Multi-layer plastic fuel tank

Abstract: A multi-layer plastic fuel tank is constituted by at least one high-density polyethylene layer, at least one polyamide layer, and at least one modified high-density polyethylene layer made of high-density polyethylene modified with an unsaturated carboxylic acid or its derivatives, which is interposed between each high-density polyethylene layer and each polyamide layer for bonding them, the polyamide layer being made of a polyamide copolymer comprising 90-60 weight % of polyamide 6 and 10-40 weight % of polyamide 66.

Description: BACKGROUND OF THE INVENTION The present invention relates to a multi-layer plastic fuel tank, and more particularly to a multi-layer plastic fuel tank comprising at least one high-density polyethylene layer, at least one polyamide layer and at least one modified high-density polyethylene layer and well moldable at a low temperature. Polyolefin resins are inexpensive and strong, and excellent in a weathering resistance and a chemical resistance, so that they are widely used for various containers. However, the polyolefin resins do not necessarily have sufficient gas barrier properties. Accordingly, they cannot be used for fuel tanks for gasoline in countries having strict regulations. In view of the above, various attempts have been made to provide thermoplastic resin compositions having excellent mechanical strength and gas barrier properties by blending polyamides such as nylons having excellent gas barrier properties with the polyolefin resins (Japanese Patent Laid-Open Nos. 54-123158, 59-232135, 62-158739, 62-241938 and 62-241941). Also, instead of blending, it was proposed to laminate polyamide layers and polyolefin resin layers to produce multilayer plastic fuel tanks having improved gas barrier properties (Japanese Patent Laid-Open No. 55-121017 and Japanese Patent Publication No. 60-14695). In this case, since the polyolefin resin layers generally have a relatively poor bonding strength to the polyamide layers, they are laminated via modified plastic layers such as those made of polyolefin resins modified with unsaturated carboxylic acids or their derivatives. Such multi-layer moldings for fuel tanks are generally produced by forming parisons by a usual extrusion molding method and then subjecting the parisons to blow molding (Japanese Patent Laid-Open Nos. 58-220738, 62-110526). Japanese Patent Publication No. 60-34461 discloses a method of producing a multi-layer, blow-molded container constituted by a laminate of a polyolefin resin layer, a polyamide or saponified ethylene-vinyl acetate copolymer layer and an intermediate layer interposed therebetween, the intermediate layer being made of a modified ethylene copolymer produced by grafting 0.01-1 weight % of maleic anhydride to a copolymer of ethylene and an α-olefin having 3 or more carbon atoms and showing a crystallinity of 2-30%. However, the polyamide layers of the above multi-layer moldings are usually made of polyamide 6, and from the viewpoint of moldability of the polyamide layer, the temperature of the high-density polyethylene layer (main layer) should be higher than that of a single-layer plastic fuel tank made of high-density polyethylene only. As a result, there arises a problem of drawdown of a parison. Apart from the above, since large amounts of flashes and defective moldings are generated in the course of blow molding, it was proposed to recover those flashes and defective moldings and reuse them by mixing them with polyolefin resins (Japanese Patent Laid-Open Nos. 54-113678 and 55-91634). Japanese Patent Laid-Open Nos. 55-91634 discloses a multi-layer molding constituted by a laminate of (a) a polyolefin resin layer, (b) a polyamide layer obtained by melt-blending (i) a modified polymer produced by grafting maleic anhydride to an ethylene/α-olefin copolymer having a crystallinity of 1-35% and a melt index of 0.01-50 g/10 minutes (maleic anhydride content: 0.05-1 weight %) and (ii) polyamide, and (c) a modified polyolefin resin layer made of a modified polymer produced by grafting maleic anhydride