Polyester injection-molded articles

Abstract: Injection-molded articles consisting of an aliphatic polyester having a melt viscosity of 6 × 10²-2 × 10⁴ poises at a temperature of 190°C at a shear rate of 1000 sec⁻¹ and a melting point of 70-190°C . The present invention provides injection-molded articles excellent in heat stability and mechanical strength as well as having biodegradability which can be used for industrial parts, automotive members, food and beverage containers, gardening pots and the like.

Description: BACKGROUND OF THE INVENTION Field of the Invention The present invention relates to injection-molded articles having excellent heat stability and mechanical strength which are prepared by using aliphatic polyesters with biodegradability and sufficiently high molecular weights and specific melt properties for practical use. Discussion of the Background Recently, with the advancement of plastics in industrial parts, automotive members, domestic articles and the like, the resulting waste of the large amount of plastics used in these materials cause pollution of rivers, oceans, soil and the like and is becoming a great social problem. To prevent such pollution the development of biodegradable plastics has been desired; for example, poly(3-hydroxybutylate) produced by fermentation methods using microorganisms, blends of general-purpose plastics and starch, a naturally occurring polymer, and the like are already known. The former polymer has a drawback in that it is poor in molding properties because the polymer has a heat decomposition temperature close to its melting point and a raw material efficiency is very bad because it is produced by microorganisms. On the other hand, since the naturally occurring polymer of the latter does not by itself have thermoplasticity, the polymer has defects in molding properties, and is greatly limited in its range of application. On the other hand, although it is known that aliphatic polyesters are biodegradable, they have hardly been used because polymeric material sufficient enough to obtain practical molded product cannot be obtained. Recently, it has been found that a ring-opening polymerization of ε -caprolactone produces a higher molecular weight polymer, and proposed to use the polymer as a biodegradable resin. However, the resulting polymer is limited to only special applications because of a low melting point of 62°C and a high cost thereof. Further, although glycolic acid, lactic acid and the like are polymerized by a ring-opening polymerization of glycolide and lactide thereof to obtain polymers with higher molecular weights so as to be sometimes used as medical fibers and the like, the polymers are not used in great amounts as industrial parts, automobile members, domestic articles and the like because their decomposition temperatures are close to their melting point and they have defects in their molding properties. Although most of these are applied to plastic injection-molded articles, it is no exaggeration to say that high molecular weight polyesters (referring to polyesters having number-average molecular weights of at least 10,000) generally used for the plastics are limited to polyethylene terephthalate, a condensate of terephthalic acid (including dimethyl terephthalate) and ethylene glycol. Although there are cases of 2,6-naphthalenedicarboxylic acid being used instead of terephthalic acid, there are no reports of trials which obtained polymers with biodegradability. Therefore, it is safe to say that there has been no concept of trying to make the molded articles in practical use by injection molding using biodegradable aliphatic polyesters in which aliphatic dicarboxylic acid was used. One of the reasons why this application concept has not been thought of is felt to be that in spite of the required special molding conditions and physical properties for the above injection-molded articles, most of the above-mentioned aliphatic polyesters have melting points of 100°C or lower even if they are crystalline, and have poor heat stability when melted above that. Of further importance is that the properties, particularly mechanical properties such as tensile strength, of these aliphatic polyesters show markedly poor values even when they are the same level of number-average molecular weight as the above-mentioned polyethylene terephthalate, so just conceiving that the molded articles having required strength and the like would be obtained was difficult. Another reason seems to be that studies for improving the physical properties of the aliphatic polyesters by increasing their number-average molecular weights have not been sufficiently advanced because of their poor heat stability. The object of the present invention is to provide injection-molded articles prepared by the above-mentioned aliphatic polyesters as their components which have sufficient high molecular weights for practical use and excellent mechanical properties represented by heat stability and tensile strength, and which can be decomposed by microorganisms and the like, i.e., are biodegradable as one means of waste disposal so that they may be easily disposed of