Reinforced polyphenylene ether-based resin composition

Abstract

To provide a polyphenylene ether-based resin composition whose compatibility to a carbon fiber of a polyphenylene ether-based resin is improved, thereby extrusion stability is improved without loss of light weight property and mechanical strength, and which is effectively usable for, especially, a peripheral member of an automobile.SOLUTION: A polyphenylene ether-based resin composition contains: polyphenylene ether (A); a styrenic resin (B); a carbon fiber (C); and one or more components (D) selected from a terpene phenol resin, a C5 / C9-based petroleum resin and a C9-based petroleum resin. Therein: a content of the component (A) is 30 to 70 pts.mass; a content of the component (B) is 10 to 60 pts.mass; a content of the component (C) is 5 to 15 pts.mass; a content of the component (D) is 5 to 25 pts.mass; a content ratio (C) / (D) is within a range of 3.5 / 6.5 to 5 / 5; and a total content of the component (A), the component (B), the component (C) and the component (D) is 87 mass% or more.SELECTED DRAWING: None

Description

[Technical field]

[0001] The present invention relates to a reinforced polyphenylene ether resin composition. [Background technology]

[0002] Polyphenylene ether-based resins are usually prepared by combining polyphenylene ether and styrene-based resins in any desired ratio depending on the required level of heat resistance and molding fluidity, and further incorporating, as necessary, an elastomer component and additive components such as a flame retardant, an inorganic filler, and a heat stabilizer to form a resin composition. Such polyphenylene ether resins are widely used in the fields of home appliances, office automation equipment, business machines, information devices, automobiles, etc., because of their excellent heat resistance, mechanical properties, moldability, acid and alkali resistance, dimensional stability, electrical properties, etc. In particular, for automobile applications, materials with lower specific gravity and higher mechanical strength are required to improve fuel efficiency by reducing weight, and the development of polyphenylene ether resin compositions containing carbon fibers is anticipated.

[0003] However, in order to impart sufficient mechanical strength to the polyphenylene ether resin composition by blending carbon fibers as a constituent component, it is necessary to blend a relatively large amount of carbon fibers. Usually, the carbon fiber to be mixed with the resin is a product of so-called chopped strands, which is a pellet or flake-shaped product obtained by cutting a continuous fiber bundle of single fibers (raw yarn) bound with a binder to a length of about 2 to 7 mm. When this is fed (side-fed) into a molten resin composition from an opening in the middle of the barrel of a twin-screw extruder and kneaded into the resin in the extruder, the carbon fiber is lighter and bulkier than a normal inorganic filler, so the feeding itself is difficult, and the fiber bundle breaks up during the feeding, which further reduces the feedability. Furthermore, the affinity with polyphenylene ether resin is not always sufficient, and during long-term production, problems such as feed blockage, extrusion strand breakage, and poor strand take-up due to insufficient kneading with the resin are frequently observed.

[0004] Conventionally, such feeding problems have been generally addressed by investigating stable feeding methods for the carbon fiber itself, reducing the production rate, adjusting extrusion conditions such as modifying the screw pattern of the extruder, etc., but sufficient effects were not necessarily obtained by these alone. Therefore, an important issue was how to achieve smooth mixing and dispersion of carbon fibers by increasing the affinity of the polyphenylene ether resin itself with carbon fibers, thereby improving production stability without compromising the material's light weight and mechanical strength.

[0005] In addition, in order to improve the extrudability of polyphenylene ether resin compositions containing a large amount of inorganic filler, a technology has been disclosed relating to a resin composition containing an aromatic hydrocarbon resin obtained from petroleum naphtha, a terpene phenolic resin, and a chromanindene resin derived from coal tar (see, for example, Patent Document 1). However, the polyphenylene ether resin composition disclosed in Patent Document 1 is a resin composition that mainly contains a high concentration of inorganic filler such as glass fiber, and is a resin composition that cannot be extruded due to torque over during extrusion, and the invention aims to improve the extrudability by improving the melt fluidity of such a resin composition. On the other hand, the present application aims to improve production stability mainly by improving the affinity between the polyphenylene ether resin and carbon fiber, and therefore the composition and the effects achieved are different from those of the invention of the present application.

[0006] Also disclosed is a technique for improving coating adhesion by incorporating a specific amount of a specific terpene phenol resin into a resin composition of a polyamide resin and a polyphenylene ether resin (see, for example, Patent Document 2). [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Special Publication No. 61-54337 [Patent Document 2] Patent No. 3812958 Summary of the Invention [Problem to be solved by the invention]

[0008] An object of the present invention is to provide a reinforced polyphenylene ether resin composition which improves the affinity of a polyphenylene ether resin with carbon fiber, thereby improving production stability without impairing light weight and mechanical strength, and which can be effectively used particularly for peripheral parts of automobiles. Another object of the present invention is to provide automobile peripheral parts using a reinforced polyphenylene ether resin composition which has improved production stability without impairing the light weight and mechanical strength. [Means for solving the problem]

[0009] The present inventors have found a resin composition that has good light weight (low specific gravity) and mechanical strength and has improved production stability of the material by blending a specific petroleum resin or a terpene phenol resin in a specific ratio in order to improve the affinity of the polyphenylene ether resin with the carbon fiber in a polyphenylene ether resin composition reinforced with carbon fiber. They have also found that the obtained polyphenylene ether resin composition can be effectively used for automobile peripheral parts, and have completed the present invention.

[0010] The present invention has been made based on the above findings, and the gist of the present invention is as follows. [1] A composition comprising polyphenylene ether (A), a styrene-based resin (B), carbon fiber (C), and one or more components (D) selected from a terpene phenol resin, a C5 / C9 petroleum resin, and a C9 petroleum resin; the content of the component (A) is 30 to 70 parts by mass, the content of the component (B) is 10 to 60 parts by mass, the content of the component (C) is 5 to 18 parts by mass, and the content of the component (D) is 5 to 25 parts by mass, relative to 100 parts by mass in total of the component (A), the component (B), the component (C), and the component (D); the content mass ratio ((C) / (D)) of the component (C) to the component (D) is within the range of (C) / (D)=3.5 / 6.5 to 5 / 5, A reinforced polyphenylene ether resin composition, characterized in that the total content of the (A) component, the (B) component, the (C) component, and the (D) component accounts for 87 mass% or more of the entire resin composition. [2] The reinforced polyphenylene ether resin composition according to [1], characterized in that the content of the crystalline resin in the resin composition is 5 mass% or less. [3] The reinforced polyphenylene ether resin composition according to [1] or [2], characterized in that it contains 3 mass % or less of an inorganic filler other than the component (C). [4] The reinforced polyphenylene ether resin composition according to any one of [1] to [3], characterized in that the resin composition contains an organic phosphorus flame retardant (E) in an amount of 8 mass% or less. [5] The (C) component is a carbon fiber bundled with an epoxy-based sizing agent, The reinforced polyphenylene ether resin composition according to any one of the above [1] to [4]. [6] The reinforced polyphenylene ether resin composition according to any one of [1] to [5], wherein the component (D) contains at least a terpene phenol resin. [7] The reinforced polyphenylene ether resin composition according to [6], characterized in that the terpene phenol resin has an SP value (δ) calculated using Hoy's constant within the range of 8.80 to 9.50. [8] An automobile peripheral part, comprising the reinforced polyphenylene ether resin composition according to any one of [1] to [7]. Effect of the Invention

[0011] According to the present invention, it is possible to provide a reinforced polyphenylene ether resin composition which has good light weight (low specific gravity) and mechanical strength, and is excellent in the production stability of the material. Furthermore, the reinforced polyphenylene ether resin composition of the present invention can be effectively used as a molded article for use in peripheral parts of an automobile. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Hereinafter, an embodiment for carrying out the present invention (hereinafter, referred to as "the present embodiment") will be described in detail. Note that the present embodiment is an example for explaining the present invention, and the present invention is not limited to the embodiment. In other words, the present invention can be modified in various ways without departing from the gist of the present invention.

