Polymer alloy and molded article

Abstract

To provide a polymer alloy that enables production of a molded article with superior mechanical characteristics.SOLUTION: A polymer alloy according to the present invention comprises a first liquid crystal polymer, a first non-liquid crystal polymer, and a compatibilizer that is a reaction product of a second liquid crystal polymer having a reactive group at its terminal and a second non-liquid crystal polymer having a reactive group capable of reacting with the reactive group at the terminal of the second liquid crystal polymer.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a polymer alloy, more particularly to a polymer alloy from which a molded article having excellent mechanical properties can be obtained, and to a molded article containing the polymer alloy. [Background technology]

[0002] Conventionally, liquid crystal polymers have excellent moldability and heat resistance, and therefore, molded products (for example, injection molded products) manufactured using liquid crystal polymers have been used in various electronic components.

[0003] In recent years, attempts have been made to improve various physical properties by mixing liquid crystal polymers with other resins such as non-liquid crystal polymers. However, when a non-liquid crystal polymer is mixed with a liquid crystal polymer, the liquid crystal polymer and the non-liquid crystal polymer are incompatible with each other, resulting in macrophase separation, which creates a large, fragile heterogeneous interface, resulting in various physical properties that are inferior to those of the liquid crystal polymer alone.

[0004] Therefore, in order to solve the above problems, a resin composition has been proposed in which a third component (compatibilizer) is added to a liquid crystal polymer and a non-liquid crystal polymer. For example, Patent Document 1 proposes a liquid crystal polyester resin composition comprising (A) polyphenylene ether, (B) liquid crystal polyester, and (C) a compound having one or more functional groups selected from an epoxy group, an oxazolyl group, an imide group, a carboxylic acid group, and an acid anhydride group, wherein component (C) is added in the form of a masterbatch that has been melt-kneaded in advance with part or all of component (B), and the resulting mixture is melt-kneaded with component (A), or with component (A) and the remaining component (B). Patent Document 2 proposes a polyamide resin composition comprising 100 parts by weight of a resin composition consisting of 20 to 80% by weight of an aromatic polyamide resin and 80 to 20% by weight of a modified polyphenylene ether resin (the sum of these weight percentages being 100% by weight), blended with 0.5 to 30 parts by weight of a liquid crystal polymer, 0.01 to 3 parts by weight of a compatibilizer, and 2 to 40 parts by weight of an inorganic filler. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Laid-Open No. 2009-30045 [Patent Document 2] Japanese Patent Application Publication No. 6-240132 Summary of the Invention [Problem to be solved by the invention]

[0006] In Patent Documents 1 and 2, a resin composition is obtained by adding a third component acting as a compatibilizer when mixing a liquid crystal polymer with another resin (polyphenylene ether). However, the third component used in these resin compositions has a molecular skeleton different from that of the liquid crystal polymer or polyphenylene ether. In Patent Document 1, a styrene / glycidyl methacrylate copolymer is used as a compatibilizer, but its heat resistance is inferior to that of the liquid crystal polymer or polyphenylene ether. Therefore, a stabilizer must be added to the liquid crystal polyester resin composition, and the liquid crystal polymer and the compatibilizer must be mixed in advance. In Patent Document 2, a low-molecular-weight compound that chemically reacts with the liquid crystal polymer is used as a compatibilizer, but excessive reaction during mixing can result in unwanted thickening and the generation of by-products. In terms of the affinity expected of a compatibilizer for each polymer, it was inferior to a compatibilizer with at least a partial identical structure, specifically, a compatibilizer with the same liquid crystal phase as a liquid crystal polymer that exhibits a liquid crystal phase when heated and melted, and was insufficient to improve physical properties (especially improving mechanical properties and maintaining heat resistance).

[0007] Therefore, an object of the present invention is to provide a polymer alloy that can give a molded article having excellent mechanical properties (e.g., flexural strength, flexural modulus, flexural elongation, Izod impact strength, weld strength, etc.), and the molded article. Another object of the present invention is to provide polymer alloys of a liquid crystal polymer with various non-liquid crystal polymers. Another object of the present invention is to provide an excellent polymer alloy by kneading a liquid crystal polymer, a non-liquid crystal polymer, and a compatibilizer in a single step. [Means for solving the problem]

[0008] The present inventors have found that a polymer alloy obtained by kneading a liquid crystal polymer, a non-liquid crystal polymer, and a compatibilizer having liquid crystallinity can improve the mechanical properties (e.g., flexural strength, flexural modulus, flexural elongation, Izod impact strength, weld strength, etc.) of the polymer alloy compared to a conventional polymer blend (without a compatibilizer) obtained by kneading a liquid crystal polymer and a non-liquid crystal polymer. The present invention was completed based on this finding.

