WO2025094875A1 - Procédé de production d'une composition de résine de poly(sulfure d'arylène) recyclée, et composition de résine de poly(sulfure d'arylène) recyclée - Google Patents
Procédé de production d'une composition de résine de poly(sulfure d'arylène) recyclée, et composition de résine de poly(sulfure d'arylène) recyclée Download PDFInfo
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- WO2025094875A1 WO2025094875A1 PCT/JP2024/038295 JP2024038295W WO2025094875A1 WO 2025094875 A1 WO2025094875 A1 WO 2025094875A1 JP 2024038295 W JP2024038295 W JP 2024038295W WO 2025094875 A1 WO2025094875 A1 WO 2025094875A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
- B29B17/04—Disintegrating plastics, e.g. by milling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B9/00—Making granules
- B29B9/10—Making granules by moulding the material, i.e. treating it in the molten state
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J3/00—Processes of treating or compounding macromolecular substances
- C08J3/20—Compounding polymers with additives, e.g. colouring
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L101/00—Compositions of unspecified macromolecular compounds
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L81/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing sulfur with or without nitrogen, oxygen or carbon only; Compositions of polysulfones; Compositions of derivatives of such polymers
- C08L81/02—Polythioethers; Polythioether-ethers
Definitions
- This disclosure relates to a method for producing a recycled polyarylene sulfide resin composition and a recycled polyarylene sulfide resin composition.
- Patent Document 1 In order to build a sustainable recycling-based society, technologies for recycling and utilizing plastic waste are being considered (for example, Patent Document 1).
- Polyarylene sulfide resins are excellent in heat resistance, mechanical properties, chemical resistance, dimensional stability, and flame retardancy, and are therefore widely used in electrical and electronic equipment part materials, automotive part materials, chemical equipment part materials, etc. Therefore, recycling and utilizing materials containing polyarylene sulfide resins can help build a sustainable recycling-oriented society.
- recycled products When recycling materials containing polyarylene sulfide resin, molded products and parts other than molded products discharged during molding (hereinafter collectively referred to as "recycled products") are crushed and then re-pelletized to form recycled pellets for molding.
- the recycled pellets may have decomposed matrix polymers, deteriorated additives, and fine fillers due to shearing during crushing the recycled products, heat history due to having been through one or more molding processes, and heat history during the re-pelletization process. In such cases, there may be changes in fluidity, crystallinity, polarity, etc. compared to virgin materials that have not been through a molding process.
- the objective of this disclosure is to provide a recycled polyarylene sulfide resin composition that causes minimal mold contamination during molding, and a method for producing the same.
- a method for producing a recycled polyarylene sulfide resin composition (Z) includes: preparing a pulverized product (X) of an article containing 100 parts by mass of a polyarylene sulfide resin (P) and 1 to 20 parts by mass of an elastomer (Q); and melt-kneading the pulverized product (X) with an antioxidant (Y) in an amount such that the blending amount of the antioxidant (Y) is 0.025 to 0.25 parts by mass per 1 part by mass of the elastomer (Q) contained in the pulverized product (X).
- the content of the elastomer (Q) is 1 to 20 parts by mass based on 100 parts by mass of the polyarylene sulfide resin (P)
- the content of the antioxidant (Y) is 0.025 to 0.25 parts by mass per part by mass of the elastomer (Q).
- This disclosure makes it possible to provide a recycled polyarylene sulfide resin composition that causes less mold contamination during molding, and a method for producing the same.
- FIG. 1 is a schematic diagram of a molded body used when evaluating mold deposits, with the upper side being a top view and the lower side being a cross-sectional view.
- the manufacturing method according to this embodiment is a manufacturing method of a recycled polyarylene sulfide resin composition (Z),
- the method includes: (1) preparing a pulverized product (X) containing 100 parts by mass of a polyarylene sulfide resin (P) and 1 to 20 parts by mass of an elastomer (Q) (a preparation step); and (2) melt-kneading the pulverized product (X) with an antioxidant (Y) in an amount such that the blending amount of the antioxidant (Y) is 0.025 to 0.25 parts by mass per 1 part by mass of the elastomer (Q) contained in the pulverized product (X) (a melt-kneading step).
- recycled pellets often have changes in fluidity, crystallinity, polarity, etc. compared to virgin pellets.
- the changes in physical properties tend to be greater. For this reason, it is difficult to predict the effect of adding even well-known additives to recycled pellets.
- the additives to be added to recycled pellets must be selected carefully.
- the inventor therefore considered using recycled raw materials that already contained antioxidants as the recycled products in order to suppress mold deposits during recycling.
- the expected effect of suppressing mold fouling was not obtained.
- the inventor discovered that by blending a specified amount of antioxidant into the recycled raw materials and melt-kneading them, it is possible to suppress mold fouling when the resulting recycled pellets are injection molded, and this led to the completion of the present disclosure.
- a ground product (X) of an article containing 100 parts by mass of polyarylene sulfide resin (P) and 1 to 20 parts by mass of elastomer (Q) is melt-kneaded with antioxidant (Y) in an amount such that the amount of antioxidant (Y) is 0.025 to 0.25 parts by mass per part by mass of elastomer (Q) contained in ground product (X), thereby obtaining a recycled polyarylene sulfide resin composition (Z) that causes little mold contamination during molding.
- Recycling means crushing an item such as a molded body (a recycled product) and recycling it as a raw material for use in manufacturing a molded body
- recycled material means recycled material
- recycled pellets means pellets of recycled material.
