain comprising carbon—carbon bonds. Its tacticity can be quantitatively determined by a nuclear magnetic resonance method using an isotopic carbon (a
13
C—NMR method). The tacticity which can be determined by the
13
C—NMR method can be called as follows in accordance with the number of existing plural continuous constitutional units. For example, in the case that the continuous units are two, the tacticity is called a diad; in the case that the continuous units are three, it is called a triad; and in the case that the continuous units are five, it is called a pentad. The styrenic polymer having the syndiotactic configuration referred to in the present invention is polystyrene, a poly(alkylstyrene), a poly(halogenated styrene), a poly(halogenated alkylstyrene), a poly(alkoxystyrene), a poly(vinyl benzoate), a hydrogenated polymer thereof, a mixture thereof or a copolymer mainly comprising any of the above-mentioned polymers in which the content of the syndiotacticity is preferably 75% or more, more preferably 85% or more in terms of a racemic diad, or it is preferably 30% or more, more preferably 50% or more in terms of a racemic pentad. Here, examples of the poly(alkylstyrene) include poly(methylstyrene), poly(ethylstyrene), poly(isopropylstyrene), poly(tert-butylstyrene), poly(phenylstyrene), poly(vinylnaphthalene) and poly(vinylstyrene). Examples of the poly(halogenated styrene) include poly(chlorostyrene), poly(bromostyrene) and poly(fluorostyrene). An example of the poly(halogenated alkylstyrene) is poly(chloromethylstyrene), and examples of the poly(alkoxystyrene) include poly(methoxystyrene) and poly(ethoxystyrene).
Above all, examples of the particularly preferable styrenic polymers include polystyrene, poly(p-methylstyrene), poly(m-methylstyrene), poly(p-tert-butylstyrene), poly(p-chlorostyrene), poly(m-chlorostyrene), poly(p-fluorostyrene), hydrogenated polystyrenes and copolymers having these constitutional units.
These styrenic polymers can be used singly or in a combination of two or more thereof.
No particular restriction is put on the molecular weight of this styrenic polymer, but its weight-average molecular weight is preferably 10000 or more, more preferably 50000 or more. In addition, the width of a molecular weight distribution is not limited, either, and the styrenic polymers having various molecular weight distributions are applicable. If the weight-average molecular weight is less than 10000, thermal properties and dynamic properties of an obtained composition or a molded article unpreferably deteriorate sometimes.
The styrenic polymer having the syndiotactic configuration can be prepared by, for example, polymerizing a styrenic monomer (which corresponds to the above-mentioned styrenic polymer) in the presence of a catalyst comprising a condensed product of a titanium compound, water and a trialkylaluminum in an inert hydrocarbon solvent or by the use of no solvent (Japanese Patent Application Laid-open No. 187708/1987). Furthermore, the poly(halogenated alkylstyrene) can be obtai
Iwashita Tohru
Miura Shin'ichi
Idemitsu Kosan Co. Ltd.
Oblon & Spivak, McClelland, Maier & Neustadt P.C.
Wilson Donald R.
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