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Long fiber filler reinforced resin pellet

Inactive Publication Date: 2009-03-26
ASAHI KASEI CHEM CORP
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0015]The present inventors have intensively studied to find a solution for the above object and have discovered that, by aligning in a pellet the long fiber filler in a long fiber filler reinforced resin pellet forming a spiral with a central axis along the longitudinal direction of the pellet, the above object can be attained, thereby completing the invention.
[0052]According to the present invention, a long fiber filler and a thermoplastic resin blend have good wettability, which suppresses extremely longitudinal fracture of a pellet during transportation and detachment of a long fiber filler from a pellet, offers good pellet appearance and superior fibrillation property of a long fiber filler during molding, and can provide a long fiber filler reinforced resin pellet able to mold a molded article with extremely high heat resistance and impact strength.

Problems solved by technology

However a long fiber reinforced resin composition has difficulty in wettability of fibers with the resin, because the contact time between the resin and the fibers is limited, as compared with a usual short fiber reinforced resin composition, which is prepared by melt-blending in an extruder with short fibers such as chopped strand, so that studies have been made to improve the wettability.
However according to the technique disclosed by Patent Literature 2, the interface strength between a resin and fibers is insufficient that the produced pellets may cause longitudinal fractures during transportation, or a long fiber filler may detach from a pellet to cause such phenomenon that the detached long fiber filler sticks on a product bag or a hopper of a molding machine and, as a consequence, the market has been requesting improvement thereof.
Further, since the interface strength between a resin and fibers is insufficient and the pellet surface is not glossy, the friction resistance between pellets becomes higher, which causes another problem of defective feeding into a molding machine.
In case, for example, polypropylene or polyamide is used as a resin, and subjected to strong twisting based on the technologies disclosed by Patent Literatures 3 and 4, the twisted long fibers are not well fibrillated due to the melt viscosity of the resin during fabrication in a molding machine, which results in insufficient exhibition of potential properties of high heat resistance or impact strength.

Method used

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  • Long fiber filler reinforced resin pellet
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  • Long fiber filler reinforced resin pellet

Examples

Experimental program
Comparison scheme
Effect test

preparation example 1

Production of LCP

[0456]In a 2-L polymerization reactor with a stirrer and a evaporation line p-hydroxybenzoic acid, 2-hydroxy-6-naphthoic acid, hydroquinone, 2,6-naphthalenedicarboxylic acid and acetic anhydride were charged and subjected to a polycondensation eliminating acetic acid according to the following procedures. The reactor charged with raw materials was heated from 40° C. to 190° C. over 3 hours under a nitrogen gas atmosphere, kept at 190° C. for 1 hour, further heated up to 325° C. over 2 hours, and left for reaction for 10 min. Next the reactor was vacuumed to 20 mmHg at 325° C. for 20 min, and left for reaction additionally for 5 min to complete polycondensation. As the result of polymerization, substantially theoretical amount of acetic acid was distilled off to obtain the liquid crystal polyester having the theoretical structural formula as represented by the following formula.

[0457]The melting point by DSC was 319° C. The melt viscosity measured using a capillary r...

preparation example 2

Production of Aromatic Polyamide

Polyamide 9T

[0458]According to the method described in an example of Japanese Patent Laid-Open No. 2000-103847, terephthalic acid as a dicarboxylic acid component, 1,9-nonamethylenediamine and 2-methyl-1,8-octamethylenediamine as diamine components, octylamine or benzoic acid as a terminal capping agent, sodium hypophosphite monohydrate as a polymerization catalyst, and distilled water were charged into an autoclave, which was closed hermetically (water content in the reaction system: 25% by mass). After replaced thoroughly with nitrogen, the autoclave was heated up over 2 hours to the internal temperature of 260° C. with stirring, and left reacting under the same condition. The internal pressure was 46 atm.

[0459]Next, keeping the internal temperature of the reactor at 260° C. and the water content at 25% by mass, the reaction product was discharged through a nozzle (6 mm diameter) at the bottom of the reactor over 3 min under a nitrogen atmosphere in...

example 1 to example 5

Examples and Comparative Examples

[0501]The maximum cylinder temperature of an extruder in a production facility of a long fiber reinforced resin, which was a co-rotating twin screw extruder (ZSK25: Coperion) provided with an feeding port at an upstream zone and a dipping bath with resin impregnating rolls (Kobe Steel, Ltd.) installed at the front end of the co-rotating twin screw extruder, was set at 320° C., and PS / PPE1 was fed through the extruder feeding port, and molten at a screw rotation speed of 300 rpm and filled in the dipping bath with resin impregnating rolls. Meanwhile, 2 long-fiber glass fiber rovings with filament diameter of 17 μm (ER2400T-448N by Nippon Electric Glass Co., Ltd.) were introduced from a roving supply stand to the dipping bath with resin impregnating rolls, where the molten resin in the dipping bath was impregnated into the long-fiber glass fiber rovings, which were then continuously drawn out through a nozzle (diameter 2.8 mm) of the dipping bath at th...

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Abstract

The invention provides a long fiber filler reinforced resin pellet composed of a long fiber filler and a thermoplastic resin blend. In the pellet, the long fiber filler is aligned to form a spiral with a central axis along the longitudinal direction of the pellet, and the pellet has a skin layer part with a lower content of the long fiber filler, and a core part with a higher content of the long fiber filler, thereby the cross-section of the core part is in a range of 30% to 70% of the cross-section of the pellet. The thermoplastic resin blend in the pellet is composed of polyphenylene ether and a thermoplastic resin other than polyphenylene ether.

Description

CROSS REFERENCE TO RELATED APPLICATION[0001]This application is a continuation-in-part of International Application No. PCT / JP2007 / 052001 filed on Feb. 6, 2007 claiming benefit of priority of Japanese Patent Application No. 2006-049469 applied on Feb. 27, 2006 in Japan, and the entire disclosure of International Application No. PCT / JP2007 / 052001 is incorporated herein by reference.TECHNICAL FIELD[0002]The present invention relates to a long fiber filler reinforced resin pellet. The present invention also relates to a resin pellet blend including the long fiber filler reinforced resin pellet, a molded article produced by melt-molding of the long fiber filler reinforced resin pellet, etc., a process for producing the long fiber filler reinforced resin pellet, and the like.BACKGROUND ART[0003]Since a thermoplastic resin has superior formability, it is used broadly for an automobile and machine related use, building materials, housing equipment parts and the like. Among others a thermop...

Claims

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Application Information

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IPC IPC(8): B32B5/16
CPCC08J5/043C08J2323/12C08J2367/02Y10T428/2998C08L23/12C08L77/00C08J2377/00
Inventor MIYOSHI, TAKAAKIKAMO, HIROSHISARUKAWA, KOJIYOSHIDA, KAZUOAKIYAMA, YOSHIKUNIFURUKAWA, HIROAKITERADA, KAZUNORI
Owner ASAHI KASEI CHEM CORP
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