to an ethylene/α-olefin copolymer having a crystallinity of 2-30% and a melt index of 0.01-50 g/10 minutes (maleic anhydride content: 0.01-1 weight %), which is interposed between the polyolefin resin layer and the polyamide layer for bonding them, the multi-layer molding suffering from only little deterioration of mechanical strength even though flashes and defective moldings of the multi-layer moldings are reused as part of starting materials. However, thermoplastic resin compositions having satisfactory bonding strength and impact resistance cannot necessarily be obtained simply by mixing the flashes and defective moldings of multi-layer moldings with polyolefin resins. This is due to a low compatibility between polyolefin resins and polyamides. Since the impact resistance is a particularly important property for the fuel tanks, its decrease greatly reduces the values of the fuel tanks. Although a high impact resistance can be maintained if flashes and defective moldings are not added as regenerated products, the cost reduction of materials for the fuel tanks cannot be achieved. In addition, when flashes and defective moldings generated in the production of multi-layer plastic fuel tanks are blended with a virgin polyolefin resin, the resin temperature should be set at 230-250°C to improve the dispersibility of polyamide. In this case, there is remarkable decrease in drawdown resistance of the parison. OBJECT AND SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a multi-layer plastic fuel tank having at least one high-density polyethylene layer and at least one polyamide layer, the high-density polyethylene layer and the polyamide layer being strongly bonded to each other, which tank has sufficient gas barrier properties and impact resistance as well as improved drawdown resistance. As a result of intense research in view of the above object, the inventors have found that by forming the polyamide layer by a polyamide 6/polyamide 66 copolymer, it is possible to produce a multi-layer plastic fuel tank even at a low resin temperature of the high-density polyethylene layer in the course of extrusion, thereby improving the drawdown resistance of the multi-layer plastic fuel tank. The inventors have also found that by blending high-density polyethylene with flashes and defective moldings of multi-layer plastic fuel tanks by using an extruder equipped with a screw having a special structure, the resulting composition can have fine polyamide particles uniformly dispersed therein, and that this composition can be used as a high-density polyethylene composition for the high-density polyethylene layer of a multi-layer plastic fuel tank to improve its various properties. The present invention is based on these findings. Thus, the multi-layer plastic fuel tank according to the present invention comprises at least one high-density polyethylene layer, at least one polyamide layer, and at least one modified high-density polyethylene layer made of high-density polyethylene modified with an unsaturated carboxylic acid or its derivatives, which is interposed between each high-density polyethylene layer and each polyamide layer for bonding them, the polyamide layer being made of a polyamide copolymer comprising 90-60 weight % of polyamide 6 and 10-40 weight % of polyamide 66. BRIEF DESCRIPTION OF THE DRAWING Fig. 1 is a partial cross-sectional view showing one example of a multi-layer structure of the multi-layer plastic fuel tank according to the present invention; DETAILED DESCRIPTION OF THE INVENTION [1] Multi-Layer Plastic Fuel Tank The multi-layer plastic fuel tank is constituted by three types of layers: a high-density polyethylene layer, a polyamide layer and a modified high-density polyethylene layer (made of high-density polyethylene modified with unsaturated carboxylic acid or its derivatives). [A] High-Density Polyethylene Layer High-density polyethylene forming the high-density polyethylene layer has a density of 0.935 g/cm³ or more, and preferably has a melt index (MI, 190°C, 2.16 kg load) of 0.003-2 g/10 minutes from the aspects of a