[0013] <Reinforced polyphenylene ether resin composition> The reinforced polyphenylene ether resin composition of the present embodiment (hereinafter also simply referred to as the "polyphenylene ether resin composition" or "resin composition") has The composition comprises polyphenylene ether (A), a styrene-based resin (B), carbon fiber (C), and one or more components (D) selected from a terpene phenol resin, a C5 / C9 petroleum resin, and a C9 petroleum resin; the content of the component (A) is 30 to 70 parts by mass, the content of the component (B) is 20 to 60 parts by mass, the content of the component (C) is 5 to 18 parts by mass, and the content of the component (D) is 5 to 25 parts by mass, relative to 100 parts by mass in total of the components (A), (B), (C), and (D); the ratio (C) / (D) of the (C) component to the (D) component is within the range of (C) / (D)=3.5 / 6.5 to 5 / 5; A reinforced polyphenylene ether resin composition, characterized in that the total content of the components (A), (B), (C) and (D) accounts for 87 mass% or more of the entire resin composition.

[0014] (Polyphenylene ether (A)) The polyphenylene ether (A) of the present embodiment (hereinafter also simply referred to as “component (A)” or “polyphenylene ether”) is a homopolymer or copolymer having repeating units (structural units) represented by the following chemical formula (1) and / or chemical formula (2). [ka] [ka]

[0015] In the above chemical formulas (1) and (2), R 4、 R5, R6, R7, and R8 each independently represent a hydrogen atom, an alkyl group having 1 to 4 carbon atoms, an aryl group having 6 to 9 carbon atoms, or a halogen atom, provided that R5 and R6 are not simultaneously hydrogen. The alkyl group preferably has 1 to 3 carbon atoms, the aryl group preferably has 6 to 8 carbon atoms, and among the monovalent residues, hydrogen is preferred.

[0016] The number of repeating units in the above chemical formulas (1) and (2) is not particularly limited since it varies depending on the molecular weight distribution of the polyphenylene ether (A). Representative examples of polyphenylene ether homopolymers include poly(2,6-dimethyl-1,4-phenylene) ether, poly(2-methyl-6-ethyl-1,4-phenylene) ether, poly(2,6-diethyl-1,4-phenylene) ether, poly(2-ethyl-6-n-propyl-1,4-phenylene) ether, poly(2,6-di-n-propyl-1,4-phenylene) ether, poly(2-methyl-6-n-butyl-1,4-phenylene) ether, poly(2-ethyl-6-isopropyl-1,4-phenylene) ether, poly(2-methyl-6-chloroethyl-1,4-phenylene) ether, poly(2-methyl-6-hydroxyethyl-1,4-phenylene) ether, and poly(2-methyl-6-chloroethyl-1,4-phenylene) ether.

[0017] Examples of the polyphenylene ether copolymer include, but are not limited to, copolymers mainly composed of a polyphenylene ether structure, such as a copolymer of 2,6-dimethylphenol and 2,3,6-trimethylphenol, a copolymer of 2,6-dimethylphenol and o-cresol, and a copolymer of 2,3,6-trimethylphenol and o-cresol. Among the polyphenylene ethers, poly(2,6-dimethyl-1,4-phenylene) ether is preferred.

[0018] In this embodiment, the polyphenylene ether chain at least partially contains a structure in which R3 and R4 in chemical formula (1) are each a methyl group (and a structure derived from this structure, as described later).

[0019] The polyphenylene ether (A) may contain polyphenylene ethers containing various phenylene ether units other than those represented by the general formulas (1) and (2) as partial structures, so long as the heat resistance of the resin composition is not excessively reduced. Examples of such phenylene ether units include, but are not limited to, 2-(dialkylaminomethyl)-6-methylphenylene ether units and 2-(N-alkyl-N-phenylaminomethyl)-6-methylphenylene ether units described in JP-A-01-297428 and JP-A-63-301222.

[0020] The polyphenylene ether (A) may have diphenoquinone or the like bonded to the main chain of the polyphenylene ether.

[0021] Furthermore, the polyphenylene ether (A) can have a configuration in which a part or all of the polyphenylene ether is replaced with a functionalized polyphenylene ether by reacting (modifying) it with a functionalizing agent containing one or more functional groups selected from the group consisting of carboxylic acid, acid anhydride, acid amide, imide, amine, orthoester, hydroxy, and ammonium carboxylate. In particular, from the viewpoint of improving adhesion to the carbon fiber (C) described later and improving heat resistance, mechanical properties, etc., it is possible to use a functionalized polyphenylene ether functionalized by reaction with an acid anhydride such as maleic anhydride or a carboxylic acid such as malic acid, citric acid, or fumaric acid in place of a part or all of the polyphenylene ether.

[0022] The ratio of the weight average molecular weight Mw to the number average molecular weight Mn (Mw / Mn value) of the polyphenylene ether (A) is preferably 2.0 to 5.5, more preferably 2.5 to 4.5, and further preferably 3.0 to 4.5. The Mw / Mn value is preferably 2.0 or more from the viewpoint of the molding processability of the resin composition, and is preferably 5.5 or less from the viewpoint of the mechanical properties of the resin composition. Here, the weight average molecular weight Mw and the number average molecular weight Mn are obtained from the polystyrene equivalent molecular weight measured by GPC (gel permeation chromatography).

[0023] The reduced viscosity of the polyphenylene ether (A) is preferably in the range of 0.25 to 0.65 dl / g, more preferably 0.30 to 0.55 dl / g, and even more preferably 0.33 to 0.42 dl / g. In addition, the reduced viscosity of the polyphenylene ether is preferably 0.25 dl / g or more from the viewpoint of sufficient mechanical properties, and is preferably 0.65 dl / g or less from the viewpoint of moldability. The reduced viscosity of the polyphenylene ether can be measured using an Ubbelohde viscometer in a chloroform solvent at 30° C. and a 0.5 g / dl solution.

[0024] The polyphenylene ether (A) is generally available as a powder, and its average particle size is preferably 1 to 1000 μm, more preferably 10 to 700 μm, and particularly preferably 100 to 500 μm. From the viewpoint of ease of handling during processing, the average particle size is preferably 1 μm or more, and from the viewpoint of suppressing the generation of unmelted material during melt kneading, the average particle size is preferably 1000 μm or less.