after the use thereof. SUMMARY OF THE INVENTION As a result of various studies of the reaction conditions for obtaining polyesters having sufficient high molecular weight for practical use and molding properties suitable for injection molding, the present inventors have obtained specific aliphatic polyesters that maintain biodegradability while having sufficient high molecular weights for practical use, then have found that injection-molded articles prepared from the polyesters have heat stability and mechanical strength as well as the above-mentioned biodegradability to achieve the present invention. That is, the present invention provides: injection-molded articles mainly consisting of an aliphatic polyester having a melt viscosity of 6 x 10 2 -2 X 10 4 poises at a temperature of 190°C and a shear rate of 1,000 sec-', having a melting point of 70-190°C ; having a number-average molecular weight of at least 10,000; and containing 0.03-3% by weight of urethane bonds. The invention further provides injection-molded articles as above consisting of an aliphatic polyester obtained by reacting 0.1-5 parts by weight of diisocyanate with 100 parts by weight of an aliphatic polyester prepolymer having a number-average molecular weight of at least 5,000 and a melting point of at least 60°C . Further features of the invention are evident from the claims. DETAILED DESCRIPTION OF THE INVENTION The present invention will be described below in further detail. The aliphatic polyester of the present invention mainly consists of a polyester obtained by reacting two components of glycols and dicarboxylic acid (or acid anhydrides thereof), and if necessary as a third component, with at least one polyfunctional component selected from the group consisting of trifunctional or tetrafunctional polyols, oxycarboxylic acids, and polybasic carboxylic acids, (or acid anhydrides thereof). The aliphatic polyesters are prepared by reacting relatively high molecular weight polyester prepolymers which have hydroxyl groups at both ends with a coupling agent so as to make them even higher molecular weight polymer. It has been known to obtain polyurethane by reacting a low molecular weight polyester prepolymer having a number-average molecular weight of 2,000-2,500, which have hydroxyl groups as the terminal groups, with diisocyanate as a coupling agent in the preparation of rubbers, foams, coatings and adhesives. However, the polyester prepolymers used in these polyurethane foams, coatings and adhesives are prepolymers having a low molecular weight and a number-average molecular weight of 2,000-2,500 which is the maximum that can be prepared by non-catalytic reaction. To obtain practical physical properties as the polyurethane, it is necessary that the content of diisocyanate should be as much as 10-20 parts by weight in relation to 100 parts by weight of this low molecular weight prepolymer. When such a large amount of diisocyanate is added to the low molecular weight polyester melted at 150°C or higher, gelation occurs so that no normal resins which can be molded in the melt state can be obtained. Therefore, polyesters which are obtained by using a large amount of diisocyanate in the reaction with a low molecular weight polyester prepolymers as a raw material cannot be used as the plastic raw material for the injection-molded articles of the present invention. Also, as shown in the case of polyurethane rubbers, although a method is coceivable in which hydroxyl groups are converted into isocyanate groups by the addition of diisocyanate, and then the number-average molecular weight thereof is further increased by using glycols, the same problem as mentioned above arises because 10 parts by weight of diisocyanate relative to 100 parts by weight of the prepolymer should be used in order to obtain practical physical properties. When a relatively high molecular weight polyester prepolymer is to be used, heavy metal catalysts required to prepare the prepolymer would promote the reactivity of the above-mentioned isocyanate groups to undesirably cause poor preservativity, generation of crosslinking and branching; hence a number-average molecular weight of not more than around 2,500 of polyester prepolymers would be the limit if they were to be prepared without catalysts. The polyester prepolymers to obtain the aliphatic polyesters used in the present invention are relatively high molecular weight saturated aliphatic polyesters having substantially hydroxyl groups at the ends thereof, number-average molecular weights of at least 5,000, preferably at least 10,000, and melting point of 60 °C or higher, which are obtained by reacting glycols and dibasic carboxylic acids (or acid anhydrides thereof) in the presence of catalysts. When a prepolymer having a number-average molecular weight of lower than 5,000 is used, the small amounts of 0.1-5 parts by weight of coupling agents used in the present invention cannot provide poyesters having good physical properties for injection molding. When polyester prepolymers having number-average molecular weights of 5,000 or higher are used, with hydroxyl values of 30 or less, the use of small amounts