[0009] That is, according to the present invention, the following inventions are provided. [1] a first liquid crystal polymer; a first non-liquid crystal polymer; a compatibilizer that is a reaction product of a second liquid crystal polymer having a terminal reactive group and a second non-liquid crystal polymer having a reactive group that can react with the terminal reactive group of the second liquid crystal polymer; A polymer alloy comprising: [2] The polymer alloy according to [1], wherein the reactive group at the end of the second liquid crystal polymer includes at least one selected from the group consisting of a carboxy group, a hydroxy group, an amide group, an acetyl group, and an amino group. [3] The polymer alloy according to [1] or [2], wherein the first liquid crystal polymer has a melting point of 270°C or higher. [4] The polymer alloy according to any one of [1] to [3], wherein the second liquid crystal polymer contains a structural unit derived from a hydroxycarboxylic acid. [5] The polymer alloy according to any one of [1] to [4], wherein the reactive group of the second non-liquid crystal polymer includes at least one selected from the group consisting of a carboxy group, a hydroxy group, an amide group, an acetyl group, and an amino group. [6] The polymer alloy according to any one of [1] to [5], wherein the second non-liquid crystal polymer contains polyphenylene ether. [7] The polymer alloy according to any one of [1] to [6], wherein the blending amount of the second non-liquid crystal polymer is 1 part by mass or more and 50 parts by mass or less per 100 parts by mass of the second liquid crystal polymer. [8] The polymer alloy according to any one of [1] to [7], wherein the compatibilizer has a cyclic acid anhydride group. [9] The polymer alloy according to any one of [1] to [8], wherein the cyclic acid anhydride group is at least one selected from the group consisting of a maleic anhydride group, a succinic anhydride group, a phthalic anhydride group, and a glutaric anhydride group.

[10] The polymer alloy according to any one of [1] to [9], wherein the first liquid crystal polymer contains a structural unit derived from a hydroxycarboxylic acid.

[11] The polymer alloy according to any one of [1] to

[10] , wherein the first non-liquid crystal polymer comprises at least one selected from the group consisting of polyether, polyamide, polysulfone, polyimide, polyimideamide, and polyether ketone.

[12] A polymer alloy according to any one of [1] to

[11] , wherein the amount of the compatibilizer is 0.1 parts by mass or more and 50 parts by mass or less per 100 parts by mass of the first liquid crystal polymer and the first non-liquid crystal polymer combined.

[13] A polymer alloy according to any one of [1] to

[11] , wherein the amount of the compatibilizer is 0.1 parts by mass or more and 20 parts by mass or less per 100 parts by mass of the total of the first liquid crystal polymer and the first non-liquid crystal polymer.

[14] A polymer alloy according to any one of [1] to

[13] , wherein the blending amount of the first non-liquid crystal polymer is 0.1 parts by mass or more and 50 parts by mass or less per 100 parts by mass of the total of the first liquid crystal polymer and the first non-liquid crystal polymer.

[15] A molded article comprising the polymer alloy according to any one of [1] to

[14] .

[16] An electric / electronic component comprising the molded article according to

[15] . [Effects of the Invention]

[0010] According to the present invention, it is possible to provide a polymer alloy from which a molded article having excellent mechanical properties (e.g., flexural strength, flexural modulus, flexural elongation, Izod impact strength, weld strength, etc.) can be obtained. Furthermore, according to the present invention, it is possible to provide a molded article having excellent mechanical properties. Modes for carrying out the invention

[0011] [Polymer alloy] The polymer alloy according to the present invention includes a first liquid crystal polymer, a first non-liquid crystal polymer, and a compatibilizer. In the present invention, the polymer alloy includes a compatibilizer that has excellent affinity with both the first liquid crystal polymer and the first non-liquid crystal polymer, thereby improving the mechanical properties (e.g., flexural strength, flexural modulus, flexural elongation, Izod impact strength, weld strength, etc.) of the molded article.

[0012] [Polymer alloy manufacturing method] The method for producing the polymer alloy according to the present invention is not particularly limited. For example, the polymer alloy according to the present invention can be produced by kneading a first liquid crystal polymer, a first non-liquid crystal polymer, and a compatibilizer by a conventionally known method. In particular, the polymer alloy according to the present invention is preferably produced by kneading the first liquid crystal polymer, the first non-liquid crystal polymer, and the compatibilizer using an extruder equipped with a twin-screw kneader. Conditions such as the kneading temperature and time can be adjusted appropriately depending on the types of the first liquid crystal polymer, the first non-liquid crystal polymer, and the compatibilizer.