drawdown resistance, a moldability and an impact resistance. The more preferred melt index is 0.01-1 g/10 minutes. Incidentally, when the flowability of the high-density polyethylene is expressed by a high-load melt index (HLMI, 190°C, 21.6 kg load), it is preferably 70 g/10 minutes or less, more preferably 1-20 g/10 minutes. [B] Polyamide Layer (a) General Polyamide Polyamides forming the polyamide layer are polymers containing amide bonds (―CONH―), and they may be produced by (1) a ring-opening polymerisation of lactams; (2) a condensation polymerization of amino carboxylic acids; (3) a condensation polymerisation of diamines and dibasic acids. Their examples include polyamide resins formed from aliphatic, alicyclic or aromatic diamines such as hexamethylenediamine, decamethylenediamine, dodecamethylenediamine, 2,2,4- or 2,4,4-trimethylhexamethylenediamine, 1,3- or 1,4-bis (aminomethyl) cyclohexane, bis (p-aminocyclohexylmethane), m- or p-xylylenediamine, and aliphatic, alicyclic or aromatic dicarboxylic acids such as adipic acid, suberic acid, sebacic acid, cyclohexane dicarboxylic acid, terephthalic acid and isophthalic acid; polyamide resins formed from amino carboxylic acids such as 6-amino caproic acid, 11-amino undecanoic acid and 12-amino dodecanoic acid; polyamide resins formed from lactams such as ε-caprolactam and ω-dodecalactam; copolymers made of these components; and mixtures of these polyamide resins. Specifically, the polyamide resins may be polyamide 6, polyamide 66, polyamide 11, polyamide 12 and copolymers consisting of these nylons. Besides, copolymers comprising 50 weight % or more of these polyamide resins and other resins may also be used. The weight-average molecular weight (Mw) of the polyamide is preferably 3,000-200,000, more preferably 10,000-100,000. To improve the impact resistance, the polyamide may contain 5-30 weight % of a plasticizer such as ε-caprolactam, N-butylbenzene sulfonamide and octyl paraoxybenzoate. The preferred amount of the plasticizer is 10-20 weight %. (b) Preferred Polyamide In the preferred embodiment, the polyamide layer is made of a polyamide copolymer comprising polyamide 6 and polyamide 66 (polyamide 6-66). The polyamide 6 is generally represented by the following formula (1): The polyamide 66 is generally represented by the following formula (2): The content of the polyamide 6 is 60-90 weight %, preferably 70-80 weight %, and the content of the polyamide 66 is 40-10 weight %, preferably 30-20 weight % in the polyamide copolymer. When the content of the polyamide 6 is lower than 60 weight % (when the content of the polyamide 66 exceeds 40 weight %), the multi-layer plastic fuel tank shows poor gas barrier properties. On the other hand, when the content of the polyamide 6 exceeds 90 weight % (when the content of the polyamide 66 is lower than 10 weight %), the multi-layer plastic fuel tank does not show an improved impact resistance. The above polyamide 6-66 can be produced, for instance, by copolymerizing hexamethylene diamine and adipic acid in the presence of ε-caprolactam. The polyamide 6-66 has a relative viscosity (JIS K6810) of 3-6.5, particularly 4-6. (c) Polyamide 6-66 Blended With Modified Olefinic Elastomer In the further preferred embodiment of the present invention, the polyamide 6-66 may be blended with a modified olefinic elastomer. The modified olefinic elastomer is an olefinic elastomer modified with an unsaturated carboxylic acid or its derivatives. The unsaturated carboxylic acid or its derivatives are monocarboxylic acids such as acrylic acid and methacrylic acid; dicarboxylic acids such as maleic acid, fumaric acid and itaconic acid; dicarboxylic anhydrides such as maleic anhydride, itaconic anhydride and endomethylenetetrahydrophthalic anhydride (hymic anhydride), and particularly maleic anhydride and endomethylenetetrahydrophthalic anhydride are preferable. The olefinic elastomers to be modified with graft monomers are copolymer rubbers comprising two or more α-olefins comprising ethylene, propylene, 1 -butene, 1 -hexene and 4-methyl-1-pentene. Among them, an