[0025] In the resin composition of the present embodiment, the content of the polyphenylene ether (A) is 30 to 70 parts by mass relative to 100 parts by mass of the total amount of the polyphenylene ether (A), the styrene-based resin (B), the carbon fiber (C), and one or more components (D) selected from terpene phenol resin, C5 / C9 petroleum resin, and C9 petroleum resin. The content of the polyphenylene ether (A) is 30 parts by mass or more from the viewpoint of imparting sufficient heat resistance and flame retardancy, and 70 parts by mass or less from the viewpoint of moldability and retention of molded appearance, relative to 100 parts by mass of the total amount of the (A), (B), (C) and (D) components. From the same viewpoint, the content of the polyphenylene ether (A) is preferably within the range of 35 to 70 parts by mass, and more preferably 38 to 67 parts by mass, per 100 parts by mass of the total content of the (A), (B), (C) and (D) components.

[0026] (Styrene-based resin (B)) The styrene-based resin (B) (hereinafter, also simply referred to as "component (B)" or "styrene-based resin") in the reinforced polyphenylene ether resin composition of this embodiment is a polymer obtained by random copolymerization of a styrene-based compound or a compound copolymerizable with a styrene-based compound in the presence or absence of a rubber polymer.

[0027] Examples of the styrene-based compound include, but are not limited to, styrene, α-methylstyrene, 2,4-dimethylstyrene, monochlorostyrene, p-methylstyrene, p-tert-butylstyrene, ethylstyrene, etc. In particular, styrene is preferred from the viewpoint of practicality of the raw material.

[0028] Examples of the compound randomly copolymerizable with the styrene-based compound include, but are not limited to, methacrylic acid esters such as methyl methacrylate and ethyl methacrylate; unsaturated nitrile compounds such as acrylonitrile and methacrylonitrile; and acid anhydrides such as maleic anhydride.

[0029] As the styrene-based resin (B), it is preferable to use rubber-reinforced polystyrene (HIPS) and general-purpose polystyrene (GPPS) from the viewpoint of improving the mechanical properties and molding flowability of the molded product.

[0030] Among these, from the viewpoint of imparting impact resistance, it is preferable to use HIPS as a part or the whole of the styrene-based resin (B). The blending ratio of HIPS in the styrene-based resin (B) (100 mass%) blended in the polyphenylene ether-based resin composition of the present embodiment is preferably 10 to 100 mass%, more preferably 20 to 90 mass%, and further more preferably 40 to 70 mass%.

[0031] In the resin composition of the present embodiment, the content of the styrene-based resin (B) is within the range of 10 to 60 parts by mass relative to 100 parts by mass of the total content of the (A), (B), (C) and (D) components. The content of the styrene-based resin (B) is 10 parts by mass or more relative to 100 parts by mass of the total content of the (A), (B), (C) and (D) components from the viewpoint of imparting sufficient molding fluidity, and 60% by mass or less from the viewpoint of maintaining sufficient heat resistance and mechanical strength. From the same viewpoint, the content of the styrene-based resin (B) is preferably within a range of 20 to 55 parts by mass, and more preferably 20 to 45 parts by mass, relative to 100 parts by mass of the total content of the components (A), (B), (C) and (D).

[0032] (Carbon fiber (C)) In the reinforced polyphenylene ether resin composition of this embodiment, carbon fiber (C) (hereinafter, also simply referred to as “component (C)” or “carbon fiber”) is blended for the purpose of improving heat resistance and mechanical strength. The carbon fiber (C) can be appropriately selected from known carbon fibers, and examples thereof include PAN-based carbon fibers, pitch-based carbon fibers, rayon-based carbon fibers, and vapor-grown carbon fibers.

[0033] As the carbon fiber (C), for example, chopped strands having a cut length of 2 to 7 mm obtained by bundling raw yarns into strands in the range of 10,000 to 90,000 strands using a bundling agent such as an epoxy-based bundling agent are used. The number of convergent chopped strands is preferably 12,000 to 90,000, more preferably 20,000 to 80,000, and even more preferably 40,000 to 80,000. The chopped strands of carbon fiber used in the reinforced polyphenylene ether resin composition of this embodiment preferably have a bundle number of 10,000 or more from the viewpoint of handleability, and more preferably have a bundle number of 90,000 or less from the viewpoint of openability and dispersibility in the polyphenylene ether resin composition.

[0034] Furthermore, from the viewpoint of providing sufficient mechanical strength to the resin composition, it is preferable that the carbon fiber (C) used in the reinforced polyphenylene ether resin composition of this embodiment is a chopped strand of carbon fiber bundled with an epoxy-based binder.

[0035] Here, the fiber diameter of the carbon fiber raw yarn contained in the carbon fiber (C) is preferably 0.5 to 15 μm, and more preferably 5 to 10 μm.

[0036] Furthermore, the fiber length of the carbon fibers after melt-kneading the carbon fibers (C) in the resin composition is preferably 50 to 700 μm, more preferably 100 to 600 μm, further preferably 150 to 400 μm, and particularly preferably 200 to 300 μm. From the viewpoint of sufficient mechanical strength, the fiber size is preferably 50 μm or more, and from the viewpoints of fiber opening and dispersibility in the resin composition, appearance retention of the molded product, and molding processability, the fiber size is preferably 700 μm or less.

[0037] In the resin composition of the present embodiment, the content of the carbon fiber (C) is within the range of 5 to 18 parts by mass relative to 100 parts by mass of the total content of the (A), (B), (C) and (D) components. The content of the carbon fiber (C) is 5 parts by mass or more relative to 100 parts by mass of the total content of the (A), (B), (C) and (D) components from the viewpoint of imparting sufficient mechanical strength, and 18% by mass or less from the viewpoint of maintaining sufficient light weight and moldability. From the same viewpoint, the content of the carbon fiber (C) is preferably within a range of 5 to 15 parts by mass, more preferably 7 to 12 parts by mass, per 100 parts by mass of the total content of the components (A), (B), (C) and (D).

[0038] (Terpene phenol resin, C5 / C9 petroleum resin, C9 petroleum resin (D)) One or more components (D) (hereinafter, also simply referred to as "component (D)") selected from a terpene phenol resin, a C5 / C9 petroleum resin, and a C9 petroleum resin used in the resin composition of this embodiment are blended as a component for improving the affinity between the carbon fiber (C) and the polyphenylene ether resin component.

[0039] The terpene phenol resin is a copolymer of terpenes and phenols. Terpenes are (C5H8) nor oxygen-containing compounds derived therefrom, such as monoterpenes (when n=2, myrcene, ocimene, α-pinene, β-pinene, limonene, terpinolene, Δ3 carene, citronellol, borneol, menthol, camphor, etc.), sesquiterpenes (when n=3, longifolene, caryophyllene, curcumene, etc.), diterpenes (when n=4, rosin, campholene, hinokiol, etc.), tetraterpenes (when n=8, carotenoids), polyterpenes (natural rubber), etc. Preferred terpenes include monoterpenes, and particularly preferred are α-pinene, β-pinene, and limonene. The phenols are compounds having at least one hydroxyl group on an aromatic ring such as a benzene ring or a naphthalene ring, and the aromatic ring may have a substituent (such as a halogen atom or an alkyl group). Examples of the phenols include phenol, cresol, xylenol, naphthol, catechol, resilicin, hydroquinone, and pyrogallol. The preferred phenol is phenol. The terpene phenol resin is preferably a copolymer of the above monoterpenes and phenol, and more preferably a copolymer of limonene and phenol, and is represented by the following structural formula:

[0040] [ka] (In the above formula, m and n are integers each representing the degree of polymerization, and are preferably integers from 2 to 10.)