of coupling agents even under severe conditions such as a molten state and the like can produce high molecular weight polyesters without gelation as the reaction is not affected by remaining catalysts. Therefore, the polymer for the injection-molded articles of the present invention has a repeated chain structure in which a polyester prepolymer having a number-average molecular weight of 5,000 or more, preferably 10,000 or more and consisting of an aliphatic glycol and aliphatic dicarboxylic acid, is combined through the urethane bonds derived from, for example, diisocyanate as a coupling agent. Further, the polymer for the injection-molded articles of the present invention has a repeated chain structure in which the above-mentioned polyester prepolymer provided with branched long chains derived from polyfunctional components is combined through the urethane bonds derived from, diisocyanate as a coupling agent. The injection-molded articles of the present invention consisting of an aliphatic polyester having a melt viscosity of 6 × 10 2 -2 × 10 4 poises at a temperature of 190°C at a shear rate of 1,000 sec-' and a melting point of 70-190°C, particularly the injection-molded articles of the present invention which essentially consists of an aliphatic polyester obtained by reacting 0.1-5 parts by weight of diisocyanate with 100 parts by weight of an aliphatic polyester prepolymer having a number-average molecular weight of 5,000 or higher and a melting point of 60°C or higher has biodegradability when embedded in the earth, is excellent in heat stability and mechanical strength; and hence, can he used for example for industrial parts, automotive members, food or beverage containers, and gardening pots. Examples of glycols which can be used as a reaction component include aliphatic glycols. Among them those having a straight chain alkylene group with even number carbon atoms of 2, 4, 6, 8 and 10 such as: ethylene glycol, 1,4-butanediol, 1,6-hexanediol 1,8-octanediol, 1,10-decanediol, and mixtures thereof are preferable. Of these glycols, those having a smaller number of carbon atoms, such as ethylene glycol, 1,4-butanediol and 1,6-hexanediol, are preferable because they can produce an aliphatic polyester having a high crystallinity and a high melting point. In particular, ethylene glycol and 1,4-butanediol are most suitable because they produce good results. Other glycols include neopentyl glycol and 1,4-cyclohexane dimethanol. Examples of aliphatic dicarboxylic acids or anhydrides thereof which provide aliphatic polyester by reacting with glycols include aliphatic dicarboxylic acids. Among them those having a straight chain alkylene group with even number carbon atoms of 2, 4, 6, 8 and 10 such as: succinic acid, adipic acid, suberic acid, sebacic acid, 1,10~ decanedicarboxylic acid, succinic anhydride, adipic anhydrides and mixtures thereof are preferable. Of these dicarboxylic acids, those having a smaller number of carbon atoms, such as succinic acid, adipic acid and succinic anhydride, are preferable because they can produce an aliphatic polyester having high crystallinity and high melting points. In particular, succinic acid, succinic anhydride and an acid mixture of succinic acid or succinic anhydride and another dicarboxylic acid such as adipic acid, suberic acid, sebacic acid or 1,10-decandicarboxylic acid are preferable. In the system of an acid mixture containing two or more acid components, for example, succinic acid and other dicarboxylic acids, the mixing ratio of succinic acid is at least 70 mol%, preferably at least 90 mol%, and the mixing ratio of the other carboxylic acids is 30 mol% or less, preferably 10 mol% or less. A combination of 1,4-butanediol and succinic acid or succinic anhydride and a combination of ethylene glycol and succinic acid or succinic anhydride are particularly preferable for the present invention because the combinations exhibit melting points close to that of polyethylene. (Third component) To these glycols and dicarboxylic acid, if necessary, may be added as a third component at least one polyfunctional component selected from the group consisting of trifunctional or tetrafunctional polyols, oxycarboxylic acid, and polybasic carboxylic acids (or acid anhydrides thereof). The addition of this third component, which causes the branching of long chains, can impart desirable properties in molten state to the polyester prepolymer, because the ratio of weight-average molecular weight (MW)/ number-average molecular weight (Mn), i.e., the molecular weight distribution, increases with increases in its molecular weight. In terms of the amount of polyfunctional components to be added without fear of gelation, a trifunctional component of 0.1-5 mole %, or a tetrafunctional component of 0.1-3 mole % is added relative to 100 mole % of the total of aliphatic dicarboxylic acid (or acid anhydride thereof) components. (Polyfunctional components) Examples of polyfunctional components as the third component include trifunctional or tetrafunctional polyols, oxycarboxylic acids, and polybasic-carboxylic acids. The trifunctional polyols representatively include trimethylol