Starch Resin Composition, Molded Product Using the Same and Method for Producing the Same

Abstract

The object is to efficiently utilize a starch substance among surplus agricultural product, and the present invention relates to a technique for blending the starch substance with a thermoplastic resin. The purpose of the present invention is to provide a starch resin composition which retains various properties of the thermoplastic resin even when the starch substance is blended in a large amount.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of an entire granulator for producing a starch resin composition (pellet) of one embodiment of the present invention.

In FIG. 2, (a) shows a sectional side view and (b) shows a horizontal sectional view of a biaxial kneading extruder to be used in one embodiment of the present invention.

In FIG. 3, (a) shows an enlarged top view of laminated paddles provided on a kneading screw, and FIG. 3(b) shows a view seen from an axial direction of a cylinder.

FIG. 4 shows actions of a pair of paddles each provided on the respective adjacent kneading screws. (a)-(e) show states captured at every 45° rotation of the kneading screws rotating in the same direction.

FIG. 5 shows a front view of an inflation molding machine for producing a film product according to one embodiment of the present invention.

DESCRIPTION FOR REFERENCE CHARACTERS

• 20 biaxial kneading extruder (kneading extruder)
• 28 discharge opening
• 30 kneading screw
• 40 heat roll
• 42 gap
• 60 inflation molding machine
• A material feeding step
• B thermal fluidization treatment step
• B1 heat-up step
• B2 gelatinization step
• C dispersion treatment step
• D, F dehydration treatment step
• E chemical reaction step
• G discharge step
• H granulation step
• I molding step
• J kneading step
• K drawing step
• P water-containing thermal fluid form
• Q starch-dispersed thermal fluid form
• R anhydrous thermal fluid form

Claims

1. A starch resin composition comprising: 5-95 parts by weight of a thermoplastic resin (X),95-5 parts by weight of a starch substance (Y), and0.2-20 parts by weight of a compatibilizer (Z) which improves an affinity at an interface between the thermoplastic resin (X) and the starch substance (Y), relative to 100 parts by weight of a total amount of the components (X) and (Y).

2. The starch resin composition according to claim 1, wherein the compatibilizer (Z) is a saturated carboxylic acid, an unsaturated carboxylic acid or a derivative thereof.

3. The starch resin composition according to claim 1, wherein the compatibilizer (Z) is the thermoplastic resin (X) modified by an unsaturated carboxylic acid or a derivative thereof.

4. The starch resin composition according to claim 1, wherein the compatibilizer (Z) is the starch substance (Y) modified by an unsaturated carboxylic acid or a derivative thereof.

5. The starch resin composition according to any one of claims 1-4, wherein the starch substance (Y) is formed of at least one material selected from the group consisting of rice, wheat, corn, potato, sweet potato and tapioca.

6. The starch resin composition according to any one of claims 1-4, wherein the starch substance (Y) is raw rice immersed in water for 5 minutes or more.

7. The starch resin composition according to claim 6, wherein at least one compound selected from the group consisting of salt, sucrose, trehalose, antioxidant, proteolysis promoter and cellulose degradation promoter is dissolved in the water.

8. The starch resin composition according to any one of Claims 1-4, wherein the starch substance (Y) is gelatinized by heating in a presence of water so that starch has α-structure.

9. The starch resin composition according to any one of Claims 1-4, wherein the starch substance (Y) is gelatinized by heating in a presence of water and dehydrated so that starch has α-structure.

10. The starch resin composition according to any one of Claims 1-4, wherein the thermoplastic resin (X) is formed of at least one compound selected from the group consisting of biodegradable polyolefin, biodegradable polyester, biodegradable polyvinyl-alcohol copolymer, biodegradable polysaccharide derivative, and biodegradable polyamide.

11. The starch resin composition according to any one of Claims 1-4, wherein an additive that imparts biodegradability is added to the thermoplastic resin (X).

12. A starch-resin-composition molded product comprising the starch resin composition according to claim 1.

13. A starch-resin-composition molded product formed from, as a main material, 5-80 parts by weight of the starch resin composition according to claim 1, and95-20 further parts by weight of the thermoplastic resin (X).

14. A method for producing a starch resin composition comprising: a material feeding step In which a starting material containing at least a thermoplastic resin (X) and a water-containing starch substance (Y) is fed into a material feeding part of a kneading extruder kept at 140° C. or less;a thermal fluidization treatment step in which the starting material fed is sent to a high-temperature high-pressure part kept at higher pressure than an atmospheric pressure and at higher temperature at which the thermoplastic resin (X) is fluidized to be a water-containing thermal fluid form, and at least a part of the starch substance (Y) present in the water-containing thermal fluid form is gelatinized as gelatinized starch;a dispersion treatment step in which the water-containing thermal fluid form is kneaded similarly at high temperature and high pressure to gelatinize the rest of the starch substance (Y) and to crush the resultant gelatinized starch as starch particles, and the starch particles are dispersed entirely in the water-containing thermal fluid form to give a starch-dispersed thermal fluid form;a dehydration treatment step in which the starch-dispersed thermal fluid form is sent to a degassing part kept at an atmospheric pressure or lower and at high temperature at which the starch-dispersed thermal fluid form is fluidized, and water contained in the starch-dispersed thermal fluid form is evaporated to give an anhydrous thermal fluid form;a discharge step in which the anhydrous thermal fluid form is discharged from a discharge opening of the kneading extruder; anda molding step in which the discharged anhydrous thermal fluid form is solidified and molded at low temperature at which a thermal fluidity is lost.

15. The method according to claim 14, further comprising a granulation step in which the starch particles are made finer by passing the anhydrous thermal fluid form through a gap between heat rolls, after the discharge step.

16. A method for producing a starch resin composition comprising: a kneading step in which a starting material containing at least a thermoplastic resin (X) and a starch substance (Y) is kneaded at temperature at which the thermoplastic resin (X) becomes a thermal fluid form, and the contained starch substance (Y) or starch particles obtained by crushing the starch substance (Y) is dispersed;a discharge step in which the kneaded thermal fluid form is discharged from a discharge opening of the kneading extruder;a granulation step in which the discharged thermal fluid form passes through a gap between heat rolls and the dispersed starch substance or starch particles are further made finer; anda molding step in which the thermal fluid form that underwent the granulation step is solidified and molded at low temperature at which a thermal fluidity is lost.

17. The method according to any one of claims 14-16, further comprising a drawing step in which the anhydrous thermal fluid form or the thermal fluid form is drawn before being solidified and forms a film.

18. The starch resin composition according to claim 5, wherein the starch substance (Y) is gelatinized by heating in a presence of water so that starch has α-structure.

19. The starch resin composition according to claim 6, wherein the starch substance (Y) is gelatinized by heating in a presence of water so that starch has α-structure.

20. The starch resin composition according to claim 5, wherein the starch substance (Y) is gelatinized by heating in a presence of water and dehydrated so that starch has α-structure.

21. The starch resin composition according to claim 6, wherein the starch substance (Y) is gelatinized by heating in a presence of water and dehydrated so that starch has α-structure.