- Recycled polyarylene sulfide resin composition is a recycled material containing a polyarylene sulfide resin composition.
- Raw material for recycling means the material (raw material) to be recycled; for example, recycled products and their crushed material correspond to raw materials for recycling.
- raw materials not used in manufacturing molded bodies are called “virgin material”
- pellets of virgin material are called “virgin pellets”
- virgin material of polyarylene sulfide resin is called “virgin polyarylene sulfide resin.”
- a pulverized product (X) of an article containing 100 parts by mass of a polyarylene sulfide resin (P) and 1 to 20 parts by mass of an elastomer (Q) is prepared.
- the "article” referred to here is an article to be recycled (recyclable article), and may be a molded article, or may be an article discharged after being retained in a cylinder for a long time during molding.
- examples include defective products generated during the manufacturing process of molded articles, parts other than the product obtained during injection molding (e.g., runners, sprues, etc.), unused products, and chunks of polyethylene sulfide resin material used as a purge during molding and discharged, and it is preferable to include one or more selected from these.
- the recycled molded article may be an injection molded article.
- the polyarylene sulfide resin (P) may be a virgin polyarylene sulfide resin, or may be a recycled polyarylene sulfide resin that has been reused at least once.
- the polyarylene sulfide resin (P) preferably contains a virgin polyarylene sulfide resin.
- the polyarylene sulfide resin (P) preferably contains a recycled polyarylene sulfide resin.
- the polyarylene sulfide resin is a resin having a repeating unit represented by the following general formula (I). -(Ar-S)-...(I) (wherein Ar represents an arylene group).
- the arylene group is not particularly limited, but examples thereof include p-phenylene group, m-phenylene group, o-phenylene group, substituted phenylene group, p,p'-diphenylenesulfone group, p,p'-biphenylene group, p,p'-diphenylene ether group, p,p'-diphenylenecarbonyl group, and naphthalene group.
- Polyarylene sulfide resins can be homopolymers using the same repeating units among the repeating units represented by the above general formula (I), as well as copolymers containing different types of repeating units.
- homopolymers those having p-phenylene sulfide groups as repeating units, which have p-phenylene groups as arylene groups, are preferred. This is because homopolymers having p-phenylene sulfide groups as repeating units have extremely high heat resistance, and exhibit high strength, high rigidity, and high dimensional stability over a wide temperature range. By using such homopolymers, molded articles with extremely excellent physical properties can be obtained.
- a combination of two or more different arylene sulfide groups among the above-mentioned arylene group-containing arylene sulfide groups can be used.
- a combination containing a p-phenylene sulfide group and an m-phenylene sulfide group is preferred from the viewpoint of obtaining a molded product with high physical properties such as heat resistance, moldability, and mechanical properties.
- a polymer containing 70 to 100 mol% of p-phenylene sulfide groups is more preferred, and a polymer containing 80 to 100 mol% is even more preferred.
- the polyarylene sulfide resin having phenylene sulfide groups is a polyphenylene sulfide resin (PPS resin).
- Polyarylene sulfide resins are generally known to have a substantially linear molecular structure with no branching or crosslinking, and a structure with branching or crosslinking, depending on the manufacturing method. In one embodiment, from the viewpoint of improving the toughness of the molded product, it is more preferable that the resin does not contain a structure with a crosslinking structure.
- the content of the polyarylene sulfide resin (P) in the pulverized material (X) is preferably 30 to 99 mass %, more preferably 50 to 95 mass %, based on the total amount of the pulverized material (X). In one embodiment, the total content of the polyarylene sulfide resin (P) and the elastomer (Q) in the resin component contained in the pulverized material (X) is preferably 80 to 100 mass%, more preferably 90 to 100 mass%, based on the total amount of the resin components. In one embodiment, the resin component contained in the pulverized material (X) may consist only of the polyarylene sulfide resin (P) and the elastomer (Q).
- elastomer (Q) examples include olefin-based elastomers, styrene-based elastomers, polyester-based elastomers, etc., which may be grafted, and it is preferable to include at least one selected from these, and for example, it may include an olefin-based elastomer. Even if the pulverized material (X) includes an elastomer, it is possible to suppress mold contamination when molding the resulting recycled polyarylene sulfide resin composition (Z).
- the elastomer (Q) may be an elastomer having a reactive functional group, such as an acid-modified elastomer modified with an acid or an acid anhydride, such as (meth)acrylic acid or maleic anhydride; an elastomer using a copolymerizable monomer having a glycidyl group or an epoxy group (such as glycidyl (meth)acrylate); or an epoxy-modified elastomer obtained by epoxidizing the unsaturated bond of an elastomer.
- a reactive functional group such as an acid-modified elastomer modified with an acid or an acid anhydride, such as (meth)acrylic acid or maleic anhydride
- an elastomer using a copolymerizable monomer having a glycidyl group or an epoxy group such as glycidyl (meth)acrylate
- Olefin-based elastomers include copolymers of ⁇ -olefins and copolymerizable monomers.
- the ⁇ -olefin is preferably one or more selected from ⁇ -olefins having 2 to 13 carbon atoms (e.g., ethylene, propylene, 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-octene, etc.).
- copolymers of ⁇ -olefins and copolymerizable monomers include, but are not limited to, ⁇ -olefin-unsaturated carboxylic acid alkyl ester copolymers, and olefin-based copolymers containing structural units derived from ⁇ -olefins and structural units derived from glycidyl esters of ⁇ , ⁇ -unsaturated acids.