propane, glycerin or anhydrides thereof. The tetrafunctional polyols representatively include pentaerythritol. The trifunctional oxycarboxylic acid components are divided into the two types of (i) a component which has two carboxyl groups and one hydroxyl group in one molecule, and (ii) another component which has one carboxyl group and two hydroxyl groups in one molecule. Malic acid which has two carboxyl groups and one hydroxyl group in one molecule becomes practical and sufficient to the purposes of the present invention in view of commercial availability at low cost. The tetrafunctional oxycarboxylic acid components are the following three types of components: (i) A component which has three carboxyl groups and one hydroxyl group in one molecule; (ii) Another component which has two carboxyl groups and two hydroxyl groups in one molecule; and (iii) The remaining component which has three hydroxyl groups and one carboxyl group in one molecule. Any type can be used, though in view of commercial availability at low cost, citric acid and tartaric acid are practical and sufficient to the purposes of the present invention. As a trifunctional polybasic carboxylic acid (or acid anhydride thereof) component trimesic acid, propane tricarboxylic acid and the like can be used. Among them, trimesic anhydride is practical for the purposes of the present invention. As a tetrafunctional polybasic carboxylic acid (or anhydride thereof) various types of aliphatic compounds, cycloaliphatic compounds, and aromatic compounds, described in certain literatures, can be used. In view of commercial availability, for example, pyromellitic anhydride, benzophenone tetracarboxylic anhydride and cyclopentane tetracarboxylic anhydride are practical and sufficient to the purposes of the present invention. These glycols and dibasic acids are mainly consisted of aliphatic series, while small amounts of other components, for example, aromatic series may be concomitantly used. These other components may be blended or copolymerized in amounts up to 20% by weight, preferably up to 10% by weight, and more preferably up to 5% by weight because using these compounds degrades biodegradability. The polyester prepolymer for aliphatic polyesters to be used in the present invention has hydroxyl groups at the terminals. To introduce the hydroxyl groups, it is necessary that glycols are used somewhat excessively. For preparation of the polyester prepolymer having a relatively high molecular weight, it is necessary to use deglycol-reaction catalysts in the deglycol reaction subsequent to the esterification. Examples of the deglycol-reaction catalysts include titanium compounds such as acetoacetoyl type titanium chelate compounds and organic alkoxy titanium compounds. These titanium compounds can be used in combination. Examples of compounds used in combination include diacetoacetoxy oxytitanium (Nippon Chemical Industry Co., Ltd.; Nursem Titanium) tetraethoxy titanium, tetrapropoxy titanium, tetrabutoxy titanium and the like. The amount of the titanium compound used is 0.001-1 part by weight, and preferably 0.01-0.1 part by weight relative to 100 parts by weight of the polyester prepolymer. These titanium compounds may be blended before the esterification, or may be blended immediately before the deglycol-reaction. To the polyester prepolymer which has a number-average molecular weight of at least 5,000, preferably at least 10,000, and whose terminal groups are substantially hydroxyl groups are added diisocyanate coupling agents in order to increase its number-average molecular weight. In the cases of oxazoline and diepoxy compounds, it is necessary that the terminal hydroxyl groups are reacted for example with acid anhydrides to convert them into carboxyl groups, then coupling agents are used. Although not limited, examples of diisocyanate include 2,4-tolylene diisocyanate, a mixture of 2,4-tolylene diisocyanate and 2,6-tolylene diisocyanate, diphenylmethane diisocyanate, 1,5-naphthylene diisocyanate, xylylene diisocyanate, hydrogenated xylylene diisocyanate, hexamethylene diisocyanate, and isophorone diisocyanate. Particularly, hexamethylene diisocyanate is preferably used in terms of hue of prepared resins, and reactivity at the time of blending polyesters. The adding amounts of these coupling agents are 0.1-5 parts by weight, and preferably 0.5-3 parts by weight relative to 100 parts by weight of polyester prepolymer. Addition of less than 0.1 part by weight causes insufficient coupling reaction, whereas with more than exceeds 5 parts by weight gelation tends to occur. The addition is preferably performed when the polyester is in a uniformly melted state under easily stirrable conditions. Although it is not impossible for the coupling agents to be added to the polyester prepolymer in the solid state and melted and mixed through an extruder, adding the agents in a polyester preparation unit, or adding them to polyester prepolymer in a melt state (for example, in a kneader) is more practical. The aliphatic polyester to be used in the present invention is required to have selected melt properties for injection molding. That is, the