Process for producing thermoplastic resin composition, and thermoplastic resin composition produced by the same

Abstract

A process for producing a thermoplastic resin composition includes kneading a mixture obtained by combining a rubber component with a ground product, the ground product being formed by grinding a thermoplastic resin molded article having an alloy resin of a polycarbonate and an ABS, and then molding the mixture after kneading. The mixture has 0.5 wt % or more and 1.5 wt % or less of the rubber component based on 100 wt % of the mixture.

What is claimed is: 
     
         1 . A recycled resin comprising an alloy resin included in a collected molded article,
 wherein the alloy resin comprises polycarbonate and ABS,   wherein a content of a virgin resin in the recycled resin is 0 wt % or more and 1.0 wt % or less based on 100 wt % of the recycled resin,   wherein the recycled resin further comprises a rubber that is different from the ABS and a fluoroolefin,   wherein a content of the rubber in the recycled resin is 0.5 wt % or more and 1.5 wt % or less based on 100 wt % of the recycled resin, and   wherein a content of the fluoroolefin in the recycled resin is 0.5 wt % or less based on 100 wt % of the recycled resin.   
     
     
         2 . The recycled resin according to  claim 1 , which has a flame retardancy of V-0 as determined by a V-test according to the UL 94 standard. 
     
     
         3 . The recycled resin according to  claim 1 , wherein the rubber is at least one selected from the group consisting of butadiene rubber, styrene butadiene rubber, acrylonitrile butadiene rubber, and silicone rubber. 
     
     
         4 . The recycled resin according to  claim 1 , wherein the rubber is a graft copolymer of at least one rubber selected from the following group A and at least one rubber selected from the following group B:
 group A: butadiene rubber, styrene butadiene rubber, acrylonitrile butadiene rubber, silicone rubber;   group B: styrene, methyl methacrylate.   
     
     
         5 . The recycled resin according to  claim 1 , wherein a content of phenols in the alloy resin is larger by 5% or more than a content of phenols in the virgin alloy resin. 
     
     
         6 . A molded article of a recycled resin, wherein the recycled resin is the recycled resin according to  claim 1 . 
     
     
         7 . A recycled resin comprising an alloy resin included in a collected molded article,
 wherein the alloy resin comprises polycarbonate and ABS,   wherein a content of a virgin resin in the recycled resin is 0 wt % or more and 1.0 wt % or less based on 100 wt % of the recycled resin,   wherein the recycled resin further comprises a rubber that is different from the ABS and a drip preventing agent,   wherein a content of the rubber in the recycled resin is 0.5 wt % or more and 1.5 wt % or less based on 100 wt % of the recycled resin, and   wherein a content of the drip preventing agent in the recycled resin is 0.5 wt % or less based on 100 wt % of the recycled resin.   
     
     
         8 . The recycled resin according to  claim 7 , which has a flame retardancy of V-0 as determined by a V-test according to the UL 94 standard. 
     
     
         9 . The recycled resin according to  claim 7 , wherein the rubber is at least one selected from the group consisting of butadiene rubber, styrene butadiene rubber, acrylonitrile butadiene rubber, and silicone rubber. 
     
     
         10 . The recycled resin according to  claim 9 , wherein the rubber is a graft copolymer of at least one rubber selected from the following group A and at least one rubber selected from the following group B:
 group A: butadiene rubber, styrene butadiene rubber, acrylonitrile butadiene rubber, silicone rubber;   group B: styrene, methyl methacrylate.   
     
     
         11 . The recycled resin according to  claim 7 , wherein a content of phenols in the alloy resin is larger by 5% or more than a content of phenols in the virgin alloy resin. 
     
     
         12 . A molded article of a recycled resin, wherein the recycled resin is the recycled resin according to  claim 7 . 
     