- glycidyl esters of ⁇ , ⁇ -unsaturated acids include, but are not limited to, glycidyl esters of acrylic acid, glycidyl esters of methacrylic acid, and glycidyl esters of ethacrylic acid.
- the olefin-based copolymer may further include structural units derived from (meth)acrylic acid esters.
- Preferred specific examples of olefin-based elastomers include ethylene propylene rubber (EPR), ethylene-glycidyl methacrylate copolymer (E-GMA), ethylene-glycidyl methacrylate-methyl acrylate copolymer (E-GMA-MA), etc.
- EPR ethylene propylene rubber
- E-GMA ethylene-glycidyl methacrylate copolymer
- E-GMA-MA ethylene-glycidyl methacrylate-methyl acrylate copolymer
- the olefin-based elastomer may be contained alone or in combination of two or more kinds.
- the styrene-based elastomer may be a block copolymer consisting of a polymer block mainly made of a vinyl aromatic compound such as styrene and a polymer block mainly made of a non-hydrogenated and/or hydrogenated conjugated diene compound.
- Specific examples of preferred styrene-based elastomers include styrene-butadiene rubber (SBR) and styrene-ethylene-butylene-styrene block copolymer (SEBS).
- SBR styrene-butadiene rubber
- SEBS styrene-ethylene-butylene-styrene block copolymer
- the styrene-based elastomer may also be a modified copolymer into which a functional group (epoxy group, carboxy group, acid anhydride group, etc.) has been introduced.
- modified copolymers include epoxidized styrene-diene copolymers in which the unsaturated bond of the diene has been epoxidized (e.g., epoxidized styrene-diene-styrene block copolymers or hydrogenated polymers thereof).
- the styrene-based elastomer may be contained alone or in combination of two or more types.
- polyester-based elastomers include block copolymers in which aromatic polyesters such as polyethylene terephthalate and polybutylene terephthalate serve as hard segments, and polyethers such as polyethylene glycol and polytetramethylene glycol, or aliphatic polyesters such as polyethylene adipate, polybutylene adipate, and polycaprolactone serve as soft segments.
- aromatic polyesters such as polyethylene terephthalate and polybutylene terephthalate
- polyethers such as polyethylene glycol and polytetramethylene glycol
- aliphatic polyesters such as polyethylene adipate, polybutylene adipate, and polycaprolactone serve as soft segments.
- the polyester-based elastomers may be used alone or in combination of two or more types.
- the elastomer (Q) When the elastomer (Q) has a reactive functional group, it can provide the virgin material with effects such as improving impact resistance and high-low temperature impact properties, and imparting toughness, but when recycled, mold deposits are more likely to occur and mold contamination is more likely to occur.
- the manufacturing method of the recycled polyarylene sulfide resin composition (Z) according to this embodiment even when the pulverized material (X) contains an elastomer (Q) having a reactive functional group, mold contamination during molding can be reduced.
- the elastomer (Q) may have a reactive functional group.
- preparing the pulverized material (X) may include preparing the pulverized material (X) of an article containing an elastomer (Q) having a reactive functional group.
- reactive functional group means a functional group that can react with an end group of a polyarylene sulfide resin to form a chemical bond at the melting temperature of the resin.
- reactive functional groups include glycidyl groups, epoxy groups, carboxy groups, hydroxyl groups, acid anhydride groups, salts of carboxy groups, carboxylate groups, amide groups, and amino groups, isocyanate groups, isothiocyanate groups, acetoxy groups, silanol groups, alkoxysilane groups, alkynyl groups, oxazoline groups, thiol groups, and sulfonic acid groups.
- the elastomer (Q) may include an olefin-based elastomer, a styrene-based elastomer, or a polyester-based elastomer that includes one or more groups selected from a glycidyl group, an epoxy group, a carboxy group, a hydroxyl group, an acid anhydride group, a salt of a carboxy group, a carboxylate ester group, an amide group, and an amino group, an isocyanate group, an isothiocyanate group, an acetoxy group, a silanol group, an alkoxysilane group, an alkynyl group, an oxazoline group, a thiol group, and a sulfonic acid group.
- a glycidyl group an epoxy group, a carboxy group, a hydroxyl group, an acid anhydride group, a salt of a carboxy group, a carboxylate ester group, an
- the elastomer (Q) may include at least one selected from an olefin-based elastomer including a constitutional unit derived from an ⁇ -olefin and a constitutional unit derived from a glycidyl ester of an ⁇ , ⁇ -unsaturated acid, and a styrene-based elastomer including an epoxidized styrene-diene copolymer in which an unsaturated bond of a diene has been epoxidized.
- the elastomer (Q) may include an elastomer (Q) containing structural units derived from an ⁇ -olefin and structural units derived from a glycidyl ester of an ⁇ , ⁇ -unsaturated acid. That is, preparing the ground material (X) may include preparing a ground material (X) of an article containing the elastomer (Q) containing structural units derived from an ⁇ -olefin and structural units derived from a glycidyl ester of an ⁇ , ⁇ -unsaturated acid.
- the content of the reactive functional group may be 0.1 to 10 mass% of the total amount of the elastomer, or may be 0.5 to 8 mass%.
- the content of the reactive functional group can be calculated from the manufacturer's catalog value of the copolymer composition and the molecular weight of the functional group.