ethylene-propylene copolymer rubber (EPR) and an ethylene-butene copolymer rubber (EBR) are particularly preferable. The ethylene-propylene copolymer rubber (EPR) used in the present invention preferably comprises 10-90 mo l % of ethylene, and 90-10 mo l % of propylene. The more preferred range is 20-80 mo l % for the ethylene and 80-20 mo l % for the propylene. The ethylene-propylene copolymer rubber (EPR) has a Mooney viscosity ML₁+₄ (100°C) of 1-120, preferably 5-100. The ethylene-butene copolymer rubber (EBR) used in the present invention preferably comprises 10-90 mo l % of ethylene, and 90-10 mo l % of butene. The more preferred range is 20-80 mo l % for the ethylene and 80-20 mo l % for the butene. The ethylene-butene copolymer rubber (EBR) has a Mooney viscosity ML₁+₄ (100°C) of 1-120, preferably 5-100. The ethylene-propylene copolymer rubber (EPR) and the ethylene-butene copolymer rubber (EBR) may further contain other α-olefins such as 4-methyl-1-pentene in such an amount that they do not deteriorate the properties of EPR or EBR. The proportion of the unsaturated carboxylic acid or its derivatives in the modified olefinic elastomer is 1.0 x 10⁻⁵ to 6.0 x 10⁻⁵ mo l /g, preferably 2.0 x 10⁻⁵ to 5.0 x 10⁻⁵ mo l /g. Specifically, in the case of maleic anhydride, its content is 0.005-5 weight %, preferably 0.01-3 weight %, and in the case of hymic anhydride (endomethylenetetrahydrophthalic anhydride), its content is 0.015-4 weight %, preferably 0.15-1.5 weight %. If the amounts of maleic anhydride and hymic anhydride are smaller than the lower limits of the above ranges, sufficient compatibility of the modified olefinic elastomer with polyamide cannot be achieved. On the other hand, if their amounts exceed the upper limits of the above ranges, the modified olefinic elastomer cannot be sufficiently dispersed in the polyamide. Such modified olefinic elastomers can be produced by a solution method or a melt blending method. The modified olefinic elastomer is blended with the polyamide 6-66 preferably in an amount of 30 weight % or less based on 100 weight % of the polyamide 6-66 + the modified olefinic elastomer. When the amount of the modified olefinic elastomer exceeds 30 weight %, the multi-layer plastic fuel tank shows reduced gas barrier properties. [C] Modified High-Density Polyethylene Layer Modified high-density polyethylene forming the modified high-density polyethylene layer is high-density polyethylene modified with an unsaturated carboxylic acid or its derivatives. The unsaturated carboxylic acid or its derivatives may be the same as used for modifying the olefinic elastomer. The high-density polyethylene to be modified with the unsaturated carboxylic acid or its derivatives may be the same as used for the high-density polyethylene layer. The proportion of the unsaturated carboxylic acid or its derivatives in the modified high-density polyethylene layer is preferably 0.005-5 weight %. Specifically, in the case of maleic anhydride, its content is preferably 0.01-3 weight %, more preferably 0.1-1 weight %, and in the case of hymic anhydride (endomethylenetetrahydrophthalic anhydride), its content is 0.015-4 weight %, more preferably 0.15-1.5 weight %. If the amounts of maleic anhydride and hymic anhydride are smaller than the lower limits of the above preferred ranges, sufficient bonding cannot be achieved between the polyamide layer and the modified high-density polyethylene layer. On the other hand, if their amounts exceed the upper limits of the above preferred ranges, a bonding strength decreases between the modified high-density polyethylene layer and the high-density polyethylene layer. Such modified high-density polyethylene can be produced by a solution method or a melt blending method. Incidentally, each of the above layers may contain other additives such as fillers, thermostabilizers, anti-oxidants, photostabilizers, flame retarders, plasticizers, anti-static agents, parting agents, foaming agents and nucleating agents to improve their properties. [D] Multi-Layer Structure The multi-layer plastic fuel tank made of the