Fiber-reinforced resin composition and molded body thereof

Abstract

Long-fiber-reinforced thermoplastic resin particles and a blend thereof are provided, wherein the opening property of the reinforcing fibers during molding is good, and a molded body exhibiting an excellent appearance and having high mechanical strength is obtained. The particles (A) contains a thermoplastic resin (A1), produced by using a metallocene catalyst, a modified polyolefin resin (A2) modified with an unsaturated carboxylic acid or a derivative thereof, and reinforcing fibers (A3) and satisfy the following requirements (1) to (5); (1) the amount of modification of the unsaturated carboxylic acid or a derivative thereof is 0.01 to 2 percent by weight in 100 percent by weight of the total of (A1) and (A2); (2) (A1) and (A2) constitute 20 to 70 percent by weight in 100 percent by weight of the total of (A1), (A2), and (A3); (3) (A3) constitutes 30 to 80 percent by weight in 100 percent by weight of the total of (A1), (A2), and (A3); (4) when 25 g of (A) is encapsulated in a 20-L chamber and is stood at 65° C. for 1 hour, the amount of acetaldehyde dissipated from (A) is 3.0 μg/m 3 or less; and (5) the melting point of the resin component in (A) is 150° C. or higher.

1 . Long-fiber-reinforced thermoplastic resin particles (A) characterized by comprising a thermoplastic resin (A1) produced by using a metallocene catalyst, a modified polyolefin resin (A2) modified with an unsaturated carboxylic acid or a derivative thereof, and reinforcing fibers (A3),
 wherein the following requirements (1) to (5) are satisfied.   (1) The amount of modification of the unsaturated carboxylic acid or a derivative thereof is 0.01 to 2 percent by weight in 100 percent by weight of the total of the thermoplastic resin (A1) and the modified polyolefin resin (A2).   (2) The total of the thermoplastic resin (A1) and the modified polyolefin resin (A2) constitute 20 to 70 percent by weight in 100 percent by weight of the total of the thermoplastic resin (A1), the modified polyolefin resin (A2), and the reinforcing fibers (A3).   (3) The reinforcing fibers (A3) constitute 30 to 80 percent by weight in 100 percent by weight of the total of the thermoplastic resin (A1), the modified polyolefin resin (A2), and the reinforcing fibers (A3).   (4) When 25 g of the long-fiber-reinforced thermoplastic resin particles (A) are encapsulated in a 20-L chamber and are stood at 65° C. for 1 hour, the amount of acetaldehyde dissipated from the long-fiber-reinforced thermoplastic resin particles (A) is 3.0 μg/m 3  or less.   (5) The melting point of the resin component in the long-fiber-reinforced thermoplastic resin particles (A) is 150° C. or higher.   
     
     
         2 . The long-fiber-reinforced thermoplastic resin particles (A) according to  claim 1 , characterized in that the thermoplastic resin (A1) constitutes 75 to 99 percent by weight and the modified polyolefin resin (A2) constitutes 1 to 25 percent by weight in 100 percent by weight of the total of the thermoplastic resin (A1) and the modified polyolefin resin (A2). 
     
     
         3 . The long-fiber-reinforced thermoplastic resin particles (A) according to  claim 1 , characterized in that the thermoplastic resin (A1)) satisfies the following requirements (a-1), (a-2), and (a-3).
 (a-1) The melt index (MI; resin temperature 230° C., load 21.18 N) is within the range of 100 to 250 g/10 min.   (a-2) The amount of components soluble into o-dichlorobenzene at 90° C. measured by cross fractionation chromatography (CFC method) is 1 percent by weight or less.   (a-3) The molecular weight distribution (Mw/Mn) is less than 3.5.   
     
     
         4 . The long-fiber-reinforced thermoplastic resin particles (A) according to  claim 1 , characterized in that the thermoplastic resin (A1) is at least one type of polymer selected from propylene homopolymers and propylene-α-olefin random copolymers. 
     
     
         5 . The long-fiber-reinforced thermoplastic resin particle dry blend material (C) characterized by comprising:
 10 to 90 percent by weight of long-fiber-reinforced thermoplastic resin particles (A) according to claims 1, and   90 to 10 percent by weight of polyolefin resin particles (B) for dilution (where the total of the long-fiber-reinforced thermoplastic resin particles (A) and the polyolefin resin particles (B) for dilution is assumed to be 100 percent by weight).   
     
     
         6 . The long-fiber-reinforced thermoplastic resin particle dry blend material (C) according to  claim 5 , characterized in that the reinforcing fibers (A3) constitute 5 to 60 percent by weight in 100 percent by weight of the total of the long-fiber-reinforced thermoplastic resin particles (A) and the polyolefin resin particles (B) for dilution. 
     
     
         7 . The long-fiber-reinforced thermoplastic resin particle dry blend material (C) according to  claim 5 , characterized in that the polyolefin resin particles (B) for dilution satisfy the following requirements (b-1), (b-2), and (b-3).
 (b-1) The melt index (MI; resin temperature 230° C., load 21.18 N) is within the range of 20 to 70 g/10 min.   (b-2) The relaxation time λ is 0.3 seconds or shorter, where the angular frequency ω=1 (rad/sec), which is calculated from the storage modulus G′ and the loss modulus G″ measured with a cone & plate rheometer.   (b-3) The molecular weight distribution (Mw/Mn) is within the range of 2.5 to 6.0.   
     
     
         8 . A molded body produced through molding by using long-fiber-reinforced thermoplastic resin particles (A) according to  claim 1 . 
     
     
         9 . A molded body produced through molding by using long-fiber-reinforced thermoplastic resin particle dry blend material (C) according to  claim 5 .