[0041] The C5 / C9 petroleum resin is an aliphatic / aromatic copolymer petroleum resin obtained from a C5 petroleum fraction (aliphatic) and a C9 petroleum fraction (aromatic) of naphtha. The C9 petroleum resin is an aromatic petroleum resin obtained only from a C9 petroleum fraction. Examples of the C5 petroleum fractions include conjugated diene unsaturated hydrocarbons having 4 to 6 carbon atoms, such as isoprene, trans-1,3-pentadiene, cis-2-pentadiene, cyclopentadiene, and methylcyclopentadiene; monoolefinic unsaturated hydrocarbons having 4 to 6 carbon atoms, such as 1,3,2,2-butene, 2-methyl-1-butene, 2-methyl-2-butene, 1-pentene, 2-pentene, and cyclopentene; aliphatic saturated hydrocarbons, such as cyclopentane, 2-methylpentane, 3-methylpentane, and n-hexane; and mixtures thereof. Examples of the C9 petroleum fraction include aromatic compounds having 8 carbon atoms, such as styrene; aromatic compounds having 9 carbon atoms, such as α-methylstyrene, β-methylstyrene, vinyltoluene, and indene; aromatic compounds having 10 carbon atoms, such as 2-isopropylenemethyl, 4-isopropylenemethyl, 1-methylindene, 2-methylindene, and 3-methylindene; aromatic compounds having 11 carbon atoms, such as 2,3,2-methylindene and 2,5,2-methylindene; and mixtures thereof.

[0042] Specific examples of the C5 / C9 petroleum resin include cyclopentadiene / styrene copolymer petroleum resins, and examples of the C9 petroleum resin include those obtained by cationic polymerization or anionic polymerization of styrene, vinyltoluene, α-methylstyrene, isopropylene methyl, indene, and the like.

[0043] The terpene phenol resin, the C5 / C9 petroleum resin, and the C9 petroleum resin are all commercially available, and various products are available from each company. In this embodiment, the type is not particularly limited, and one type may be blended alone in the resin composition of the present application, or two or more types may be blended in combination. However, from the viewpoint of long-term extrusion stability and improved performance balance of the composition, terpene phenol resin is preferred. In particular, it is more preferred to use one having an SP value (δ) calculated using Hoy's constant within the range of 8.80 to 9.50.

[0044] In the resin composition of this embodiment, the content of (D) is within the range of 7.5 to 20 parts by mass relative to 100 parts by mass of the total content of the (A), (B), (C) and (D) components. The content of the (D) component is 5 parts by mass or more relative to 100 parts by mass of the total content of the (A), (B), (C) and (D) components from the viewpoint of ensuring sufficient long-term extrusion stability, and is 25 parts by mass or less from the viewpoint of maintaining the performance balance of the resin composition. From the same viewpoint, the content of (D) is preferably within the range of 7 to 20 parts by mass, and more preferably 10 to 17 parts by mass, per 100 parts by mass of the total content of the (A), (B), (C) and (D) components.

[0045] Furthermore, the content mass ratio ((C) / (D)) of the (C) component to the (D) component is within the range of (C) / (D)=3.5 / 6.5 to 5 / 5. The content mass ratio ((C) / (D)) is 3.5 or more / 6.5 or less from the viewpoint of extrusion stability, and is 5 or less / 5 or more from the viewpoint of ensuring sufficient miscibility between the (C) component and the resin component and production stability. From the same viewpoint, the content mass ratio ((C) / (D)) is preferably within a range of 3.7 / 6.3 to 5 / 5, more preferably within a range of 3.8 / 6.2 to 4.7 to 5.3, and even more preferably within a range of 4 / 6 to 4.5 / 5.5.

[0046] (Other Ingredients) In the reinforced polyphenylene ether resin composition of this embodiment, from the viewpoint of improving the mold releasability and chemical resistance of the molded article, it is also possible to further blend a small amount of a polyolefin resin or a crystalline resin such as polyamide, polyester, or polyphenylene sulfide.

[0047] Examples of the polyolefin resin include polyolefin resins such as polyethylene and polypropylene, and polyolefin copolymers such as ethylene-propylene copolymer, ethylene-octene copolymer, ethylene-ethyl acrylate copolymer, and ethylene-ethyl methacrylate copolymer.

[0048] The content of the crystalline resin in the resin composition of the present embodiment is preferably 5% by mass or less from the viewpoint of maintaining mechanical strength, more preferably 3% by mass or less, and even more preferably 2% by mass or less from the same viewpoint.

[0049] In addition, in the resin composition of the present embodiment, from the viewpoint of maintaining mechanical strength and light weight, it is preferable that the inorganic filler other than the carbon fiber (C) is contained in an amount of 3 mass % or less, more preferably 1 mass % or less, and even more preferably 0.5 mass % or less, within a range that does not significantly decrease physical properties such as mechanical strength, light weight, and toughness. Examples of inorganic fillers other than the carbon fibers (C) include, but are not limited to, glass fibers, mica, glass flakes, talc, milled glass fibers, chlorite, kaolin clay, and organic clay.

[0050] In the resin composition of the present embodiment, an organic phosphorus flame retardant (E) can be blended within a range that does not significantly reduce physical properties such as heat resistance and light weight. The organic phosphorus flame retardant is not limited to the following, but examples thereof include triphenyl phosphate, tricresyl phosphate, trixylenyl phosphate, cresyl diphenyl phosphate, xylenyl diphenyl phosphate, dixylenyl phenyl phosphate, hydroxynonbisphenol phosphate, resorcinol bisphosphate, bisphenol A bisphosphate, triphenyl-substituted aromatic phosphate esters such as tetrakis(2,6-dimethylphenyl)-m-phenylene bisphosphate, and phenoxyphosphazenes such as phosphonitrilic acid phenyl ester. Among them, tetrakis(2,6-dimethylphenyl)-m-phenylene bisphosphate is preferred. From the viewpoints of maintaining heat resistance and light weight, the content of the organic phosphorus flame retardant (E) in the resin composition of the present embodiment is preferably 8% by mass or less. From the same viewpoint, the content of the organic phosphorus flame retardant is more preferably 5% by mass or less, and further preferably 3% by mass or less.

[0051] In addition, in the resin composition of the present embodiment, styrene-based thermoplastic elastomers such as SEBS, stabilizers such as antioxidants, ultraviolet absorbers, and heat stabilizers, colorants, mold release agents, etc. can be contained in the resin composition of the present application in a proportion of 0.001 to 3 mass % within a range that does not significantly deteriorate the heat resistance, mechanical strength, and surface appearance of the molded product. The content of these components is preferably 0.01 to 2 mass %, more preferably within a range of 0.2 to 1 mass %. From the viewpoint of sufficient addition effect, it is desirable to make it 0.001 mass % or more, and from the viewpoint of maintaining physical properties, it is desirable to make it 3 mass % or less.

[0052] In the resin composition of this embodiment, the total content of the (A), (B), (C) and (D) components must account for 87% by mass or more of the entire resin composition. This is to maintain sufficient light weight, mechanical strength and balance of other physical properties. From the same viewpoint, the total content of the (A), (B), (C) and (D) components is preferably 90% by mass or more, more preferably 95% by mass or more, and even more preferably 97% by mass or more.