above resins has a multi-layer structure in which adjacent high-density polyethylene layer and polyamide layer are bonded to each other via a modified high-density polyethylene layer. A typical example of such multi-layer structure is shown in Fig. 1, which comprises outer and inner high-density polyethylene layers 1, 1, a central polyamide layer 2 and intermediate modified high-density polyethylene layers 3, 3 for bonding adjacent high-density polyethylene layer 1 and polyamide layer 2. The thickness proportions of the two high-density polyethylene layers 1, 1, the two modified high-density polyethylene layers 3, 3 and the polyamide layer 2 are preferably 99-60 : 0.5-20 : 0.5-20. When the total thickness of the two high-density polyethylene layers is smaller than 60% of the thickness of the multi-layer plastic fuel tank, the multi-layer plastic fuel tank does not have a sufficient strength. When the polyamide layer is thinner than 0.5% of the thickness of the multi-layer plastic fuel tank, the fuel tank does not have sufficient gas barrier properties. And when each modified high-density polyethylene layer is thinner than 0.25% (0.5% x 1/2) of the thickness of the multi-layer plastic fuel tank, a sufficient bonding strength cannot be achieved between the high-density polyethylene layer and the polyamide layer. The thickness of each layer of the multi-layer plastic fuel tank may be determined depending upon the impact resistance and gas barrier properties required as the fuel tank. Specifically, in the case of a gasoline tank, the high-density polyethylene layer has a thickness of 1.5-5 mm, the polyamide layer has a thickness of 20-500 µm, and the modified high-density polyethylene layer has a thickness of 20-500 µm. Incidentally, if there are two or more layers in each category of the layers, it should be noted that the above thickness means a total thickness. [E] Reuse of Regenerated Product for High-Density Polyethylene Layer In the present invention, part or whole of the multi-layer plastic fuel tank is reused as a regenerated high-density polyethylene composition for the high-density polyethylene layer. A proportion of the regenerated product (obtained from part or whole of the multi-layer plastic fuel tank) to be blended with virgin high-density polyethylene may differ depending upon the thickness of each layer, but it is generally 20-200 parts by weight per 100 parts by weight of the virgin high-density polyethylene. When the proportion of the regenerated product is lower than 20 parts by weight, sufficient cost reduction by using the regenerated product cannot be achieved. On the other hand, when it exceeds 200 parts by weight, the percentage of polyamide is too high in the high-density polyethylene layer, resulting in the decrease in an impact resistance. The preferred proportion of the regenerated product in the high-density polyethylene layer is 20-150 parts by weight. [2] Production of Multi-Layer Plastic Fuel Tank by Using Single-Screw Extruder The multi-layer plastic fuel tank can be produced, for instance, by extruding a resin for each layer from an extruder, forming a cylindrical parison having the above layer structure by a usual co-extrusion method, setting this parison in a blow molding die cavity having a desired shape and subjecting it to blow molding. (a) In the Case of Using Polyamide 6-66 In the process of extruding a parison, the extrusion temperature of the high-density polyethylene layer as a main layer is lower than the usual extrusion temperature. Namely, although the extrusion temperature of high-density polyethylene is usually 230-250°C, the extrusion temperature of the high-density polyethylene layer is determined within the range of 200-230°C, by the melting temperature of the polyamide 6-66. For instance, in a case where a weight ratio of the polyamide 6 (a) to the polyamide 66 (b) is 90:10, the resin for the high-density polyethylene layer is extruded at 220-230°C. In the case of (a)/(b) = 70:30 , the extrusion temperature is 210-220°C. Also, in the case of (a)/(b) = 60:40 , the extrusion temperature is 