aliphatic polyester to be used in the present invention needs to have a melt viscosity of 6 × 10 2 -2 × 10 4 poises, preferably 2 × 10 3 -8 × 10 3 poises, and more preferably 2 × 10 3 -6 × 10 3 poises at a temperature of 190°C at a shear rate of 1,000 sec -1 . A melt property of less than 6 × 10 2 poises tends to show instability of the injection molding as well as poor strength of resultant molded articles. On the other hand, a melt property of more than 2 × 10 4 poises makes the injection molding more difficult, and the obtained injection-molded articles tends to distort because of remaining strain. The melt viscosity at a shear rate of 1000 sec -1 was calculated from a graph which shows the relation between the apparent viscosities and shear rates measured using a nozzle having a diameter of 1.0 mm and L/D of 10 at a resin temperature of 190°C . The melting point of the aliphatic polyester to be used in the present invention needs to be 70-190°C preferably 70-150°C , and more preferably 80-135°C . A melting point lower than 70°C will give injection-molded articles poor heat resistance to distort them, whereas with higher than 190°C it is difficult to carry out injection molding. To achieve a melting point higher than 70°C the polyester prepolymer need to have a melting point of at least 60°C. When urethane bonds are contained in the aliphatic polyester to be used in the present invention, the amount of urethane bonds is 0.03-3.0% by weight, preferably 0.05-2.0% by weight, and more preferably 0.1-1.0% by weight. The amount of urethane bonds is measured by 13 C NMR, showing good correlation with the charged amount. Less than 0.03% by weight of urethane bonds has a little effect on polymerization and leads to poor molding properties, whereas more than 3.0% by weight causes gelation. It is needless to say that when the above-mentioned aliphatic polyester is used to obtain the injection-molded articles according to the present invention, it necessary, lubricants, waxes, coloring agents, crystallizing promoters and reinforcing fibers as well as antioxidants, thermal stabilizers, and UV absorbers can be used concomitantly. That is, antioxidants include hindered phenol antioxidants such as p-tert-butyl hydroxytoluene and p-tert-butyl hydroxyanisole, sulfur antioxidants such as distearyl thiodipropionate and dilauryl thiodipropionate; heat stabilizers include triphenyl phosphate, trilauryl phosphite, and tris-nonylphenyl phosphite; UV absorbers include p-tert-butyl phenyl salicylate, 2-hydroxy-4-methoxybenzophenone, 2-hydroxy-4-methoxy-2'-carboxybenzophenone, and 2,4,5-trihydroxybutylophenone; lubricants include calcium stearate, zinc stearate, barium stearate, and sodium palmitate; antistatic agents include N,N-bis(hydroxyethyl) alkyl amine, alkyl amine, alkyl allyl sulfonate, and alkyl sulfonate; flame retarders include hexabromocyclododecane, tris-(2,3-dichloropropyl) phosphate, and pentabromophenyl allyl ether; inorganic fillers include calcium carbonate, silica, titanium oxide, talc, mica, barium sulfate, and alumina; crystallizing promoters include polyethylene terephthalate, and poly-trans-cyclohexane dimethanol terephthalate; reinforcing fibers include inorganic fibers such as glass fiber, carbon fiber, boron fiber, silicon carbide fiber, graphite fiber, alumina fiber and amorphous fiber, and organic fibers such as-aramide fiber. The raw material mainly comprising the aliphatic polyesters to be used in the present invention is molded by a conventional injection molding machine, the molding temperature generally being 170-240°C and preferably 180-230°C. The molding properties of the polyester become poor near melting point, and the distortion of molded articles and heat decomposition of the polyesters tends to occur easily when over 240 °C. The injection-molded articles mainly consisting of the aliphatic polyester according to the present invention have a tensile strength of 200-450 kg/cm 2 , preferably 300-450 kg/cm 2 as their physical properties. Injection-molded articles having a tensile strength of less than 200 kg/cm 2 can not be used in practical applications. EXAMPLES The present invention will be illustrated with reference to the following Examples and Comparative Examples but the invention is not intended to be limited only thereto. In the following Examples, the tensile strength was measured according to JIS K-6758 at a tensile rate of 50 mm/min. (Example 1) A 700 L reactor was purged with nitrogen, then 183 kg of 1,4-butanediol and 224 kg of succinic acid were charged in it. After the temperature was elevated under nitrogen stream, esterification by dehydration condensation was carried out for 3.0 hr at 195-210°C , and after ceasing nitrogen charge, for further 3.5 hr under reduced pressure of 15-5 mmHg. A sample collected had an acid value of 6.3 mg/g, a number-average molecular weight (Mn) of 5,200 and a weight average molecular weight (Mw) of 10,000. Subsequently, 34 g of tetraisopropoxy titanium, a catalyst, was added at normal pressure under nitrogen stream. The temperature was elevated to carry out a deglycol-reaction at temperatures of 215-220°C under reduced pressures of 5-0.2 mmHg for 7.5 hr. A sample collected had a number-average molecular weight (Mn) of 18,600 and a weight average molecular weight (Mw) of 50,300. The yield of resulting polyester prepolymer (A1) was 339 kg except condensate water. 