[0013] (First liquid crystal polymer) The first liquid crystal polymer is not particularly limited, and conventionally known liquid crystal polymers can be used. In a preferred embodiment of the present invention, the first liquid crystal polymer preferably contains a structural unit (I) derived from a hydroxycarboxylic acid, and may further contain a structural unit (II) derived from a diol and a structural unit (III) derived from a dicarboxylic acid, or may further contain a structural unit (IV) derived from an aromatic monomer having two functional groups (excluding the structural units (I) to (III)). Each structural unit will be described in detail below.

[0014] The melting point of the first liquid crystal polymer is not particularly limited, but considering heat resistance, it is generally required to be 250°C or higher. The lower limit of the melting point of the first liquid crystal polymer is preferably 270°C or higher, more preferably 280°C or higher, even more preferably 300°C or higher, and even more preferably 310°C or higher. The upper limit of the melting point of the first liquid crystal polymer may be, for example, 370°C or lower. By setting the melting point of the first liquid crystal polymer within the above numerical range, it is possible to maintain moldability within a practical temperature range while improving the heat resistance of molded articles produced using the polymer alloy against heat processing. In this specification, the melting point of the first liquid crystal polymer is a value measured by a differential scanning calorimeter (DSC). Specifically, the temperature is raised from 30°C to 350-400°C at a rate of 10°C / min to completely melt the first liquid crystal polymer, then the temperature is lowered to 30°C at a rate of 10°C / min, and then the temperature is raised again at a rate of 10°C / min to the same temperature as in the first cycle. The temperature at the apex of the endothermic peak in the second cycle of the temperature rise process is defined as Tm2, ​​and Tm2 is defined as the melting point (°C).

[0015] The liquid crystallinity of the first liquid crystal polymer can be confirmed by using a polarizing microscope (product name: ECLIPSE E600 POL) manufactured by Nikon Corporation equipped with a large specimen cooling and heating stage for microscopes (product name: 10083L) manufactured by Japan High Tech, to heat and melt the first liquid crystal polymer on the microscope heating stage, and then observing whether or not it has optical anisotropy.

[0016] Hereinafter, each of the structural units contained in the first liquid crystal polymer according to the present invention will be described in detail.

[0017] (Structural unit (I) derived from hydroxycarboxylic acid) The structural unit (I) derived from a hydroxycarboxylic acid is preferably a structural unit derived from an aromatic hydroxycarboxylic acid, and more preferably a structural unit derived from an aromatic hydroxycarboxylic acid represented by the following formula (1): Only one type of structural unit (I) may be contained, or two or more types may be contained.

[0018] [ka] In the above formula, Ar 1 is a structure derived from an aromatic hydrocarbon, and may have a substituent or a hetero element as desired. Examples of the structure derived from an aromatic hydrocarbon include those having a skeleton derived from a monocyclic benzene, an aromatic polycyclic compound such as biphenyl or 4,4'-isopropylidenediphenyl, or a condensed compound such as naphthalene, anthracene, or phenanthrene. Examples of the substituent include a hydrogen atom, an alkyl group, an alkoxy group, and a fluorine atom. The alkyl group preferably has 1 to 10 carbon atoms, more preferably 1 to 5 carbon atoms. The alkyl group may be a linear or branched alkyl group. The alkoxy group preferably has 1 to 10 carbon atoms, more preferably 1 to 5 carbon atoms.

[0019] Examples of raw material monomers that provide the structural unit represented by formula (I) include 6-hydroxy-2-naphthoic acid (HNA), p-hydroxybenzoic acid (HBA), m-hydroxybenzoic acid (m-HBA), and acylated products, ester derivatives, and acid halides thereof.

[0020] From the viewpoint of mechanical properties, the composition ratio (mol %) of the structural unit (I) in the first liquid crystal polymer has a lower limit of preferably 30 mol % or more, more preferably 35 mol % or more, and particularly preferably 40 mol % or more, and an upper limit of preferably 100 mol % or less, 90 mol % or less, or 80 mol % or less.

[0021] (Diol-derived structural unit (II)) The diol-derived structural unit (II) is preferably a structural unit derived from an aromatic diol, and is preferably a structural unit derived from an aromatic diol represented by the following formula (2): Only one type of structural unit (II) may be contained, or two or more types may be contained.

[0022] [ka] In the above formula, Ar 2 is a structure derived from an aromatic hydrocarbon, and may have a substituent or a hetero element as desired. Examples of the structure derived from an aromatic hydrocarbon include those having a skeleton derived from a monocyclic benzene, an aromatic polycyclic compound such as biphenyl or 4,4'-isopropylidenediphenyl, or a condensed compound such as naphthalene, anthracene, or phenanthrene. Examples of the substituent include a hydrogen atom, an alkyl group, an alkoxy group, and a fluorine atom. The alkyl group preferably has 1 to 10 carbon atoms, more preferably 1 to 5 carbon atoms. The alkyl group may be a linear or branched alkyl group. The alkoxy group preferably has 1 to 10 carbon atoms, more preferably 1 to 5 carbon atoms.