200-210°C. This low extrusion temperature serves not only to prevent the drawdown of a parison but also to shorten a molding cycle time. In this embodiment, since the polyamide layer of the multi-layer plastic fuel tank is made of the polyamide 6-66, the resin temperature of the high-density polyethylene can be reduced in the formation of its parison. As a result, the drawdown of the parison can be prevented. The reason therefor is not necessarily clear, but it may be presumed that since the polyamide 6-66 has lower melting point and crystallization temperature, and better heat resistance and a moldability as compared with polyamide 6 as a homopolymer, the co-extrusion of the polyamide 6-66, the high-density polyethylene and the modified high-density polyethylene can be conducted at a lower temperature. (b) Single-Screw Extruder In a method for producing a fuel tank in accordance with the present invention, a single-screw extruder having an L/D ratio of 20 or more is used. The extrusion rate of the resin blended by such an extruder can be a appropriately determined depending upon the size of the extruder. For instance, in the case of an extruder having a cylinder inner diameter of 90 mm, the extrusion rate is preferably about 150-200 kg/hr. When the extrusion rate of the resin is too high, the time period during which the resin resides in the extruder is short, resulting in insufficient blending. In a composition for the high-density polyethylene layer obtained by blending by means of the above-described extruder, the dispersed polyamide particles have as small an average particle size as 10 µm or less. In a case where flashes and defective moldings generated in the blow molding of parisons for multi-layer plastic fuel tanks are blended with virgin high-density polyethylene for the high-density polyethylene layer of the multi-layer plastic fuel tank, good dispersion of polyamide in the high-density polyethylene matrix can be achieved at a lower melt blending temperature than the conventional one, because the polyamide 6-66 has a lower melting point than that of the polyamide 6. Accordingly, the multi-layer plastic fuel tank thus obtained, whose high-density polyethylene layer is made of a composition containing flashes and defective moldings generated in the production of the multi-layer plastic fuel tanks, shows properties such as impact resistance, which are only little deteriorated, if any. In this embodiment, part or whole of the multi-layer plastic fuel tank is mixed with virgin high-density polyethylene, and the resulting mixture is melt-blended by an extruder having the above-described structure and reused for the high-density polyethylene layer of the multi-layer plastic fuel tank. The multi-layer plastic fuel tank obtained from such regenerated product does not suffer from the deterioration of properties such as impact resistance. This is due to the fact that fine particles of polyamide can be well dispersed in a composition for the high-density polyethylene layer by synergistic effects of each portion of the extruder used in the present invention, in which the virgin high-density polyethylene and the regenerated product are blended in the feed portion, metered in the metering portion, subjected to melt blending in the direction lateral to the resin flow in the cross-saw portion, and then subjected to melting of the unmolten resin portions and blending in the high-shear portion in both longitudinal and lateral directions. The present invention will be explained in further detail by way of the following Examples. Incidentally, starting materials (high-density polyethylene, modified high-density polyethylene, modified olefinic elastomer and polyamide) used are as follows: [1] High-density polyethylene HDPE [Melt index (MI, 190°C, 2.16 kg load): 0.03 g/10 minutes, high-load melt index (HLMI, 190°C, 21.6 kg load): 5.5 g/10 minutes, density: 0.945 g/m³, weight-average molecular weight (Mw): 20 x 10⁴] [2] Modified high-density polyethylene CMPE [Melt index (MI, 190°C, 2.16 kg load): 0.3 g/10 minutes, maleic anhydride graft ratio: 0.4 