4.07 kg of hexamethylene diisocyanate was added to the reactor containing 339 kg of the polyester prepolymer (A1) to perform a coupling reaction for 1 hr at 180-200°C . The viscosity was rapidly increased, but no gelation occurred. Then, 1.70 kg of Irganox 1010 (Ciba-geigy) as an antioxidant and 1.70 kg of calcium stearate as a lubricant were added, and the mixture was further stirred for 30 min. The resulting reaction product was extruded into water, and cut by a cutter into pellets. The aliphatic polyester (B1) obtained after drying in a vacuum at 90°C for 6 hr had a yield of 270 kg. The obtained polyester (B1) was a slightly ivorylike white, waxy crystal, and had a melting point of 110°C , a number-average molecular weight (Mn) of 29,500 a weight-average molecular weight (Mw) of 127,000, a MFR (190°C ) of 9.2 g/10 min, a viscosity of 170 poises in a 10% ortho-chlorophenol solution and a melt viscosity of 3.0 × 10 3 poises at a temperature of 190°C and a shear rate of 1,000 sec -1 . The average molecular weight was measured by a Shodex GPC System-11 (Showa Denko, gel permeation chromatography) using a HFIPA solution containing 5 mmol CF 3 COONa (concentration of 0.1% by weight) as a medium. A calibration curve was drawn using a PMMA standard sample (Shodex Standard M-75, Showa Denko). Injection-molded articles were prepared from the polyester (B1) by an injection molding machine (Toshiba Machine Co., IS-80 A) at a molding temperature of 210°C . When the obtained injection-molded articles were measured for tensile strength, their tensile strength was 370 kg/cm 2 and their tensile elongation was 420 %, being extremely strong. Further, after being embedded in the earth for 5 months, the molded-article decomposed to an easily destroyable state. (Example 2) Injection-molded articles were prepared from the polyester (B1) by using the same injection molding machine as in Example 1 at a molding temperature of 180°C. The obtained injection-molded articles were measured for tensile strength, and showed a tensile strength of 390 kg/cm 2 and a tensile elongation of 400%, being extremely strong. Further, after being embedded in the earth for 5 months, the molded article was in the same state as in Example 1. (Example 3) A 700 L reactor was purged with nitrogen, then 177 kg of 1,4-butanediol, 198 kg of succinic acid and 25 kg of adipic acid were charged in it. After the temperature was elevated under nitrogen stream, esterification by dehydration condensation was performed for 3.5 hr at 190-210°C , and after ceasing nitrogen charge, for further 3.5 hr under reduced pressures of 20-2 mmHg. A sample collected had an acid value of 9.6 mg/g, a number-average molecular weight (Mn) of 6,100 and weight-average molecular weight (Mw) of 12,200. Subsequently, 20 g of tetraisopropoxy titanium, a catalyst, was added at normal pressures under nitrogen stream. The temperature was elevated to perform a deglycol-reaction at temperatures of 210-220°C under reduced pressures of 15-0.2 mmHg for 6.5 hr. A sample collected had a number-average molecular weight (Mn) of 17,300 and a weight-average molecular weight (Mw) of 46,400. The resulting polyester (A2) had a yield of 337 kg except condensate water. 4.66 kg of hexamethylene diisocyanate was added to the reactor containing 337 kg of polyester (A2) to perform a coupling reaction for 1 hr at 180-200°C . The viscosity was rapidly increased, but no gelation occurred. Then, 1.70 kg of Irganox 1010 (Ciba-Geigy) as an antioxidant and 1.70 kg of calcium stearate as a lubricant were added, and the mixture was further stirred for 30 min. The resulting reaction product was extruded into water by an extruder, and cut by a cutter into pellets. The aliphatic polyester (B2) obtained after drying in a vacuum at 90°C for 6 hr had a yield of 300 kg. The obtained polyester (B2) was a slightly ivory-like white, waxy crystal, and had a melting point of 103°C , a number-average molecular weight (Mn) of 36,000, a weight-average molecular weight (Mw) of 200,900, a MFR (190°C ) of 0.52 g/10 min, a viscosity of 680 poises in a 10% orthochlorophenol solution and a melt viscosity of 5.0 × 10 3 poises at a temperature of 190°C at a shear rate of 1,000 sec -1 . Injection-molded articles were prepared from the polyester (B2) by using the same injection molding machine as in Example 1 at a molding temperature of 220°C . The obtained injection-molded articles were measured for tensile strength, and showed a tensile strength of 390 kg/cm 2 and a tensile elongation of 450%, being extremely strong. Further, after being embedded in the earth for 5 months, the molded article decomposed to an easily destroyable state. (Example 4) Injection-molded articles were prepared from the polyester (B2) by using the same injection molding machine as in Example 1 at a molding temperature of 190°C . The obtained injection-molded articles were measured for tensile strength, and showed a