- the content of the elastomer (Q) in the pulverized material (X) is 1 to 20 parts by mass, preferably 2 to 15 parts by mass, more preferably 3 to 10 parts by mass, and even more preferably 3 to 8.5 parts by mass, per 100 parts by mass of the polyarylene sulfide resin (P).
- the content of the elastomer (Q) in the pulverized material (X) may be 6.2 parts by mass per 100 parts by mass of the polyarylene sulfide resin (P). In all aspects, these values may be combined to form the upper or lower limit of the numerical range.
- the elastomer content may be the manufacturer's catalog value for the article. The elastomer content may also be measured by thermogravimetry.
- the ground material (X) may contain 1 to 20% by mass, 2 to 18% by mass, or 3 to 16% by mass of an elastomer having a reactive functional group relative to the total amount of the ground material (X).
- the pulverized material (X) may contain other components contained in the recycled molded product in addition to the above-mentioned polyarylene sulfide resin (P) and elastomer (Q).
- examples of other components that the pulverized material (X) may contain include organic or inorganic fillers, and other additives that are generally added to thermoplastic resins (e.g., flame retardants, colorants such as dyes and pigments, stabilizers such as ultraviolet absorbers, lubricants, crystallization accelerators, crystal nucleating agents, etc.).
- Organic or inorganic fillers include fibrous fillers such as high-melting point organic fibrous substances such as glass fiber, carbon fiber, zinc oxide fiber, titanium oxide fiber, wollastonite, silica fiber, silica-alumina fiber, alumina fiber, zirconia fiber, boron nitride fiber, silicon nitride fiber, boron fiber, potassium titanate fiber, stainless steel fiber, aluminum fiber, titanium fiber, copper fiber, brass fiber, polyamide, high molecular weight polyethylene, aramid, fluororesin, polyester resin, and acrylic resin; carbon black, graphite, silica, quartz powder, and glass beads.
- fibrous fillers such as high-melting point organic fibrous substances such as glass fiber, carbon fiber, zinc oxide fiber, titanium oxide fiber, wollastonite, silica fiber, silica-alumina fiber, alumina fiber, zirconia fiber, boron nitride fiber, silicon nitride fiber, boron fiber, potassium titanate fiber, stainless steel fiber, aluminum
- milled glass fiber glass balloons, glass powder, talc (granular), silicates such as calcium silicate, aluminum silicate, diatomaceous earth, metal oxides such as iron oxide, titanium oxide, zinc oxide, alumina (granular), metal carbonates such as calcium carbonate, magnesium carbonate, metal sulfates such as calcium sulfate, barium sulfate, and other powdered and granular fillers such as silicon carbide, silicon nitride, boron nitride, and various metal powders; plate-shaped fillers such as mica, glass flakes, talc (plate-shaped), mica, kaolin, clay, alumina (plate-shaped), and various metal foils; and the like. In terms of mechanical strength, heat resistance, and the like, it is preferable to contain an inorganic filler.
- the content of the organic or inorganic filler in the pulverized material (X) is preferably 10 to 70% by mass, more preferably 15 to 65% by mass, and even more preferably 20 to 60% by mass.
- the pulverized material (X) may or may not contain an antioxidant. According to the manufacturing method of this embodiment, in either case, a recycled polyarylene sulfide resin composition that causes less mold contamination during molding can be obtained.
- the pulverized material (X) may be the same type as the antioxidant (Y) or a different type.
- the pulverized material (X) contains an antioxidant the content thereof may be, for example, 0.05 to 2.0 mass%, 0.1 to 1.0 mass%, or 0.1 to 0.5 mass% relative to the total amount (100 mass%) of the pulverized material (X).
- the average particle size of the pulverized material (X) is preferably 0.3 to 20 mm, more preferably 0.4 to 15 mm, even more preferably 1 to 10 mm, even more preferably 1 to 5 mm, and particularly preferably 1 to 3 mm, from the viewpoint of reducing the bite of the screw and/or torque of the extruder when producing recycled pellets.
- the average particle size of the pulverized material (X) is the volume-based cumulative 50% diameter (D50) measured by a laser diffraction scattering method.
- preparing the pulverized material (X) preferably includes preparing a pulverized material (X) having an average particle size of 0.3 to 20 mm.
- the melt viscosity of the pulverized product (X) is not limited within a range that does not impair the effects of the present disclosure, and the melt viscosity measured at 310° C. and a shear rate of 1200 sec ⁇ 1 may be 10 to 1000 Pa ⁇ s, or 30 to 700 Pa ⁇ s.
- the melt viscosity can be measured, for example, using a known capillary rheometer, using a 1 mm ⁇ 20 mmL flat die as a capillary, at a barrel temperature of 310° C. and a shear rate of 1000 sec ⁇ 1 .
- the method for crushing the article is not limited, and can be performed by a known method using, for example, a jet mill, a roller mill, a high-speed rotary crusher, a container-driven mill, etc.
- the preparation step may include classifying the crushed material (X) by sieving, etc., as necessary.
- melt-kneading process In the melt-kneading step, the pulverized material (X) and the antioxidant (Y) are melt-kneaded in an amount such that the blending amount of the antioxidant (Y) is 0.025 to 0.25 parts by mass per part by mass of the elastomer (Q) contained in the pulverized material (X).
- melt-kneading the antioxidant (Y) in the above blending amount with the pulverized material (X) it is possible to suppress mold contamination when molding the obtained recycled pellets.