weight %, density: 0.953 g/m³, weight-average molecular weight (Mw): 12 x 10⁴] [3] Modified olefinic elastomer CMEBR Modified ethylene-butene copolymer rubber [ethylene-butene copolymer rubber (ethylene content: 50 weight %) grafted with 0.4 weight % of maleic anhydride, melt index (MI, 190°C, 2.16 kg load): 0.3 g/10 minutes] [4] Polyamide (1) Polyamide 6 PA-1 [Nylon 6, relative viscosity: 4] PA-2 [Nylon 6, relative viscosity: 4.2] PA-3 [Nylon 6, relative viscosity: 6.0] (2) Polyamide 6-66 CPA-1 [Nylon 6 : Polyamide 66 = 90:10, relative viscosity: 4] CPA-2 [Nylon 6 : Polyamide 66 = 70:30, relative viscosity: 4] CPA-3 [Nylon 6 : Polyamide 66 = 50:50, relative viscosity: 4] CPA-4 [Nylon 6 : Polyamide 66 = 96:4, relative viscosity: 4] (3) Polyamide 6-12 CPA-5 [Nylon 6 : Polyamide 12 = 70:30, relative viscosity: 4] (4) Polyamide 6-66/modified olefinic elastomer CPA-B1 [Blend of CPA-2 and CMEBR, CPA-2:CMEBR = 90:10] CPA-B2 [Blend of CPA-2 and CMEBR, CPA-2:CMEBR = 70:30] Examples 1-4, Comparative Examples 1-4 Production of Multi-Layer Plastic Fuel Tank A multi-layer plastic fuel tank (capacity: 40 liter) of a 3-type, 5-layer structure as shown in Table 1 was produced from high-density polyethylene, modified high-density polyethylene and various polyamides listed in Table 2 at a temperature shown in Table 2 by using a multi-layer blow molding machine (NB-60G, manufactured by The Japan Steel Works, Ltd.). Layer Type of Resin Thickness (mm) Outer Layer HDPE 2.6 Bonding Layer CMPE 0.1 Barrier Layer PA 0.1 Bonding Layer CMPE 0.1 Outer Layer HDPE 2.6 In the course of producing a parison, its drawdown was observed. And each of the resulting fuel tanks was measured with respect to a thickness distribution (minimum thickness), and subjected to a drop impact test at -40°C and a gasoline permeability test at 40°C. The molding cycle time of the fuel tank was also measured. The results are shown in Table 2. As is clear from Table 2, the multi-layer plastic fuel tanks of Examples 1-5 whose polyamide layers were made of the nylon 6-66 are excellent in a drawdown resistance, a minimum thickness, an impact resistance and gas barrier properties. On the other hand, the multi-layer plastic fuel tank of Comparative Example 1 whose polyamide layer was made of nylon 6, and the multi-layer plastic fuel tank of Comparative Example 4 whose polyamide layer was made of nylon 6-12 are poor in a drawdown resistance. Also, that of Comparative Example 2 shows poor gas barrier properties, and that of Comparative Example 3 shows an insufficient impact resistance. Incidentally, as the drawdown becomes smaller, the minimum thickness becomes larger. In this sense, the minimum thickness is a parameter showing the moldability (drawdown resistance) of the parison. Examples 5-8 Evaluation of Extrudability of Mixture of Pulverized Multi-Layer Plastic Fuel Tank and Virgin High-Density Polyethylene A multi-layer plastic fuel tank (capacity: 40 liter) of a 3-type, 5-layer structure as shown in Table 1 was produced from high-density polyethylene, modified high-density polyethylene and various polyamides shown in Table 3 at a temperature shown in Table 3 by using a multi-layer blow molding machine (NB-60G, manufactured by The Japan Steel Works, Ltd.). The resulting multi-layer plastic fuel tank was pulverized by a crusher having a punching plate diameter of 8 mm. The pulverized multi-layer plastic fuel tank and high-density polyethylene (virgin resin) were dry-blended at a weight ratio of 50:50 to produce a resin mixture. The resin mixture was melt-blended at a temperature shown in Table 3 to produce a single-layer parison. With respect to the parison thus obtained, a particle size of polyamide particles was measured. The dispersibility of polyamide particles was evaluated as " ○ " when the polyamide particles had a particle size of 10 µm or less., and "X" when the polyamide particles had a particle size exceeding 10 µm. The results are shown in Table 3 together with the type of polyamide used. The parisons were further measured with respect to a tensile elongation and a tensile impact strength