tensile strength of 410 kg/cm 2 and a tensile elongation of 430%, being extremely strong. Further, after being embedded in the earth for 5 months, the molded article was in the same state as in Example 3. (Example 5) A 700 L reactor was purged with nitrogen, then 145 kg of ethylene glycol, 251 kg of succinic acid and 4.1 kg of citric acid were charged in it. After the temperature was elevated under nitrogen stream, esterification by dehydration condensation was performed for 3.5 hr at 190-210°C , and after ceasing nitrogen charge, for further 5.5 hr under reduced pressures of 20-2 mmHg. A sample collected had an acid value of 8.8 mg/g, a number-average molecular weight (Mn) of 6,800 and a weight-average molecular weight (Mw) of 13,500. Subsequently, 20 g of tetraisopropoxy titanium, a catalyst, was added at normal pressures under nitrogen stream. The temperature was elevated to perform a deglycol-reaction at temperatures of 210-220°C under reduced pressures of 15-0.2 mmHg for 4.5 hr. A sample collected had a number-average molecular weight (Mn) of 33,400 and a weight-average molecular weight (Mw) of 137,000. The resulting polyester (A3) had a yield of 323 kg except condensate water. 3.23 kg of hexamethylene diisocyanate was added to the reactor containing 323 kg of polyester (A3) to perform a coupling reaction for 1 hr at 180-200°C . The viscosity was rapidly increased, but no gelation occurred. Then, 1.62 kg of Irganox 1010 (Ciba-Geigy) as an antioxidant and 1.62 kg of calcium stearate as a lubricant were added, and the mixture was further stirred for 30 min. The resulting reaction product was extruded into water by an extruder, and cut by a cutter into pellets. The polyester (B3) obtained after drying in a vacuum at 90°C for 6 hr had a yield of 300 kg. The obtained polyester (B3) was a slightly ivory-like white, waxy crystal, and had a melting point of 96°C , a number-average molecular weight (Mn) of 54,000, a weight-average molecular weight (Mw) of 324,000, a MFR (190°C ) of 1.1 g/10 min, a viscosity of 96 poises in a 10% orthochlorophenol solution and a melt viscosity of 4.7 × 10 3 poises at a temperature of 190°C at a shear rate of 1,000 sec -1 . Injection-molded articles were prepared from the polyester (B3) by using the same injection molding machine as in Example 1 at a molding temperature of 220°C . The obtained injection-molded articles were measured for tensile strength, and showed a tensile strength of 365 kg/cm 2 and a tensile elongation of 470%, being extremely strong. (Example 6) A 700 L reactor was purged with nitrogen, then 200 kg of 1,4-butanediol, 250 kg of succinic acid and 2.8 kg of trimethylol propane were charged in it. After the temperature was elevated under nitrogen stream, esterification by dehydration condensation was performed for 4.5 hr at 195-210°C , and after ceasing nitrogen charge, for further 3.5 hr under reduced pressures of 15-5 mmHg. A sample collected had an acid value of 1.2 mg/g, a number-average molecular weight (Mn) of 8,990 and a weight average molecular weight (Mw) of 32,800. Subsequently, 37 g of tetraisopropoxy titanium, a catalyst, was added at normal pressures under nitrogen stream. The temperature was elevated to perform a deglycol-reaction at temperatures of 215-220°C under reduced pressures of 3-0.4 mmHg for 9 hr. A sample collected had a number-average molecular weight (Mn) of 16,600 and a weight-average molecular weight (Mw) of 46,800. The resulting polyester (A4) had a yield of 367 kg except condensate water of 76 kg. 3.67 kg of hexamethylene diisocyanate was added to the reactor containing 367 kg of polyester (A4) to perform a coupling reaction for 1 hr at 160-180°C . The viscosity was rapidly increased, but no gelation occurred. Then, 367 g of Irganox 1010 (Ciba-Geigy) as an antioxidant and 367 g of calcium stearate as a lubricant were added, and the mixture was further stirred for 30 min. The resulting reaction product was extruded into water by an extruder, and cut by a cutter into pellets. The polyester (B4) obtained after drying in a vacuum at 90°C for 6 hr had a yield of 310 kg. The obtained polyester (B4) was a slightly ivorylike white, waxy crystal, and had a melting point of 110°C , a number-average molecular weight (Mn) of 27,100 a weight-average molecular weight (Mw) of 148,000 (Mw/Mn=5.5), a MFR (190°C ) of 7.7 g/10 min and a melt viscosity of 2.0 × 10 3 poises at a temperature of 190°C at a shear rate of 1000 sec -1 . The average molecular weight was measured in the same manner as in Example 1. Injection-molded articles were prepared from the polyester (B4) by using the same injection molding machine as in Example 1 at a molding temperature of 210°C . The obtained injection-molded articles were measured for tensile strength, and showed a tensile strength of 390 kg/cm 2 and a tensile elongation of 400%, being extremely strong. Further, after being embedded in the earth for 5 months, the molded article decomposed to an easily destroyable state. (Comparative Example 1) Although polyester (A1) was molded under the same conditions as under those in Example 1, injection-molded articles having enough strength could not be obtained.