- the antioxidant (Y) includes phenol-based antioxidants, phosphorus-based antioxidants, and thioether-based antioxidants, and is preferably one or more selected from the group consisting of these, and more preferably includes a phenol-based antioxidant.
- the antioxidant (Y) may be used alone or in combination of two or more.
- the melt-kneading preferably includes melt-kneading the pulverized material (X) with one or more antioxidants (Y) selected from the group consisting of phenol-based antioxidants, phosphorus-based antioxidants, and thioether-based antioxidants.
- the phenolic antioxidant may be a compound having one or more alkylphenol groups in its molecular structure.
- a compound having a phenyl group substituted with a hydroxyl group (-OH) and a tert-butyl group is preferred.
- a compound having two or more tert-butyl groups per phenolic hydroxyl group is more preferred.
- phenol-based antioxidant examples include 2,6-di-tert-butyl-p-cresol, stearyl-(3,5-dimethyl-4-hydroxybenzyl)thioglycolate, stearyl- ⁇ -(4-hydroxy-3,5-di-tert-butylphenyl)propionate, distearyl-3,5-di-tert-butyl-4-hydroxybenzylphosphonate, distearyl(4-hydroxy-3-methyl-5-tert-butyl)benzylmalonate, 2,2'-methylenebis(4-methyl-6-tert-butylphenol), 4,4'-methylenebis(2,6-di-tert-butylphenol), 2,2'-methylenebis[6-(1-methylcyclohexyl) -p-cresol], bis[3,3-bis(4-hydroxy-3-tert-butylphenyl)butyric acid]glycol ester, 4,4'-butylidenebis(
- phosphorus-based antioxidants include tetrakis(2,4-di-tert-butylphenyl)-4,4'-bisphenylene phosphonite, bis(2,6-di-tert-butyl-4-methylphenyl)pentaerythritol diphosphite, bis(2,4-di-butylphenyl)pentaerythritol diphosphite, tris(2,4-di-tert-butylphenyl)phosphite, 4,4'-[bis(2,4-di-tert-butyl-5-methylphenoxy)-phosphino]biphenyl, tris(nonylphenyl)phosphite, and di-stearyl pentaerythritol diphospha.
- Examples of the phosphorus-based antioxidant include phosphate, triphenyl phosphite, diphenyl alkyl phosphite, tridecyl phosphite, trioctyl phosphite, cyclic neopentane tetrale-bis(octadecyl phosphite), 3,5-di-butyl-4-hydroxybenzyl phosphonate diethyl ester, triphenyl phosphine, tridodecyl phosphine, tripropyl phosphine, trioctyl phosphine, tetraalkyl phosphonium halide, tetraalkyl phosphonium sulfonate chloride, bis(4-tert-butylphenyl) phosphate sodium salt, etc.
- the phosphorus-based antioxidant may be used alone or in combination of two or more.
- Thioether antioxidants include compounds that have at least one thioether bond in their molecular structure. Specific examples of thioether antioxidants include tetrakis[methylene-3-(dodecylthio)propionate]methane, dilauryl-3,3'-thiodipropionate, and distearyl-3,3'-thiodipropionate. Thioether antioxidants may be used alone or in combination of two or more.
- the amount of antioxidant (Y) is preferably 0.026 to 0.20 parts by mass, more preferably 0.027 to 0.15 parts by mass, even more preferably 0.028 to 0.10 parts by mass, and particularly preferably 0.030 to 0.085 parts by mass, per part by mass of elastomer (Q) contained in pulverized material (X).
- the amount of antioxidant (Y) may be 0.05 parts by mass per part by mass of elastomer (Q) contained in pulverized material (X). In all aspects, these numerical values may be combined to form the upper or lower limit of the above numerical range.
- melt-kneading temperature is a temperature equal to or higher than the melting point of the pulverized material (X), and is usually preferably 280 to 360°C, more preferably 290 to 350°C.
- the mixing method is not particularly limited as long as it can uniformly mix the pulverized material (X) and the antioxidant (Y), and examples of the method include a melt-kneading method using a melt-kneading device such as a conventional single-screw or twin-screw extruder. After melt-kneading and extruding the components, the resulting recycled polyarylene sulfide resin composition (Y) can be processed into the desired form such as powder, flakes, pellets, etc.
- the recycled polyarylene sulfide resin composition (Z) contains a pulverized product (X) of an article containing a polyarylene sulfide resin (P) and an elastomer (Q), and an antioxidant (Y),
- the content of the elastomer (Q) is 1 to 20 parts by mass based on 100 parts by mass of the polyarylene sulfide resin (P)
- the content of the antioxidant (Y) is 0.025 to 0.25 parts by mass per part by mass of the elastomer (Q).
- the content of the antioxidant (Y) is 0.025 to 0.25 parts by mass per part by mass of the elastomer (Q), so there is little mold contamination during molding.
- the types and contents of the polyarylene sulfide resin (P), elastomer (Q), pulverized material (X), and antioxidant (Y), as well as the manufacturing method for the recycled polyarylene sulfide resin composition (Z), are as described above.
- the content of the elastomer (Q) is 1 to 20 parts by mass, preferably 2 to 15 parts by mass, more preferably 3 to 10 parts by mass, and even more preferably 3 to 8.5 parts by mass, per 100 parts by mass of the polyarylene sulfide resin (P).
