Kaneka Corporation

Masakuni Ueno

Katsumi Yamaguchi

Ryuji Furukawa

Masahiro Miyamoto

Yoshihiro Ikeda

Chiho Yoshimi

Kazuki Nishiyama

Shinya Hongou

An epoxy resin composition comprises an epoxy resin (A) and rubber-like polymer particles (B). The rubber-like polymer particles (B) maintain a finely dispersed state of primary particles. The content of the rubber-like polymer particles (B) is 0.5 to 80% by weight when the total amount of the epoxy resin (A) and rubber-like polymer particles (B) is 100% by weight. Rubber-like polymer particles (B) are obtainable by graft-polymerizing 5 to 50% by weight of a shell layer (B-2) with 50 to 95% by weight of a rubber particle core (B-1), and average particle diameter of the rubber-like polymer particles (B) is 0.03 to 2 &#x3bc;m. Rubber particle core (B-1) comprises elastic material of not less than 50% by weight of at least one monomer selected from diene monomers and (meth)acrylate monomers and less than 50% by weight of another coploymerizable vinyl monomer, or polysiloxane rubber elastic materials, or a mixture thereof.

Process for producing modified epoxy resin

This invention provides a process for producing an epoxy resin composition having core/shell rubber particles (rubber-like polymer particles) dispersed in an epoxy resin, wherein an epoxy resin composition excellent in the dispersed state of rubber-like polymer particles in an epoxy resin with a reduced amount of contaminants is produced easily and efficiently. The epoxy resin composition having rubber-like polymer particles dispersed well in an epoxy resin with less contaminant is obtained by bringing an aqueous latex of rubber-like polymer particles (B) into contact with an organic medium (C) showing partial solubility in water, then bringing an organic medium (D) having lower partial solubility in water than that of the organic medium (C) into contact therewith to separate water substantially, to remove the rubber-like polymer particles as a dispersion (F) having the polymer particles dispersed in the organic medium, and mixing it with an epoxy resin (A), followed by distilling volatile components away.

A thermosetting resin composition having rubbery polymer particles dispersed therein of the present invention, that does not precipitate the thermosetting resin rubbery polymer particles over a long period of time, has excellent fluidity, is easily cured and molded, and sufficiently exhibits original properties of the thermosetting resin, comprises 100 parts by weight of a thermosetting resin, and 1 to 80 parts by weight of rubbery polymer particles, the rubbery polymer particles being dispersed in the form of a primary particle, wherein the solid content concentration is 60% to 90% by weight, and the water concentration is 3% by weight or less, and can efficiently be produced industrially in the state that the rubbery polymer particles are maintained in a stable state. The composition can be produced by a process for production of a thermosetting resin composition having rubbery polymer particles dispersed therein of the present invention, comprising a concentration step of deaerating a gas phase adjacent to a mixed solution comprising the rubbery polymer particles, the thermosetting resin, water and an organic solvent to reduce the pressure therein, thereby reducing the amounts of the water and the organic solvent in the mixed solution.

Thermosetting resin composition having rubbery polymer particle dispersed therein, and process for production thereof

The present invention provides a method for efficiently filtering slurry suspensions in a vessel including a nozzle flange near the vessel, when solids in the slurry suspensions being treated in the vessel are filtered for cleaning or for other purposes and subsequently subjected to reslurrying, dissolving or dispersing operation. A method for producing suspensions, solutions or dispersions comprising separating solids from slurry suspensions and then slurrying, dissolving or dispersing the solids again by adding a solvent, characterized in that the above described solids are separated in the same vessel as the one in which the operation to obtain the above described slurry suspensions has been performed and/or inside a flange directly connected to the same vessel.

Process for production of suspensions, solutions, or dispersions

A process for efficiently producing an agglomerate resulting from removal of impurities from a water-base latex of rubbery polymer particles or dry Powder thereof and producing a dispersion having rubbery polymer particles dispersed in an organic solvent, and a process for efficiently producing a resin composition of low impurity content, in which the state of dispersion of rubbery polymer particles is excellent, from the above dispersion. In particular, a rubbery polymer particle agglomerate of low impurity content is obtained by first mixing a water-base latex of rubbery polymer particles with an organic solvent exhibiting partial solubility in water, bringing the resultant mixture into contact with water to thereby form a rubbery polymer particle agglomerate, and thereafter separating the water phase from the agglomerate/water phase mixture. Further, a resin composition of low impurity content having rubbe, polymer particles favorably dispersed is obtained by first adding an organic solvent to the above agglomerate, mixing the obtained dispersion with a polymerizable organic compound having a reactive group, such as an epoxy resin, and thereafter distilling off volatile components.

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Takasago, Japan

Masakuni Ueno