Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Processes of preparing a desired or intentional composition...
Patent
1997-05-23
1999-08-03
Szekely, Peter A.
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Processes of preparing a desired or intentional composition...
523216, 524445, 524446, 524447, 524449, 524451, 524413, C08K 904, C08K 334, C08K 310
Patent
active
059326344
DESCRIPTION:
BRIEF SUMMARY
TECHNICAL FIELD
The present invention relates to a resin composition with exceptional heat resistance, rigidity and impact resistance, suitable for use in fields such as automobiles, household electronics parts, construction materials and industrial materials.
BACKGROUND ART
Resin compositions having high mechanical strength are required in a variety of fields. Therefore, the rigidity, heat resistance and impact resistance of resins have been improved by the dispersion of inorganic fillers as filling materials. In particular, many attempts at increasing the mechanical properties and heat resistance of macromolecular materials by means of the dispersion of fillers on the nano-level have been made.
For example, a method has been proposed of intercalating (inserting) a monomer which is a source for a macromolecular material between the layers of a layered clay mineral, then dispersing the layered clay mineral on the nano-level by applying energy when polymerizing the monomer (for example, see Japanese Patent Application, First Publication No. Hei2-102261 and Japanese Patent Application, First Publication No. Hei2-105856). Additionally, a method has been tested of pre-swelling a layered clay mineral with organic cations, then further performing unlimited swelling with an organic solvent so that the layered clay mineral takes the form of a cardhouse, then bringing this into contact with a polymer melt in order to disperse the layered clay minerals on the nano-level (Japanese Patent Application, First Publication No. Hei 7-70357).
However, of the above-mentioned methods, while the former which is due to polymerization efficiently disperses the filler, it requires equipment for polymerization, so that the production costs are high and cannot be considered to be economical. Additionally, at present, the reaction is restricted to condensation polymerization employed for polyamides, aromatic polyesters and the like, radical polymerization wherein reactive monomers such as heat-hardening types are entered between the layers, or cationic polymerization and the like.
Additionally, since the monomers inserted between the layers must stably exist within the layers, those which are gases at standard pressure are not suitable, so as to be restricted to liquid monomers.
Therefore, there is the drawback that only limited resin material and a low-concentration filler can be obtained when obtaining a resin composition dispersed with fillers on the angstrom-level.
As a result, it is not possible to use, for example, anionic coordination polymerization used for polyolefins. That is, if active hydrogens such as amino acids exist between the layers of the layered clay mineral, they act as a catalyst poison in titanium/organic aluminum anion coordination catalysis.
Additionally, with this method which is due to polymerization, the clay minerals react with amino groups when polyamide monomers are inserted between the layers, so that the terminal groups of the polyamides form carboxylic acids after polymerization. For this reason, the reactivity of the terminal groups is sealed off, and there is a marked reduction in the dye-affinity and adhesive property. Additionally, when forming a polymer alloy with other resins, there are problems in that the adhesive property at the interface is poor even if a compatibility agent has been added, as a result of which the dispersive phase tends to easily un-mix and the capabilities become difficult to activate. As a measure for improvement on this problem, a method has been proposed of adding polyhydric amines afterwards, in order to induce a reaction with the terminal groups of the polyamides (Japanese Patent Application, First Publication No. Sho 63-230766).
However, there are disadvantages in that it is difficult to induce a uniform reaction because a reaction cannot be performed in a dilute solvent, and in that intermolecular crosslinking is encouraged so that reductions in the fluidity and moldability are likely to occur. Similarly, in the case of polyesters, di-alcohols of the monomers
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Hosokawa Teruo
Inoue Hirofumi
Moteki Yoshihiro
Showa Denko K.K.
Szekely Peter A.
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