- the content of the elastomer (Q) may be 6.2 parts by mass per 100 parts by mass of the polyarylene sulfide resin (P). In all aspects, these values may be combined to form the upper or lower limit of the above numerical range.
- the content of the elastomer (Q) in the recycled polyarylene sulfide resin composition (Z) can be measured, for example, by thermogravimetry.
- the content of the antioxidant (Y) is preferably 0.026 to 0.20 parts by mass, more preferably 0.027 to 0.15 parts by mass, even more preferably 0.028 to 0.10 parts by mass, and particularly preferably 0.030 to 0.085 parts by mass, per 100 parts by mass of the elastomer (Q).
- the amount of the antioxidant (Y) may be 0.05 parts by mass per part by mass of the elastomer (Q) contained in the pulverized material (X). In all aspects, these values may be combined to form the upper or lower limit of the above numerical range.
- the content of the antioxidant (Y) in the recycled polyarylene sulfide resin composition (Z) can be measured by, for example, GC/MS, LC/MS, fluorescent X-ray analysis, etc.
- the elastomer (Q) may have a reactive functional group.
- the elastomer (Q) may include an elastomer (Q) that includes a structural unit derived from an ⁇ -olefin and a structural unit derived from a glycidyl ester of an ⁇ , ⁇ -unsaturated acid.
- the reactive functional group and the like are also as described above. The other descriptions regarding the elastomer (Q) in the first embodiment also apply here.
- the melt viscosity of the recycled polyarylene sulfide resin composition (Z) is not limited as long as it does not impair the effects of the present disclosure, and the melt viscosity measured at 310 ° C. and a shear rate of 1200 sec -1 may be 10 to 1000 Pa ⁇ s, or 30 to 700 Pa ⁇ s.
- the method for measuring the melt viscosity is as described in the section on the pulverized material (X).
- the recycled polyarylene sulfide resin composition (Z) may contain other components that may generally be blended into thermoplastic resins.
- other components include organic or inorganic fillers, and other additives that are generally added to thermoplastic resins (e.g., flame retardants, colorants such as dyes and pigments, stabilizers such as ultraviolet absorbers, lubricants, crystallization accelerators, crystal nucleating agents, etc.).
- organic or inorganic fillers include the same organic or inorganic fillers that may be contained in the ground material (X).
- the method for producing the recycled polyarylene sulfide resin composition (Z) is as described above.
- the form of the recycled polyarylene sulfide resin composition (Z) is not limited, and may be in any desired form such as powder, flakes, pellets, etc.
- the recycled polyarylene sulfide resin composition (Z) has a mold adhesion measured by the following method of preferably 0 to 45 ⁇ g, more preferably 0 to 40 ⁇ g, even more preferably 0 to 35 ⁇ g, and particularly preferably 0 to 30 ⁇ g.
- ⁇ Measurement method> Using a nested mold in which the vent and cavity are detachable, the molded article shown in Fig. 1 is continuously molded for 4 hours (1000 times) using an injection molding machine under the following conditions: Before and after the continuous molding, the total weight of the vent and cavity removed from the mold is measured, and the total weight change of the vent and cavity before and after the continuous molding is regarded as the weight of the material adhering to the mold.
- ⁇ Injection molding conditions> Cylinder temperature: 340°C Injection time: 2 seconds Cooling time: 10 seconds Mold temperature: 140°C
- the manufacturing method according to this embodiment is a method for manufacturing a recycled material-virgin material mixed resin composition (W), and includes mixing the recycled polyarylene sulfide resin composition (Z) manufactured by the above-mentioned manufacturing method of the recycled polyarylene sulfide resin composition (Z) with a virgin polyarylene sulfide resin or its composition (V).
- a virgin polyarylene sulfide resin or its composition (V) By mixing with the virgin polyarylene sulfide resin or its composition (V), the excellent physical properties of the polyarylene sulfide resin can be reinforced.
- the manufacturing method of the recycled polyarylene sulfide resin composition (Z) and the recycled polyarylene sulfide resin composition (Z) are as described above, so the description will be omitted here.
- the virgin polyarylene sulfide resin is a virgin material of the polyarylene sulfide resin.
- the virgin polyarylene sulfide resin composition may be a composition containing a virgin polyarylene sulfide resin and, if necessary, other components.
- Examples of the polyarylene sulfide resin containing the virgin polyarylene sulfide resin or its composition (V) include the same ones as those described for the recycled polyarylene sulfide resin composition (Z) described above, and from the viewpoint of quality control, etc., it is preferable that the composition is the same as the polyarylene sulfide resin in the recycled polyarylene sulfide resin composition (Z).
- the other components include compounds similar to the other components that may be contained in the recycled polyarylene sulfide resin composition (Z), elastomers, and antioxidants.
- the virgin polyarylene sulfide resin or its composition (V) is a composition, it is preferable that the composition is the same as the recycled polyarylene sulfide resin composition (Z) from the viewpoint of quality control, etc. (for example, the type and content of additives are the same).
- the amount of recycled polyarylene sulfide resin composition (Z) is preferably 50% by mass or more, more preferably 50 to 99.99% by mass, and even more preferably 60 to 100% by mass, relative to the total amount (100% by mass) of recycled polyarylene sulfide resin composition (Z) and virgin polyarylene sulfide resin or its composition (V), in order to increase the amount of recycled material used. Even if the amount of recycled polyarylene sulfide resin composition (Z) is increased, a recycled material-virgin material mixed resin composition (W) with less mold contamination during molding can be obtained.