[0053] <Method of producing resin composition> The resin composition of the present embodiment can be produced by melt-kneading the above-mentioned components (A), (B), (C), and (D), as well as other materials as necessary. The conditions for producing the resin composition of the present embodiment are not necessarily limited to the following, and it is possible to produce the resin composition of the present application by melt-kneading all of the components (A), (B), (C), and (D) of the present application, as well as any other materials, all at once. However, it is preferable, from the viewpoint of improving performance such as mechanical properties and achieving the effects of the present application, to produce the resin composition of the present application by first supplying and melt-kneading the component (D) together with the components (A), (B), and any other components from the most upstream part (top feed) of the extruder, and then blending and melt-kneading the component (C) from a side feed from the extruder barrel midway through.

[0054] The method for preparing the resin composition of the present embodiment is not limited to the following, but in order to stably produce a large amount of the resin composition, a twin-screw extruder is preferably used from the viewpoint of production efficiency. The screw diameter of the twin-screw extruder is preferably within a range of 25 to 90 mm, and more preferably within a range of 40 to 70 mm. For example, when using a ZSK40MC twin screw extruder (manufactured by Werner & Pfleiderer, Germany, number of barrels 13, screw diameter 40 mm, L / D = 50; screw pattern having kneading disk L: 2, kneading disk R: 6, and kneading disk N: 4), a method of melt kneading under conditions of a cylinder temperature of 270 to 330 ° C, a screw rotation speed of 150 to 600 rpm, and an extrusion rate of 40 to 150 kg / h, and a method of melt kneading under conditions of a cylinder temperature of 270 to 330 ° C, a screw rotation speed of 150 to 600 rpm, and an extrusion rate of 250 to 600 kg / h when using a TEM58SS twin screw extruder (manufactured by Toshiba Machine Co., Ltd., number of barrels 13, screw diameter 58 mm, L / D = 53; screw pattern having kneading disk L: 2, kneading disk R: 14, and kneading disk N: 2), can be mentioned as a suitable method. Here, the "L" is the "screw barrel length" of the extruder, and the "D" is the "screw barrel diameter."

[0055] When the resin composition of this embodiment is produced using a twin-screw extruder, from the viewpoint of imparting heat resistance and mechanical strength to the material by maintaining a sufficient fiber length of the carbon fibers in the resin composition, it is preferable that the (A), (B) and (D) components are supplied from a supply port (top feed) at the most upstream part of the extruder, and the (C) component is supplied from a raw material pushing-in supply port (side feed) provided midway through the extruder.

[0056] <Molded products, automotive peripheral parts> The molded article of the present embodiment can be obtained by molding the reinforced polyphenylene ether resin composition of the present embodiment described above. The method for molding the resin composition is not particularly limited, but suitable examples include injection molding, extrusion molding, vacuum molding, and pressure molding. In particular, injection molding is preferred from the viewpoints of the appearance characteristics of the molded product and mass productivity. Suitable molded products are automobile peripheral parts, which have an excellent balance of light weight and mechanical strength and have a good molded appearance, such as instrument panels, door beams, under covers, spare tire covers, front ends, bumpers, air spoilers, lamp reflectors, and lamp extensions. EXAMPLES

[0057] The present invention will be described below with reference to specific examples and comparative examples, but the present invention is not limited to the following examples.

[0058] [Constituents of each resin composition] The components contained in each sample of the examples and comparative examples are shown below. Polyphenylene ether resin (A) (A-1) Poly(2,6-dimethyl-1,4-phenylene ether) powder ((A-1) having a reduced viscosity of 0.50 dl / g (0.5 g / dl chloroform solution, 30°C, measured with an Ubbelohde viscometer), a number average molecular weight of 18,300, a terminal OH group of 0.71 per 100 units, and a N,N-dibutylaminomethyl group of 0.39 per 100 units was prepared by solution polymerization (hereinafter, may be simply referred to as "A-1"). (A-2) Poly(2,6-dimethyl-1,4-phenylene ether) powder (A-2) having a reduced viscosity of 0.40 dl / g (0.5 g / dl chloroform solution, 30°C, measured with an Ubbelohde viscometer), a number average molecular weight of 15,800, 0.74 terminal OH groups per 100 units, and 0.43 N,N-dibutylaminomethyl groups per 100 units was prepared by solution polymerization. (Hereinafter, this will be referred to simply as "A-2").

[0059] Styrene-based resin (B) (B-1) General purpose polystyrene ((B-1) GPPS), product name: Polystyrene 680 (registered trademark), manufactured by PS Japan Co., Ltd. (hereinafter, sometimes simply referred to as "B-1"). (B-2) High impact polystyrene ((B-2) HIPS), product name: Polystyrene CT60 (registered trademark), manufactured by Petrochemicals Corporation (hereinafter, sometimes simply referred to as "B-2").

[0060] Carbon fiber (C) (C-1) Product name: Pyrofil TR06YLB6R (registered trademark), sizing agent: epoxy-based, number of sizing strands: 60,000, manufactured by Mitsubishi Chemical Corporation (hereinafter, sometimes simply referred to as "C-1").

[0061] Terpene phenol resin, petroleum resin (D) (D-1) Terpene phenol resin. Product name: YS Polystar N125 (registered trademark), SP value δ (calculated using Hoy's constant): 9.18, manufactured by Yasuhara Chemical Co., Ltd. (hereinafter, sometimes simply referred to as "D-1"). (D-2) Terpene phenol resin. Product name: YS Polystar G150 (registered trademark), SP value δ (calculated using Hoy's constant): 9.07, manufactured by Yasuhara Chemical Co., Ltd. (hereinafter, sometimes simply referred to as "D-2"). (D-3) C5 / C9 petroleum resin. Product name: Petrotac 100V (registered trademark), manufactured by Tosoh Corporation. (Hereinafter, sometimes simply referred to as "D-3"). (D-4) C9 petroleum resin. Product name: Petokol 140 (registered trademark), manufactured by Tosoh Corporation. (Hereinafter, sometimes simply referred to as "D-4").

[0062] Other raw materials (PKHH) Phenoxy resin (bisphenol A epichlorohydrin epoxy resin). Product name: PKHH (registered trademark), manufactured by Gabriel Phenoxys Co., Ltd. (hereinafter sometimes simply referred to as "PKHH"). (PX-200) Organophosphorus flame retardant (tetrakis(2,6-dimethylphenyl)-m-phenylene bisphosphate), product name: PX-200 (registered trademark), manufactured by Daihachi Chemical Industry Co., Ltd. (hereinafter sometimes simply referred to as "PX-200").

[0063] <Examples 1 to 11 and Comparative Examples 1 to 6> Using the above-mentioned components, polyphenylene ether resin compositions of each sample were prepared under the conditions shown below.