at -40°C according to a tensile test method (ASTM D638) and a tensile impact test (ASTM D 1822), respectively. The measured values of these properties were compared with those of parisons produced from virgin resins under the same conditions as above. The results are shown in Table 3. Production Conditions Example No. 5 6 7 8 Polyamide CPA-1 CPA-2 CPA-B1 CPA-B2 Blending Temperature (°C) 220-230 210-230 220-230 210-230 Particle Size of Polyamide (µm) 1-2 1-2 1-2 1-2 Dispersibility of Polyamide ○ ○ ○ ○ Tensile Elongation (%) 100 100 100 100 It is clear from Table 3 that when the pulverized multi-layer plastic fuel tank is blended with virgin high-density polyethylene, good dispersion of polyamide particles can be obtained even at a low temperature. Accordingly, the resulting high-density polyethylene composition does not suffer from decrease in tensile properties as compared with the virgin high-density polyethylene. Examples 9-12 Production of Multi-Layer Plastic Fuel Tank A multi-layer plastic fuel tank (capacity: 40 liter) of a 3-type, 5-layer structure as shown in Table 1 was produced from a resin mixture obtained in Examples 5-8 as high-density polyethylene, modified high-density polyethylene and various polyamides listed in Table 4 at a temperature shown in Table 4 by using a multi-layer blow molding machine (NB-60G, manufactured by The Japan Steel Works, Ltd.). In the course of producing a parison, its drawdown was observed. And each of the resulting fuel tanks was measured with respect to a thickness distribution (minimum thickness), and subjected to a drop impact test at -40°C and a gasoline permeability test at 40°C. The molding cycle time of the fuel tank was also measured. The results are shown in Table 4. Example No. 9 10 11 12 Production Conditions of Multi-Layered Plastic Fuel Tank Polyamide CPA-1 CPA-2 CPA-B1 CPA-B2 Blending Temperature of HDPE (°C) 220-230 210-230 220-230 210-230 Properties of Parison Minimum Thickness (mm) (1) 3.5 3.5 3.5 3.5 Drawdown ○ ○ ○ ○ Properties of Multi-Layered Plastic Fuel Tank Drop Impact Resistance (2) ○ ○ ○ ○ Gasoline Barrier Property (3) ○ ○ ○ ○ Cycle Time (Minutes) 3 3 3 3 The multi-layer plastic fuel tanks of Examples 9-12 whose high-density polyethylene layers were made of compositions consisting of the above pulverized tanks and virgin high-density polyethylene were excellent in all of the drawdown resistance, the thickness distribution, the impact resistance and the gas barrier properties, and showed a low molding temperature so that their molding cycle time was as short as about 3 minutes. It is clear from the above results that the flashes and defective moldings of the multi-layer plastic fuel tanks are reusable by blending them with virgin high-density polyethylene in the present invention.

Claims: A multi-layer plastic fuel tank comprising at least one high-density polyethylene layer, at least one polyamide layer, and at least one modified high-density polyethylene layer made of high-density polyethylene modified with an unsaturated carboxylic acid or its derivatives, which is interposed between each high-density polyethylene layer and each polyamide layer for bonding them, said polyamide layer being made of a polyamide copolymer comprising 90-60 weight % of polyamide 6 and 10-40 weight % of polyamide 66. The multi-layer plastic fuel tank according to claim 1, wherein said high-density polyethylene layer is made of 100 parts by weight of virgin high-density polyethylene and 20-200 parts by weight of a regenerated product obtained from part or whole of said multi-layer plastic fuel tank.

Inventors: NAKASATO TOSHIKAZU C O TECHNIC, NOGATA TETSURO C O TECHNICAL D, TAKADO YUTAKA C O TECHNICAL DE, TEZUKA EIJI, YOKOI TOSHIO, NAKASATO, TOSHIKAZU, C/O TECHNICAL DEV. CENTER, NOGATA, TETSURO, C/O TECHNICAL DEV. CENTER, TAKADO, YUTAKA, C/O TECHNICAL DEVELOPMENT CENTER, TEZUKA, EIJI, YOKOI, TOSHIO
Applicants: TONEN SEKIYUKAGAKU KK, TOYOTA MOTOR CO LTD, TONEN CHEMICAL CORPORATION, TOYOTA JIDOSHA KABUSHIKI KAISHA
Application year: 1991
Main classification: B32B27
IPC codes: B29C47, B29C49, B32B27