     
         13 . A recycled resin comprising a degraded alloy resin,
 wherein the alloy resin comprises polycarbonate and ABS,   wherein a content of a virgin resin in the recycled resin is 0 wt % or more and 1.0 wt % or less based on 100 wt % of the recycled resin,   wherein the recycled resin further comprises a rubber that is different from the ABS and a fluoroolefin,   wherein a content of the rubber in the recycled resin is 0.5 wt % or more and 1.5 wt % or less based on 100 wt % of the recycled resin, and   wherein a content of the fluoroolefin in the recycled resin is 0.5 wt % or less based on 100 wt % of the recycled resin.   
     
     
         14 . The recycled resin according to  claim 13 , which has a flame retardancy of V-0 as determined by a V-test according to the UL 94 standard. 
     
     
         15 . The recycled resin according to  claim 13 , wherein the rubber is at least one selected from the group consisting of butadiene rubber, styrene butadiene rubber, acrylonitrile butadiene rubber, and silicone rubber. 
     
     
         16 . The recycled resin according to  claim 15 , wherein the rubber is a graft copolymer of at least one rubber selected from the following group A and at least one rubber selected from the following group B:
 group A: butadiene rubber, styrene butadiene rubber, acrylonitrile butadiene rubber, silicone rubber;   group B: styrene, methyl methacrylate.   
     
     
         17 . The recycled resin according to  claim 13 , wherein a content of phenols in the alloy resin is larger by 5% or more than a content of phenols in the virgin alloy resin. 
     
     
         18 . A molded article of a recycled resin, wherein the recycled resin is the recycled resin according to  claim 13 . 
     
     
         19 . A recycled resin comprising a degraded alloy resin,
 wherein the alloy resin comprises polycarbonate and ABS,   wherein a content of a virgin resin in the recycled resin is 0 wt % or more and 1.0 wt % or less based on 100 wt % of the recycled resin,   wherein the recycled resin further comprises a rubber that is different from the ABS and a drip preventing agent,   wherein a content of the rubber in the recycled resin is 0.5 wt % or more and 1.5 wt % or less based on 100 wt % of the recycled resin, and   wherein a content of the drip preventing agent in the recycled resin is 0.5 wt % or less based on 100 wt % of the recycled resin.   
     
     
         20 . The recycled resin according to  claim 19 , which has a flame retardancy of V-0 as determined by a V-test according to the UL 94 standard. 
     
     
         21 . The recycled resin according to  claim 19 , wherein the rubber is at least one selected from the group consisting of butadiene rubber, styrene butadiene rubber, acrylonitrile butadiene rubber, and silicone rubber. 
     
     
         22 . The recycled resin according to  claim 21 , wherein the rubber is a graft copolymer of at least one rubber selected from the following group A and at least one rubber selected from the following group B:
 group A: butadiene rubber, styrene butadiene rubber, acrylonitrile butadiene rubber, silicone rubber;   group B: styrene, methyl methacrylate.   
     
     
         23 . The recycled resin according to  claim 19 , wherein a content of phenols in the alloy resin is larger by 5% or more than a content of phenols in the virgin alloy resin. 
     
     
         24 . A molded article of a recycled resin, wherein the recycled resin is the recycled resin according to  claim 19 . 
     
     
         25 . A process for producing a recycled resin, comprising the steps of:
 preparing a ground product obtained by grinding a collected molded article;   mixing the ground product and additives; and   kneading the mixture obtained by the mixing step to obtain a recycled resin,   wherein the ground product comprises polycarbonate, ABS and an alloy resin,   wherein contents of a rubber that is different from the ABS, a fluoroolefin, and a virgin resin are respectively 0.5 wt % or more and 1.5 wt % or less, 0.5 wt % or less, and 0 wt % or more and 1.0 wt % or less, based on the total of the additives and the recycled resin taken to be 100 wt %.   
     
     
         26 . The process for producing a recycled resin according to  claim 25 , wherein the ground product has an average particle size of 3 mm or more and 8 mm or less. 
     