- the mixing method is not limited, and the recycled polyarylene sulfide resin composition (Z) and virgin polyarylene sulfide resin or its composition (V) may be dry blended, melt-kneaded using a conventional melt-kneading device such as a single-screw or twin-screw extruder, or mixed in the hopper (material supply member) of an injection molding machine.
- the resulting recycled-virgin mixed resin composition (W) can be processed into the desired form such as powder, flakes, pellets, etc.
- the recycled material-virgin material mixed resin composition (W) contains the above-mentioned recycled polyarylene sulfide resin composition (Z) and virgin polyarylene sulfide resin or its composition (V).
- virgin polyarylene sulfide resin or its composition (V) By containing virgin polyarylene sulfide resin or its composition (V), the excellent physical properties of the polyarylene sulfide resin can be reinforced.
- the recycled polyarylene sulfide resin composition (Z) and the virgin polyarylene sulfide resin or its composition (V) are as described in the section on the manufacturing method of the recycled material-virgin material mixed resin composition (W).
- the content of the recycled polyarylene sulfide resin composition (Z) is preferably 50% by mass or more, more preferably 50 to 99.99% by mass, and even more preferably 60 to 100% by mass, based on the total amount of the recycled polyarylene sulfide resin composition (Z) and the virgin polyarylene sulfide resin or its composition (V), in order to increase the amount of recycled material used.
- the recycled material-virgin material mixed resin composition (W) causes little mold contamination during molding, even when the recycled polyarylene sulfide resin composition (Z) has a high content.
- the total content of the recycled polyarylene sulfide resin composition (Z) and virgin polyarylene sulfide resin or a composition thereof is preferably 80 to 100 mass%, more preferably 90 to 100 mass%, even more preferably 95 to 100 mass%, and may be 100 mass%, relative to the total amount (100 mass%) of resin components contained in the recycled material-virgin material mixed resin composition (W).
- the melt viscosity of the recycled material-virgin material mixed resin composition (W) is not limited as long as it does not impair the effects of the present disclosure, and the melt viscosity measured at 310° C. and a shear rate of 1200 sec ⁇ 1 may be 10 to 1000 Pa ⁇ s, or 30 to 700 Pa ⁇ s.
- the method for measuring the melt viscosity is as described in the section on the pulverized material (X).
- the recycled material-virgin material mixed resin composition (W) may contain other components that can be generally blended into thermoplastic resins.
- other components include organic or inorganic fillers, and other additives that are generally added to thermoplastic resins (e.g., flame retardants, colorants such as dyes and pigments, stabilizers such as ultraviolet absorbers, lubricants, crystallization accelerators, crystal nucleating agents, etc.).
- organic or inorganic fillers include those exemplified as organic or inorganic fillers that may be contained in the ground material (X).
- the form of the recycled material-virgin material mixed resin composition (W) is not limited, and may be in any desired form such as powder, flakes, pellets, etc.
- the recycled material-virgin material mixed resin composition (W) can suppress mold contamination during molding, and therefore can be suitably used as a resin composition for injection molding or a resin composition for extrusion molding.
- the recycled molded product according to this embodiment is a molded product containing the above-mentioned recycled polyarylene sulfide resin composition (Z).
- the manufacturing method of the recycled molded product is not limited, and the recycled polyarylene sulfide resin composition (Z) can be manufactured by performing known injection molding, profile/solidification extrusion processing, press molding, spinning processing, etc., using the recycled polyarylene sulfide resin composition (Z) together with other thermoplastic resins and additives as necessary.
- the recycled polyarylene sulfide resin composition (Z) causes less mold contamination during molding, so the number of mold replacements can be reduced, and the productivity of the recycled molded product can be improved.
- the method according to the present embodiment is a method for suppressing mold contamination during molding of a recycled polyarylene sulfide resin composition (Z) obtained from a pulverized product (X) containing 100 parts by mass of a polyarylene sulfide resin (P) and 1 to 20 parts by mass of an elastomer (Q),
- the method includes melt-kneading the pulverized material (X) and the antioxidant (Y) in an amount such that the amount of the antioxidant (Y) is 0.025 to 0.25 parts by mass per part by mass of the elastomer (Q) contained in the pulverized material (X).
- the polyarylene sulfide resin (P), the elastomer (Q), the pulverized material (X), and the antioxidant (Y) are as described above.
- the use according to this embodiment is the use of an antioxidant (Y) for suppressing mold contamination during molding of a recycled polyarylene sulfide resin composition (Z) obtained from a pulverized product (X) containing 100 parts by mass of a polyarylene sulfide resin (P) and 1 to 20 parts by mass of an elastomer (Q),
- the method includes melt-kneading an antioxidant (Y) with the pulverized material (X) in an amount such that the antioxidant (Y) is blended in an amount of 0.025 to 0.25 parts by mass per part by mass of the elastomer (Q) contained in the pulverized material (X).
- the antioxidant (Y) By melt-kneading the antioxidant (Y) with the pulverized material (X) in a predetermined amount, it is possible to suppress mold contamination during molding.
- the polyarylene sulfide resin (P), the elastomer (Q), the pulverized material (X), and the antioxidant (Y) are as described above.
- preparing the pulverized material (X) includes preparing a pulverized material (X) of an article comprising the elastomer (Q) having a reactive functional group.