Claims: Injection-molded articles mainly consisting of an aliphatic polyester having a melt viscosity of 6 x 10 2 - 2 x 10 4 poises at a temperature of 190°C and a shear rate of 1,000 sec -1 , having a melting point of 70 - 190°C having a number-average molecular weight of at least 10,000 and containing 0.03-3.0% by weight of urethane bonds. Injection-molded articles as claimed in claim 1 wherein the aliphatic polyester contains 0.05-2.0% by weight of urethane bonds. Injection-molded articles as claimed in claim 2 wherein the aliphatic polyester contains 0.1-1.0% by weight of urethane bonds. The injection-molded articles as claimed in any one preceding claims consisting of an aliphatic polyester obtained by reacting 0.1-5 parts by weight of diisocyanate with 100 parts by weight of an aliphatic polyester prepolymer having a number-average molecular weight of at least 5,000 and a melting point of at least 60°C. Injection-molded articles as claimed in any one of claims 1 to 4 wherein the tensile strength is 200-450 kg/cm 2 . Injection-molded articles as claimed in claim 1 wherein the aliphatic polyester has a repeated chain structure in which a polyester prepolymer having a number-average molecular weight (Mn) of 5,000 or more and consisting of an aliphatic glycol and aliphatic dicarboxylic acid, is combined through the urethane bonds. Injection-molded articles as claimed in claim 1 wherein the aliphatic polyester has a repeated chain structure in which a polyester prepolymer having a number-average molecular weight (Mn) of 5,000 or more and obtained by reacting an aliphatic glycol, aliphatic dicarboxylic acid and, as the third component, at least one polyfunctional component selected from the group consisting of trifunctional or tetrafunctional polyols, oxycarboxylic acids and polybasic carboxylic acids or acid anhydrides thereof, is combined through the urethane bonds. Injection-molded articles as claimed in claim 6 or 7 wherein the polyester prepolymer has a unit selected from the group consisting of ethylene glycol, 1,4-butanediol, 1,6-hexanediol, 1,8 octanediol, 1,10 decanediol, neopentyl glycol and 1,4-cyclohexane dimethanol as a glycol unit, and has a unit selected from the group consisting of succinic acid, adipic acid, suberic acid, sebacic acid, 1,10-decanedicarboxylic acid, succinic anhydride and adipic anhydride as a dicarboxylic acid unit. Injection-molded articles as claimed in claim 7 wherein the polyester prepolymer contains one or more compounds selected from the group consisting of trimethylol propane, glycerin and pentaerythritol as the trifunctional or tetrafunctional polyol of the third component. Injection-molded articles as claimed in claim 7 where-in the polyester prepolymer contains one or more compounds selected from the group consisting of malic acid, citric acid and tartaric acid as the trifunctional or tetrafunctional oxycarboxylic acid of the third component. The injection-molded articles as claimed in claim 7 wherein the polyester prepolymer contains one or more compounds selected from the group consisting of trimesic acid, propane tricarboxylic acid, trimellitic anhydride, pyromellitic anhydride, benzophenone tetracarboxylic anhydride and cyclopentane tetracarboxylic anhydride as the trifunctional or tetrafunctional polybasic carboxylic acid of the third component.

Inventors: TAKIYAMA EIICHIRO, YASUDA TETSUA C O SHOWA DENKO, TAKIYAMA, EIICHIRO, YASUDA, TETSUA, Yasuda, Tetsua, c/o Showa Denko K. K.
Applicants: SHOWA DENKO KK, SHOWA HIGHPOLYMER, SHOWA DENKO KABUSHIKI KAISHA, SHOWA HIGHPOLYMER CO., LTD.
Application year: 1993
Main classification: C08G18
IPC codes: D04H13, C08J5, C08J9, B32B27, C08G18, C08G63, D01D5, D01F6