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
2000-09-22
2002-06-25
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...
C525S216000, C525S232000, C525S238000, C525S240000, C525S241000, C525S242000, C526S319000, C526S335000, C526S336000, C526S340000, C526S346000, C526S347000, C526S348000, C526S943000
Reexamination Certificate
active
06410649
ABSTRACT:
TECHNICAL FIELD
The present invention relates to a resin composition which is excellent in the impact resistance, moldability, weather resistance and chemical resistance and which is useful for an injection molded product, an extrusion molded product, a film, a sheet, etc., its molded product and a damping material made of the resin composition.
BACKGROUND ART
A polyolefin such as polyethylene or polypropylene is a typical general purpose plastic and has been used in a large amount for household products. For example, polyethylene or polypropylene is excellent in e.g. mechanical strength, moldability, heat resistance and chemical resistance and thus is used in various fields as a general purpose resin for e.g. films or containers. Further, in recent years, high performance polyolefin has become obtainable by an improvement in the polymerization technology for polyolefins, and it has been attempted to use it in a field where an engineering plastic has heretofore been used. However, its impact resistance is inadequate, and it has been difficult to employ it as an automobile part material such as a bumper or an instrument panel, or as a housing part material for a household product such as a refrigerator or a washing machine.
In the field of transparent soft resins, a so-called soft vinyl chlorine resin is widely used. However, as it contains chlorine, an environmental load resulting from incineration has become problematic. Accordingly, a substitute material for such a vinyl chlorine resin is desired.
On the other hand, an aromatic vinyl compound type resin such as a styrene type resin or a rubber-reinforced styrene type resin is a material excellent in the dimensional stability and rigidity, but has a drawback that it is inferior in the mechanical property, particularly in toughness.
For the purpose of overcoming such a drawback, a method is known in which an olefin type elastomer such as ethylene/isobutene is, for example, incorporated to a polyolefin. However, there will be a drawback that the surface hardness tends to decrease, and the surface tends to be susceptible to scratching. A resin composition with an ethylene/&agr;-olefin copolymer has a drawback such that it is inferior in the transparency.
For an aromatic vinyl compound type resin, it is common to employ a method of dispersing a rubber phase having elasticity non-continuously in a hard resin for the purpose of improving the impact resistance. At that time, it is common to add e.g. a styrene/butadiene random copolymer, a styrene/butadiene block copolymer, a styrene/isoprene block copolymer or a hydrogenated styrene/butadiene block copolymer. However, there is a drawback such that the resin is likely to undergo thermal deterioration during molding due to the double bond of butadiene or isoprene of the copolymer, or in the case of a styrene/butadiene block copolymer or the like, the styrene blocks have no solvent resistance, and the resin tends to be inferior in the solvent resistance. Further, the hydrogenated styrene/butadiene block copolymer has a problem that the rigidity of the resin composition tends to substantially decrease.
From such a background, a polymer composition is desired wherein different properties, such as high rigidity and glass transition temperature of an aromatic vinyl compound type polymer, flexibility and low glass transition point of an olefin polymer, and a high solvent resistance attributable to a crystal structure, are well balanced. However, heretofore, a composition obtained by blending an aromatic vinyl compound type polymer and an olefin type polymer, has not provided the desired physical properties, since compatibility of these resins is poor. Therefore, various compatibilizing agents have been studied. As a compatibilizing agent, a block copolymer of an aromatic vinyl compound with a diene compound or SEBS having such a copolymer hydrogenated, has been, for example, employed. (J. Polym. Sci., Polym. Letters, 19, 79 (1981), JP-A-56-38338, U.S. Pat. No. 4,020,025, etc.) Further, a case wherein styrene butadiene rubber (SBR) or hydrogenated SBR is employed as a compatibilizing agent, has also been reported.
Recently, as a copolymer made of an aromatic vinyl compound monomer and an olefin type monomer, a styrene/ethylene solid random copolymer is disclosed in JP-A-7-70223 or U.S. Pat. No. 5,703,187. Such a pseudorandom copolymer is a copolymer obtained by means of a geometrically constrained catalyst (CGCT catalyst). According to JP-A-6-49132, it is superior to a styrene type block copolymer in the compatibility with other resins. However, the pseudorandom copolymer contains no head-to-tail chain structure of aromatic vinyl compound units, and accordingly, the compatibility tends to be limited. Further, no significant stereoregularity is observed, and it is a non-crystalline resin in a region where the styrene content is at least from 15 to 20 mol %, whereby the mechanical property such as breaking strength is not sufficient, and the solvent resistance is also not sufficient.
WO98/10015 discloses a composition comprising an intercopolymer of an aromatic vinylidene monomer with an &agr;-olefin monomer and a polyolefin, and W098/10014 discloses a composition comprising an intercopolymer of an aromatic vinylidene monomer with an &agr;-olefin monomer and an interpolymer of an aromatic vinylidene monomer or the like. However, Examples of these specifications are directed to pseudorandom copolymers by means of the above-mentioned CGCT catalysts.
Further, JP-A-10-60194 discloses a composition comprising an ethylene/vinylidene aromatic monomer copolymer and a propylene type resin. However, in Examples, the CGCT catalyst is likewise employed.
DISCLOSURE OF THE INVENTION
The present inventors have conducted an extensive study on an aromatic vinyl compound/olefin random copolymer having a true random structure i.e. not a pseudorandom structure and on its physical properties and as a result, have found a method for its production, and they have found that the random copolymer is one provided with the properties of an aromatic vinyl compound type polymer and an olefin type polymer in good balance and further have found a resin composition comprising the random copolymer having overcome the above-mentioned drawbacks of a conventional aromatic vinyl compound type polymer or an olefin type polymer, whereby the present invention has been completed.
Namely, the present invention relates to a resin composition characterized by comprising from 5 to 95 wt % of an aromatic vinyl compound/olefin random copolymer (A) which has an aromatic vinyl compound content of from 1 to 99 mol % and has a head-to-tail chain structure composed of two or more aromatic vinyl compound units, and from 95 to 5 wt % of an &agr;-olefin type polymer (B) and/or an aromatic vinyl compound type polymer (C); a molded product thereof and a damping product thereof.
Now, the present invention will be described in detail.
The aromatic vinyl compound/olefin random copolymer (A) constituting the resin composition of the present invention is such an aromatic vinyl compound/olefin random copolymer (A) having an aromatic vinyl content of from 1 to 99 mol % and has a head-to-tail chain structure composed of two or more aromatic vinyl compound units.
It will be described with reference to a styrene-ethylene random copolymer which is suitably used as the random copolymer (A).
The aromatic vinyl compound/olefin random copolymer constituting the present invention has main peaks at the following positions by
13
C-NMR using TMS as standard.
Namely, it shows peaks attributable to main chain methylene and main chain methine carbon in the vicinity of from 24 to 25 ppm, in the vicinity of 27 ppm, in the vicinity of 30 ppm, in the vicinity of from 34 to 37 ppm, in the vicinity of from 40 to 41 ppm and in the vicinity of from 42 to 46 ppm, and peaks attributable to five carbons not bonded to the polymer main chain in the phenyl group in the vicinity of 126 ppm and in the vicinity of 128 ppm, and a peak attributable to one carbon bonded to the polymer mai
Arai Toru
Nakajima Masataka
Oda Takeshi
Okamoto Akio
Suzuki Shigeru
Denki Kagaku Kogyo Kabushiki Kaisha
Nutter Nathan M.
Oblon & Spivak, McClelland, Maier & Neustadt P.C.
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