- preparing the pulverized material (X) includes preparing a pulverized material (X) of an article comprising the elastomer (Q) that contains a structural unit derived from an ⁇ -olefin and a structural unit derived from a glycidyl ester of an ⁇ , ⁇ -unsaturated acid.
- preparing the pulverized material (X) includes preparing the pulverized material (X) having an average particle size of 0.3 to 20 mm.
- melt-kneading step includes melt-kneading the pulverized material (X) with one or more antioxidants (Y) selected from the group consisting of phenol-based antioxidants, phosphorus-based antioxidants, and thioether-based antioxidants.
- the content of the elastomer (Q) is 1 to 20 parts by mass based on 100 parts by mass of the polyarylene sulfide resin (P),
- the content of the antioxidant (Y) is 0.025 to 0.25 parts by mass per part by mass of the elastomer (Q).
- a recycled material-virgin material mixed resin composition (W) comprising the recycled polyarylene sulfide resin composition (Z) according to [7] or [8] and a virgin polyarylene sulfide resin or a composition thereof (V).
- an antioxidant (Y) for suppressing mold contamination during molding of a recycled polyarylene sulfide resin composition (Z) obtained from a pulverized product (X) containing 100 parts by mass of a polyarylene sulfide resin (P) and 1 to 20 parts by mass of an elastomer (Q), Use comprising melt-kneading an antioxidant (Y) with the pulverized material (X) in an amount such that the blending amount of the antioxidant (Y) is 0.025 to 0.25 parts by mass per 1 part by mass of the elastomer (Q) contained in the pulverized material (X).
- Antioxidant (Y) Tetrakis[methylene-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate]methane, IRGANOX 1010 (product name), manufactured by BASF Japan Ltd.
- Example 1 20 g of antioxidant (Y) (0.05 parts by mass per part by mass of the elastomer in the pulverized material (X1)) was added to 10 kg of the pulverized material (X1) and dry-blended. The mixture was put into a twin-screw extruder with a cylinder temperature of 320° C. and melt-kneaded to obtain pellets (recycled pellets) of the recycled polyarylene sulfide resin composition (Z) of Example 1.
- Comparative Example 2 The ground material (X2) was fed into a twin-screw extruder having a cylinder temperature of 320°C and melt-kneaded to obtain pellets (recycled pellets) of the recycled polyarylene sulfide resin composition of Comparative Example 2.
- Reference Example 1 As Reference Example 1, virgin pellets of the above polyarylene sulfide resin composition A (containing no antioxidant) were used.
- Reference Example 2 As Reference Example 2, virgin pellets of the above polyarylene sulfide resin composition B (containing an antioxidant) were used.
- the amount of material adhering to the mold was 27 ⁇ g when the recycled pellets of Example 1 were used.
- the amount of material adhering to the mold was 69 ⁇ g when the recycled pellets of Comparative Example 1 were used, and the amount of material adhering to the mold was 57 ⁇ g when the recycled pellets of Comparative Example 2 were used.
- the amount of material adhering to the mold when the virgin pellets of Reference Example 1 were used was 51 ⁇ g
- the amount of material adhering to the mold when the virgin pellets of Reference Example 2 were used was 31 ⁇ g.
- the recycled pellets of Example 1 resulted in less mold fouling than the virgin pellets of Reference Examples 1 and 2, and the mold fouling was reduced to about 40% of that of the recycled pellets of Comparative Example 1 not containing an antioxidant (i.e., the mold fouling was reduced to about 60%).Furthermore, the mold fouling was reduced to about 47% of that of the recycled pellets of Comparative Example 2 (i.e., the mold fouling was reduced to about 53%).
- the recycled pellets of Comparative Example 1 resulted in more mold fouling than the virgin pellets of Reference Example 1.
- the recycled pellets of Comparative Example 2 resulted in more mold fouling than the virgin pellets of Reference Example 2, and also resulted in more mold fouling than the virgin pellets of Reference Example 1. From these results, it can be seen that the recycled pellets cause worse mold fouling than the virgin pellets, and that even when the recycled product contains an antioxidant, the effect of suppressing mold fouling is low.
- the method for producing the recycled polyarylene sulfide resin composition of this embodiment can suppress mold contamination during molding, and therefore has industrial applicability as a method for producing a resin composition for injection molding or a resin composition for extrusion molding.
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Abstract
L'invention concerne : une composition de résine de poly(sulfure d'arylène) recyclée produisant l'adhérence de peu de saleté à un moule métallique pendant le moulage ; et son procédé de production. Le procédé de production d'une composition de résine de poly(sulfure d'arylène) recyclée (Z) comprenant : une étape de préparation consistant à préparer un produit pulvérisé (X) d'un article contenant 100 parties en masse d'une résine de poly(sulfure d'arylène) (P) et 1 à 20 parties en masse d'un élastomère (Q) ; et une étape de malaxage à l'état fondu pour malaxer à l'état fondu le produit pulvérisé (X) et un antioxydant (Y), la quantité mélangée de l'antioxydant (Y) étant de 0,025 à 0,25 partie en masse pour 1 partie en masse de l'élastomère (Q) contenu dans le produit pulvérisé (X).
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| JP2023-187281 | 2023-10-31 | ||
| JP2023187281 | 2023-10-31 |
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| PCT/JP2024/038295 Pending WO2025094875A1 (fr) | 2023-10-31 | 2024-10-28 | Procédé de production d'une composition de résine de poly(sulfure d'arylène) recyclée, et composition de résine de poly(sulfure d'arylène) recyclée |
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