[0064] [Comparative Example 1] 55 parts by mass of (A-1), 20 parts by mass of (B-1), and 20 parts by mass of (B-2) were fed from the most upstream part (top feed) of a TEM58SS twin screw extruder (screw pattern with 2 kneading disks L, 14 kneading disks R, and 2 kneading disks N) manufactured by Toshiba Machine Co., Ltd., with a barrel number of 13 and a screw diameter of 58 mm, and 5 parts by mass of (C-1) were side fed from barrel 8 in the middle, and melt kneaded under the conditions of a cylinder temperature of 300°C, a screw rotation speed of 400 rpm, an extrusion rate of 400 kg / h, a nozzle die hole number of 20, and a vent vacuum degree of -0.085 to -0.090 MPa, and a continuous extrusion operation was performed for 1 hour. At that time, a sample of the resin composition was obtained and the extrusion stability was evaluated. The physical properties of the resin composition and the results of the extrusion stability evaluation are shown in Table 1.

[0065] [Comparative Example 2] A resin composition sample was obtained by melt kneading under the same conditions as in Comparative Example 1, except that 5 parts by mass of the 20 parts by mass of (B-1) were replaced with (C-1) and 10 parts by mass of (C-1) were side-fed from barrel 8 during the process, and the extrusion stability was evaluated. The physical properties of the resin composition and the results of the extrusion stability evaluation are shown in Table 1.

[0066] [Comparative Example 3] A resin composition sample was obtained by melt kneading under the same conditions as in Comparative Example 1, except that 10 parts by mass of the 20 parts by mass of (B-1) were replaced with (C-1) and 15 parts by mass of (C-1) were side-fed from barrel 8 during the process, and the extrusion stability was evaluated. The physical properties of the resin composition and the results of the extrusion stability evaluation are shown in Table 1.

[0067] [Example 1] 55 parts by mass of (A-1), 10 parts by mass of (B-1), 10 parts by mass of (B-2), and 15 parts by mass of (D-1) were fed from the most upstream part (top feed) of a TEM58SS twin screw extruder (screw pattern with 2 kneading disks L, 14 kneading disks R, and 2 kneading disks N) manufactured by Toshiba Machine Co., Ltd., with a barrel number of 13 and a screw diameter of 58 mm, and 10 parts by mass of (C-1) were side fed from barrel 8 in the middle, and melt kneaded under the conditions of a cylinder temperature of 300°C, a screw rotation speed of 400 rpm, an extrusion rate of 400 kg / h, a nozzle die hole number of 20, and a vent vacuum degree of -0.085 to -0.090 MPa, and a continuous extrusion operation was performed for 1 hour. At that time, a sample of the resin composition was obtained and the extrusion stability was evaluated. The physical properties of the resin composition and the results of the extrusion stability evaluation are shown in Table 1.

[0068] [Example 2] A resin composition sample was obtained by melt kneading under the same conditions as in Example 1, except that 15 parts by mass of (D-1) was replaced with (D-3) and fed from the top feed, and the extrusion stability was evaluated. The physical properties of the resin composition and the results of the extrusion stability evaluation are shown in Table 1.

[0069] [Example 3] A resin composition sample was obtained by melt kneading under the same conditions as in Example 1, except that 15 parts by mass of (D-1) was replaced with (D-4) and fed from the top feed, and the extrusion stability was evaluated. The physical properties of the resin composition and the results of the extrusion stability evaluation are shown in Table 1.

[0070] [Comparative Example 4] A resin composition sample was obtained by melt kneading under the same conditions as in Example 1, except that 15 parts by mass of (D-1) was replaced with (PKHH) and fed from the top feed, and the extrusion stability was evaluated. The physical properties of the resin composition and the results of the extrusion stability evaluation are shown in Table 1.

[0071] [Comparative Example 5] A resin composition sample was obtained by melt kneading under the same conditions as in Example 1, except that 15 parts by mass of (D-1) was replaced with (PX-200) and fed from the top feed, and the extrusion stability was evaluated. The physical properties of the resin composition and the results of the extrusion stability evaluation are shown in Table 1.

[0072] [Comparative Example 6] A resin composition sample was obtained by melt kneading under the same conditions as in Comparative Example 5, except that 5 parts by mass of the 15 parts by mass of (PX-200) were replaced with (D-1) and fed from the top feed, and the extrusion stability was evaluated. The physical properties of the resin composition and the results of the extrusion stability evaluation are shown in Table 1.

[0073] [Example 4] A resin composition sample was obtained by melt kneading under the same conditions as in Comparative Example 5, except that 10 parts by mass of the 15 parts by mass of (PX-200) were replaced with (D-1) and fed from the top feed, and the extrusion stability was evaluated. The physical properties of the resin composition and the results of the extrusion stability evaluation are shown in Table 1.

[0074] [Comparative Example 7] 39 parts by mass of (A-1), 24 parts by mass of (B-1), and 27 parts by mass of (B-2) were fed from the most upstream part (top feed) of a TEM58SS twin screw extruder (screw pattern with 2 kneading disks L, 14 kneading disks R, and 2 kneading disks N) manufactured by Toshiba Machine Co., Ltd., having a barrel number of 13 and a screw diameter of 58 mm, and 10 parts by mass of (C-1) were side fed from barrel 8 in the middle, and melt kneaded under the conditions of a cylinder temperature of 300 ° C., a screw rotation speed of 400 rpm, an extrusion rate of 400 kg / h, a nozzle die hole number of 20, and a vent vacuum degree of -0.085 to -0.090 MPa, and a continuous extrusion operation was performed for 1 hour. A sample of the resin composition was obtained and the extrusion stability was evaluated. The physical properties of the resin composition and the results of the extrusion stability evaluation are shown in Table 2.

[0075] [Comparative Example 8] A resin composition sample was obtained by melt kneading under the same conditions as in Comparative Example 7, except that 5 parts by mass of the 24 parts by mass of (B-1) were replaced with (D-2) and fed from the top feed, and the extrusion stability was evaluated. The physical properties of the resin composition and the results of the extrusion stability evaluation are shown in Table 2.

[0076] [Example 5] A resin composition sample was obtained by melt kneading under the same conditions as in Comparative Example 7, except that 10 parts by mass of the 24 parts by mass of (B-1) were replaced with (D-2) and fed from the top feed, and the extrusion stability was evaluated. The physical properties of the resin composition and the results of the extrusion stability evaluation are shown in Table 2.

[0077] [Example 6] A resin composition sample was obtained by melt kneading under the same conditions as in Comparative Example 7, except that 15 parts by mass of the 24 parts by mass of (B-1) were replaced with (D-2) and fed from the top feed, and the extrusion stability was evaluated. The physical properties of the resin composition and the results of the extrusion stability evaluation are shown in Table 2.

[0078] [Example 7] 39 parts by mass of (A-1), 26 parts by mass of (B-2), and 20 parts by mass of (D-2) were fed from the most upstream part (top feed) of a TEM58SS twin-screw extruder (kneading disk L: 2 pieces, kneading disk R: 14 pieces, kneading disk N: 2 pieces) manufactured by Toshiba Machine Co., Ltd., with a barrel number of 13 and a screw diameter of 58 mm, and 15 parts by mass of (C-1) were side-fed from barrel 8 in the middle, and melt-kneaded under the conditions of a cylinder temperature of 300 ° C., a screw rotation speed of 400 rpm, an extrusion rate of 400 kg / h, a nozzle die hole number of 20 holes, and a vent vacuum degree of -0.085 to -0.090 MPa to obtain a sample of the resin composition, and an evaluation of extrusion stability was performed. The physical properties and extrusion stability evaluation results of the resin composition are shown in Table 2.

