Stock material or miscellaneous articles – Composite – Of polyamidoester
Reexamination Certificate
2001-12-19
2004-10-26
Gorr, Rachel (Department: 1711)
Stock material or miscellaneous articles
Composite
Of polyamidoester
C525S132000, C525S133000, C525S134000, C525S396000, C525S143000, C525S109000, C523S330000, C428S319700
Reexamination Certificate
active
06808810
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a resin composition, a laminate and a method for producing a laminate. More specifically, the present invention relates to a resin composition which can give strong adhesion of an olefin-based and/or styrene-based thermoplastic elastomer and a polyurethane, a laminate obtained by using this resin composition, and a method for producing the laminate.
2. Description of Related Art
As materials having a cushioning property such as interior parts of automobiles, shoe soles, cushioning materials and the like, laminates manufactured by laminating a skin layer and substrate layer on a foamed layer of polyurethane manifesting a cushioning property are used, and conventionally, a vinyl chloride resin and the like are used as the skin layer and the substrate layer. However, from the standpoint of recent environmental problems, materials substituting for a vinyl chloride resin are desired, and as these materials, studies are being developed using an olefin-based or styrene-based thermoplastic elastomer. However, since adhesion between an olefin-based or styrene-based thermoplastic elastomer and a polyurethane is not sufficient, it is necessary to use an adhesive and primer containing an organic solvent for obtaining a strong laminate as disclosed, for example, in JP06-246858A. However, the technology using this adhesive has a problem of deterioration in working environments due to an organic solvent contained in the adhesive, in addition to process complexity owing to an application process of an adhesive.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a resin composition which can give strong adhesion of an olefin-based or styrene-based thermoplastic elastomer and a polyurethane, without using a conventional adhesive and primer containing an organic solvent, further, to provide a laminate obtained by using said resin composition and a method for producing said laminate.
Namely, the present invention relates to a resin composition comprising 3 to 80 parts by weight of a resol type phenol resin(B1) or 3 to 150 parts by weight of a polyhydric phenol(B2), based on 100 parts by weight of a copolymer (Å) of an epoxy group-containing monomer and an olefin.
Further, the present invention relates to a resin composition powder comprising the above-mentioned resin composition and having an average particle size of 30 to 1000 &mgr;m.
Furthermore, the present invention relates to a laminate manufactured by laminating a layer (
1
) made of the above-mentioned resin composition and a layer (
2
) made of polyurethane or a layer (
3
) made of an olefin-based and/or styrene-based thermoplastic elastomer.
Still further, the present invention relates to a laminate manufactured by laminating a layer (
2
) made of polyurethane and a layer (
3
) made of an olefin-based and/or styrene-based thermoplastic elastomer via a layer (
1
) made of the above-mentioned resin composition.
Even further, the present invention relates to a method of producing the above-mentioned laminate, comprising producing a layer (
1
) made of the above-mentioned resin composition by a powder molding method.
The present invention will be described below.
DETAILED DESCRIPTION OF THE INVENTION
The copolymer (Å) of an epoxy group-containing monomer and an olefin used in the present invention is a polymer having repeating units derived from a monomer having an epoxy ring and a carbon-carbon unsaturated bond (a) and repeating units derived from an olefin having 2 to 10 carbon atoms (b). As the monomer having an epoxy ring and a carbon-carbon unsaturated bond, glycidyl acrylate, glycidyl methacrylate, vinyl glycidyl ether, allyl glycidyl ether, methacryl glycidyl ether, glycidyl itaconate and the like are listed, and one or more of them can be used. As the olefin having 2 to 10 carbon atoms, ethylene, propylene, 1-butene and the like are listed, and one or more of them can be used.
The copolymer (Å) may contain a monomer unit (c) other than the repeating units (a) and (b), and examples of a monomer constituting the monomer unit (c) include vinyl carboxylates such as vinyl acetate, vinyl propionate and the like; vinyl ketones such as methyl vinyl ketone, ethyl vinyl ketone and the like; vinyl aromatic compounds such as styrene, &agr;-methylstyrene, vinyltoluene and the like; acrylates such as methyl acrylate, ethyl acrylate, propyl acrylate, n-butyl acrylate, n-octyl acrylate, methyl methacrylate, ethyl methacrylate and the like, and these can be used alone or in combination of two or more.
Examples of the copolymer (Å) of an epoxy group-containing monomer and an olefin are an ethylene-glycidyl acrylate copolymer, ethylene-glycidyl methacrylate-vinyl acetate copolymer, ethylene-glycidyl methacrylate-methyl acrylate copolymer, ethylene-glycidyl methacrylate-ethyl acrylate copolymer, ethylene-glycidyl methacrylate-butyl acrylate copolymer, and among them, an ethylene-glycidyl acrylate copolymer, ethylene-glycidyl methacrylate-vinyl acetate copolymer and ethylene-glycidyl methacrylate-methyl acrylate copolymer are preferable from the standpoint of easy availability.
The contents of the repeating units (a) and (b) in the copolymer (Å) are preferably 5 to 40% by weight and 60 to 95% by weight, respectively. When the content of the repeating unit(a) is less than 5% by weight, an adhesiveness to a polyurethane may become insufficient. On the other hand, When the content of the repeating unit(a) is more than 40% by weight, the storage stability may deteriorate. Herein, the sum of the contents of the repeating units (a) and (b) is 100% by weight.
These can be produced by a known method.
The component (B) to be mixed with the copolymer (Å) in the present invention is a resol type phenolic resin(B1) or polyhydric phenol(B2). As the resol type phenolic resin(B1) is a phenolic resin obtained by reacting phenols and formaldehyde with a basic catalyst. The phenols are a compound having a structure containing a benzene ring, naphthalene ring or other aromatic ring in which at least one OH group is bonded to a carbon atom of the ring, and examples thereof include phenol, hydroquinone, resorcin, catechol, pyrogallol, hydroxyhydroquinone, phloroglucin, &agr;-naphthol and &bgr;-naphthol.
Of the resol type phenolic resins, resol type alkylphenolic resins obtained by reacting a phenol containing at least one alkylphenol, and formaldehyde with a basic catalyst are preferable from the standpoint of storage stability. The alkylphenol is a compound having a structure containing a benzene ring in which at least one OH group and alkyl group and/or phenyl group are bonded to carbon atoms of the ring, and examples thereof include methylphenol, octylphenol, nonylphenol, tert-octylphenol, tert-butylphenol, tetramethylbutylphenol, orcine and urushiol. Of them, resol type alkylphenol resins having a softening point measured according to JIS K-7234 (1986) of 50° C. or more are preferable, from the standpoint of simplicity in handling.
The compounding amount of a resol type phenolic resin(B1) is from 3 to 80 parts by weight, preferably from 5 to 70 parts by weight per 100 parts by weight of the copolymer (Å). When the compounding amount of a resol type phenolic resin (B1) is less than 3 parts by weight, adhesion with polyurethane may be insufficient, on the other hand, when the compounding amount of a resol type phenolic resin (B1) is more than 80 parts by weight, the storage stability of a composition may decrease. When an olefin-based polymer (C) described later is used, the compounding amount of a resol type phenol resin(B1) is preferably from 3 to 80 parts by weight, more preferably from 5 to 70 parts by weight based on 100 parts by weight of the total amount of a copolymer (Å), and an olefin-based polymer (C). When the compounding amount of a resol type phenolic resin (B1) is less than 3 parts by weight, adhesion with polyurethane may be insufficient, on the other hand, when the compounding amount of a resol type
Ohtani Kohsuke
Shimizu Hikaru
Gorr Rachel
Sumitomo Chemical Company Limited
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