     
         27 . A process for producing a molded article, comprising the step of:
 preparing a resin; and   molding the resin,   wherein the resin is a recycled resin obtained by the process for producing a recycled resin according to  claim 25 .   
     
     
         28 . The process for producing a molded article according to  claim 27 , wherein the step of molding the resin is selected from the group consisting of injection molding, extrusion molding, sandwich molding, two-color molding, and core back molding. 
     
     
         29 . A process for producing a recycled resin, comprising the steps of:
 preparing a ground product obtained by grinding a collected molded article;   mixing the ground product and additives; and   kneading the mixture obtained by the mixing step to obtain a recycled resin,   wherein the ground product comprises polycarbonate, ABS and an alloy resin,   wherein contents of a rubber that is different from the ABS, a drip preventing agent, and a virgin resin are respectively 0.5 wt % or more and 1.5 wt % or less, 0.5 wt % or less, and 0 wt % or more and 1.0 wt % or less, based on the total of the additives and the recycled resin taken to be 100 wt %.   
     
     
         30 . The process for producing a recycled resin according to  claim 29 , wherein the ground product has an average particle size of 3 mm or more and 8 mm or less. 
     
     
         31 . A process for producing a molded article, comprising the step of:
 preparing a resin; and   molding the resin,   wherein the resin is a recycled resin obtained by the process for producing a recycled resin according to  claim 29 .   
     
     
         32 . The process for producing a molded article according to  claim 31 , wherein the step of molding the resin is selected from the group consisting of injection molding, extrusion molding, sandwich molding, two-color molding, and core back molding. 
     
     
         33 . A process for producing a recycled resin, comprising the steps of:
 preparing a ground product obtained by grinding a degraded molded article;   mixing the ground product and additives; and   kneading the mixture obtained by the mixing step to obtain a recycled resin,   wherein the ground product comprises polycarbonate, ABS and an alloy resin,   wherein contents of a rubber that is different from the ABS, a fluoroolefin, and a virgin resin are respectively 0.5 wt % or more and 1.5 wt % or less, 0.5 wt % or less, and 0 wt % or more and 1.0 wt % or less, based on the total of the additives and the recycled resin taken to be 100 wt %.   
     
     
         34 . The process for producing a recycled resin according to  claim 33 , wherein the ground product has an average particle size of 3 mm or more and 8 mm or less. 
     
     
         35 . A process for producing a molded article, comprising the step of:
 preparing a resin; and   molding the resin,   wherein the resin is a recycled resin obtained by the process for producing a recycled resin according to  claim 33 .   
     
     
         36 . The process for producing a molded article according to  claim 35 , wherein the step of molding the resin is selected from the group consisting of injection molding, extrusion molding, sandwich molding, two-color molding, and core back molding. 
     
     
         37 . A process for producing a recycled resin, comprising the steps of:
 preparing a ground product obtained by grinding a degraded molded article;   mixing the ground product and additives; and   kneading the mixture obtained by the mixing step to obtain a recycled resin,   wherein the ground product comprises polycarbonate, ABS and an alloy resin,   wherein contents of a rubber that is different from the ABS, a drip preventing agent, and a virgin resin are respectively 0.5 wt % or more and 1.5 wt % or less, 0.5 wt % or less, and 0 wt % or more and 1.0 wt % or less, based on the total of the additives and the recycled resin taken to be 100 wt %.   
     
     
         38 . The process for producing a recycled resin according to  claim 37 , wherein the ground product has an average particle size of 3 mm or more and 8 mm or less. 
     
     
         39 . A process for producing a molded article, comprising the step of:
 preparing a resin; and   molding the resin,   wherein the resin is a recycled resin obtained by the process for producing a recycled resin according to  claim 37 .   
     
     
         40 . The process for producing a molded article according to  claim 39 , wherein the step of molding the resin is selected from the group consisting of injection molding, extrusion molding, sandwich molding, two-color molding, and core back molding.