[0079] [Example 8] A resin composition sample was obtained by melt kneading under the same conditions as in Example 7, except that 5 parts by mass of the 26 parts by mass of (B-2) were replaced with (D-2) and 25 parts by mass of (D-2) were fed from the top feed, and the extrusion stability was evaluated. The physical properties of the resin composition and the results of the extrusion stability evaluation are shown in Table 2.

[0080] [Comparative Example 9] A resin composition sample was obtained by melt kneading under the same conditions as in Example 7, except that 10 parts by mass of the 26 parts by mass of (B-2) were replaced with (D-2) and 30 parts by mass of (D-2) were fed from the top feed, and the extrusion stability was evaluated. The physical properties of the resin composition and the results of the extrusion stability evaluation are shown in Table 2.

[0081] [Comparative Example 10] 65 parts by mass of (A-1), 18 parts by mass of (B-1), and 17 parts by mass of (B-2) were fed from the most upstream part (top feed) of a TEM58SS twin screw extruder (kneading disk L: 2 pieces, kneading disk R: 14 pieces, kneading disk N: 2 pieces) manufactured by Toshiba Machine Co., Ltd., with a barrel number of 13 and a screw diameter of 58 mm, and melt-kneaded under the conditions of a cylinder temperature of 300 ° C., a screw rotation speed of 400 rpm, an extrusion rate of 400 kg / h, a nozzle die hole number of 20 holes, and a vent vacuum degree of -0.085 to -0.090 MPa to obtain a sample of a resin composition, and an evaluation of extrusion stability was performed. The physical properties and extrusion stability evaluation results of the resin composition are shown in Table 3.

[0082] [Comparative Example 11] A resin composition sample was obtained by melt kneading under the same conditions as in Comparative Example 10, except that 15 parts by mass of the 18 parts by mass of (B-1) were replaced with (D-2) and fed from the top feed, and the extrusion stability was evaluated. The physical properties of the resin composition and the results of the extrusion stability evaluation are shown in Table 3.

[0083] [Comparative Example 12] 20 parts by mass of (A-1), 45 parts by mass of (A-2), 10 parts by mass of (B-1), and 15 parts by mass of (B-2) were fed from the most upstream part (top feed) of a TEM58SS twin-screw extruder (kneading disk L: 2 pieces, kneading disk R: 14 pieces, kneading disk N: 2 pieces) manufactured by Toshiba Machine Co., Ltd., with a barrel number of 13 and a screw diameter of 58 mm, and 10 parts by mass of (C-1) were side-fed from barrel 8 in the middle, and melt-kneaded under the conditions of a cylinder temperature of 300 ° C., a screw rotation speed of 400 rpm, an extrusion rate of 400 kg / h, a nozzle die hole number of 20 holes, and a vent vacuum degree of -0.085 to -0.090 MPa to obtain a sample of the resin composition, and an evaluation of extrusion stability was performed. The physical properties and extrusion stability evaluation results of the resin composition are shown in Table 3.

[0084] [Example 9] A resin composition sample was obtained by melt kneading under the same conditions as in Comparative Example 12, except that 5 parts by mass of the total amount of 10 parts by mass of (B-1) and 15 parts by mass of (B-2) were replaced with 15 parts by mass of (D-2) and fed from the top feed. The physical properties of the resin composition and the results of the evaluation of extrusion stability are shown in Table 3.

[0085] <Evaluation> Each sample resin composition obtained by the above method was evaluated as follows. The evaluation results are shown in Table 1 for Examples 1 to 4 and Comparative Examples 1 to 6, in Table 2 for Examples 5 to 8 and Comparative Examples 7 to 9, and in Table 3 for Example 9 and Comparative Examples 10 to 12.

[0086] (1) Extrusion stability (CF kneadability, strand take-up) When the resin compositions of the Examples and Comparative Examples were produced by continuous extrusion operation for 1 hour, the feeding state of the carbon fiber (CF) pushed into the extruder body from the push feeder of the side feeder was visually evaluated. The samples were rated as follows: ◯: the CF was not retained in the screw of the push-in feed section and was smoothly transported to the extruder body; △: the CF was periodically retained; and ×: the extrusion was interrupted due to feed clogging caused by CF retention during the 1-hour extrusion run. The sample was rated as ◯: the CF kneading ability was excellent. In addition, during the one-hour extrusion operation, the case where no strand breakage occurred was rated as ◯, the case where strand breakage occurred 5 times or less was rated as △, and the case where strand breakage occurred 6 times or more or the extrusion operation was stopped due to the occurrence of CF feed clogging was rated as ×. The rating of ◯ was judged to indicate excellent strand take-up property. In addition, only those compositions that were evaluated as ◯ for both the CF kneadability and the strand take-up property were judged to be suitable for use as the resin composition of the present invention.

[0087] (2) Deflection temperature under load (DTUL) Pellets of the resin compositions prepared in the Examples and Comparative Examples were dried in a hot air dryer at 90° C. for 1 hour. The dried resin composition was used in an injection molding machine (EC75SXII, Shibaura Machine Co., Ltd.) equipped with an ISO physical property test piece mold, and the cylinder temperature was 290°C, the mold temperature was 90°C, the injection pressure was SSP + 10%, the injection speed was 25 mm / sec, the metering was 42 mm, and the screw rotation speed was 100 min ―1 The injection pressure was set to 10 MPa, and the injection time / cooling time was set to 20 sec / 20 sec to mold a dumbbell-shaped multipurpose test piece A of ISO3167. The obtained dumbbell-shaped multipurpose test piece A was cut to prepare a molded piece of 80 mm x 10 mm x 4 mm. The deflection temperature under load (DTUL) of the test piece was measured at 1.8 MPa by the flatwise method in accordance with ISO75. The evaluation criteria were that the higher the measured value (average value of three samples), the better the heat resistance.

[0088] (3) Molding fluidity (SSP) When the resin compositions of the Examples and Comparative Examples were used to mold ISO dumbbell pieces in the above (1), the SSP (Short Shot Pressure) of the molded pieces, i.e., the minimum injection pressure (the numerical value displayed on the display of the control panel) at which molding (full filling) was possible, was determined for each resin composition. As an evaluation criterion, the smaller the SSP value, the better the molding fluidity was judged to be.

[0089] (4) Tensile strength (TY) Using the ISO3167 multipurpose test piece A-type dumbbell molded piece prepared in (1) above, the tensile strength was measured at 23°C and a test speed of 5 mm / min in accordance with ISO527. As an evaluation criterion, the higher the measured tensile strength value (average value of five measured pieces), the more excellent the mechanical strength was judged to be.

[0090] (5) Flexural strength (FS), flexural modulus (FM) The ISO3167 multipurpose test piece A-type dumbbell molded piece prepared in (1) above was cut to prepare a molded piece of 80 mm x 10 mm x 4 mm. The flexural strength and flexural modulus of elasticity were measured at 23°C using the test piece in accordance with ISO178. The evaluation criteria were that the higher the measured values ​​of bending strength and bending modulus (average values ​​of three pieces measured), the more excellent the mechanical strength.

[0091] (6) Specific gravity The dead end gripping portions of the ISO3167 and A-type dumbbell molded pieces prepared in (1) above were cut off to obtain three test pieces, and measurements were made using an Alpha Mirage SD-200L electronic specific gravity meter. As an evaluation criterion, the smaller the specific gravity measurement value (average value of three measurements) was, the more excellent the light weight was judged to be.

[0092] [Table 1]

[0093] [Table 2]

[0094] [Table 3]

[0095] As can be seen from the results in Table 1, since the resin composition of Comparative Example 1 did not contain component (D), extrusion was unstable, and the feeding of CF was smooth at the start, but eventually periodic retention began to occur in the conveying screw part of the push-in feeder, and partial strand breakage occurred multiple times during operation. The resin compositions of Comparative Examples 2 and 3 did not contain the component (D), and the amount of the component (C) was increased compared to Comparative Example 1. Therefore, extrusion was unstable, and the feeding of CF was smooth at the start, but then periodic retention began to occur in the conveying screw of the push-in feeder, In all cases, CF feed clogging occurred about 30 to 40 minutes after the start of operation, and extrusion was temporarily stopped to remove the clogging, and then restarted to complete the extrusion operation. The physical properties of the resin compositions all tended to be high SSP (low molding flowability). In addition, the resin compositions of Comparative Examples 4 and 5 were prepared by investigating the improvement of extrusion stability by blending components other than the (D) component, but the composition of Comparative Example 4 also had the same extrusion operation conditions as Comparative Example 2. In terms of physical properties, the balance between mechanical properties, heat resistance, and molding fluidity tends to decrease. In Comparative Example 5, the incorporation of the flame retardant PX-200 showed a tendency for CF kneading to improve, and no CF feed clogging occurred until the end of extrusion, but strand breakage occurred periodically and multiple times. In terms of the physical properties of the resin composition, a significant decrease in heat resistance was observed. In addition, in Comparative Example 6, component (D) was blended, but since it was outside the scope of the claims of the present application, sufficient improvement in extrusion stability was not observed. In terms of physical properties, the heat resistance was low, similar to Comparative Example 5, and the material did not necessarily have an excellent balance between sufficient heat resistance and molding fluidity. On the other hand, the resin compositions of Examples 1 to 4 are all resin compositions containing component (D) within the scope of the claims of the present application, but the CF was smoothly transported to the extruder body without retention during continuous extrusion operation, and no strand breakage was observed until the end of operation. In terms of physical properties, there was no deterioration in mechanical properties, and materials with an excellent balance of heat resistance and molding flow properties were obtained.

[0096] From the results in Table 2, the resin compositions of Comparative Examples 7, 8, and 9 do not contain the (D) component or the blending ratio of the (D) component to the (C) component is outside the range of the claims of the present application, so none of them have sufficient extrusion stability. The extrusion state of Comparative Example 7 is almost the same as that of Comparative Example 2. Comparative Example 8 contains the (D) component, but the blending ratio of the (D) component to the (C) component is below the lower limit of the range of the claims of the present application, so no sufficient improvement in extrusion stability is observed. On the other hand, in Comparative Example 9, the blending ratio of the (D) component to the (C) component exceeds the upper limit of the range of the claims of the present application, and further the blending amount of the (D) component exceeds the blending amount of the claims of the present application, so although the kneading property of the CF is improved, the strand breakage is observed multiple times, and the extrusion stability is insufficient. On the other hand, the resin compositions of Examples 5 to 8 all contain component (D) and are within the scope of the claims of the present application, and during continuous extrusion, the CF was smoothly transported without stagnation in the extruder body, and no strand breakage was observed until the end of operation. In terms of physical properties, all of the materials obtained have an excellent balance of physical properties, especially between heat resistance and molding flowability.

[0097] From the results in Table 3, the resin compositions of Comparative Examples 10 and 11 are compared with the performance of resin compositions not containing component (C) with or without component (D). Since neither of them contains component (C), the extrusion stability is good, but the mechanical properties such as tensile and flexural strength, and flexural modulus are insufficient. In addition, compared with resin compositions containing component (C) in the amount specified in the claims of the present application (for example, Comparative Example 12 and Example 9 described later), the effect of improving molding flowability (SSP) by the incorporation of component (D) is small, and the decrease in heat resistance (DTUL) is large, so the improvement in the balance between molding flowability and heat resistance is also insufficient. On the other hand, the resin compositions of Comparative Example 12 and Example 9 are comparisons of the performance of resin compositions containing the specified amount of component (C) within the claimed range, with and without the incorporation of component (D). Comparative Example 12, which does not contain component (D), did not have sufficient extrusion stability, and the extrusion state was almost the same as that of Comparative Example 2. Example 9, which contains the specified amount of component (D) within the claimed range, has good extrusion stability and is also excellent in terms of physical properties, similar to Example 1. In particular, the improvement in molding flowability (SPP) due to the incorporation of component (D) is remarkable, and the decrease in DTUL is slight, so it can be seen that this is a composition with an excellent balance of physical properties between molding flowability and heat resistance. [Industrial Applicability]

[0098] The reinforced polyphenylene ether resin composition of the present invention is excellent in lightness and mechanical strength, and has improved extrusion stability of the resin composition, by improving the affinity of the polyphenylene ether resin with carbon fiber. In addition, since it has an excellent balance of other physical properties, it can be effectively used under the usage environment where such performance is required, and can be effectively used in molded products of automobile peripheral parts in particular.

Claims

1. The present invention comprises polyphenylene ether (A), a styrene-based resin (B), carbon fiber (C), and one or more components (D) selected from a terpene phenol resin, a C5 / C9 petroleum resin, and a C9 petroleum resin, the content of the component (A) is 30 to 70 parts by mass, the content of the component (B) is 10 to 60 parts by mass, the content of the component (C) is 5 to 18 parts by mass, and the content of the component (D) is 5 to 25 parts by mass, relative to 100 parts by mass of the total content of the component (A), the component (B), the component (C), and the component (D); the content mass ratio ((C) / (D)) of the component (C) to the component (D) is within a range of (C) / (D)=3.5 / 6.5 to 5 / 5; A reinforced polyphenylene ether resin composition, characterized in that the total content of the (A) component, the (B) component, the (C) component and the (D) component accounts for 87 mass% or more of the entire resin composition.

2. 2. The reinforced polyphenylene ether resin composition according to claim 1, wherein the content of the crystalline resin in the resin composition is 5% by mass or less.

3. 3. The reinforced polyphenylene ether resin composition according to claim 1, further comprising 3% by mass or less of an inorganic filler other than the component (C).

4. 3. The reinforced polyphenylene ether resin composition according to claim 1, further comprising an organophosphorus flame retardant (E) in an amount of 8 mass % or less in the resin composition.

5. 3. The reinforced polyphenylene ether resin composition according to claim 1, wherein the component (C) is carbon fiber bundled with an epoxy-based sizing agent.

6. 3. The reinforced polyphenylene ether resin composition according to claim 1, wherein the component (D) contains at least a terpene phenol resin.

7. The reinforced polyphenylene ether resin composition according to claim 6, wherein the terpene phenol resin has an SP value (δ) calculated by Hoy's constant in the range of 8.80 to 9.

50.

8. 3. An automobile peripheral part comprising the reinforced polyphenylene ether resin composition according to claim 1 or 2.

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