[0023] Examples of raw material monomers that provide the structural unit (II) include 4,4'-dihydroxybiphenyl (BP), hydroquinone (HQ), methylhydroquinone (MeHQ), 4,4'-isopropylidenediphenol (BisPA), and their acylated derivatives, ester derivatives, and acid halides.

[0024] From the viewpoint of mechanical properties, the composition ratio (mol %) of the structural unit (II) in the first liquid crystal polymer has a lower limit of preferably 5 mol % or more, more preferably 10 mol % or more, and an upper limit of preferably 35 mol % or less, more preferably 32.5 mol % or less, and even more preferably 30 mol % or less.

[0025] (Structural unit (III) derived from dicarboxylic acid) The structural unit (III) derived from a dicarboxylic acid is preferably a structural unit derived from an aromatic dicarboxylic acid, and is preferably a structural unit derived from an aromatic dicarboxylic acid represented by the following formula (3): Only one type of structural unit (III) may be contained, or two or more types may be contained.

[0026] [ka] In the above formula, Ar 3 is a structure derived from an aromatic hydrocarbon, and may have a substituent or a hetero element as desired. Examples of the structure derived from an aromatic hydrocarbon include those having a skeleton derived from a monocyclic benzene, an aromatic polycyclic compound such as biphenyl or 4,4'-isopropylidenediphenyl, or a condensed compound such as naphthalene, anthracene, or phenanthrene. Examples of the substituent include a hydrogen atom, an alkyl group, an alkoxy group, and a fluorine atom. The alkyl group preferably has 1 to 10 carbon atoms, more preferably 1 to 5 carbon atoms. The alkyl group may be a linear or branched alkyl group. The alkoxy group preferably has 1 to 10 carbon atoms, more preferably 1 to 5 carbon atoms.

[0027] Examples of raw material monomers that provide the structural unit (III) include terephthalic acid (TPA), isophthalic acid (IPA), 2,6-naphthalenedicarboxylic acid (NADA), and acylated products, ester derivatives, and acid halides thereof.

[0028] From the viewpoint of mechanical properties, the composition ratio (mol %) of the structural unit (III) in the first liquid crystal polymer has a lower limit of preferably 5 mol % or more, more preferably 10 mol % or more, and an upper limit of preferably 35 mol % or less, more preferably 32.5 mol % or less, and even more preferably 30 mol % or less.

[0029] (Structural unit (IV) derived from an aromatic monomer having two functional groups) In addition to the above-described structural units (I) to (III), the first liquid crystal polymer may also contain a structural unit (IV) derived from an aromatic monomer having two functional groups. The two functional groups in the structural unit (IV) are selected from the group consisting of a hydroxy group, a carboxy group, and an amino group, and preferably contain at least one amino group. Examples of aromatic monomers having two functional groups include aromatic hydroxy monoamines and aromatic diamines.

[0030] An example of a structural unit derived from an aromatic hydroxymonoamine is a structural unit represented by the following formula (4): Raw material monomers that provide this structural unit include acetaminophen (AAP), p-aminophenol, etc. [ka]

[0031] An example of a structural unit derived from an aromatic diamine is a structural unit represented by the following formula (5): Raw material monomers that provide this structural unit include 4,4'-diaminodiphenyl ether (ODA) and the like. [ka]

[0032] The composition ratio (mol%) of the structural unit (IV) in the first liquid crystal polymer can be appropriately adjusted according to the composition ratios of the other structural units. The composition ratio (mol%) of the structural unit (IV) is preferably 10 mol% or less, more preferably 7 mol% or less, even more preferably 5 mol% or less, still more preferably 3 mol% or less, and may be 0 mol%.

[0033] (First method for producing liquid crystal polymer) The first liquid crystal polymer can be produced, for example, by polymerizing the raw material monomers of the first liquid crystal polymer described above by a conventionally known method. In a preferred embodiment of the present invention, the first liquid crystal polymer can be produced only by melt polymerization. Alternatively, the first liquid crystal polymer can be produced by a method (two-stage polymerization) including a step of obtaining a polymer by melt polymerization and a step of obtaining a polymer alloy by solid-state polymerization of the polymer.

[0034] From the viewpoint of efficiently obtaining the first liquid crystal polymer, the melt polymerization is preferably carried out under reflux of acetic acid in the presence of 1.03 to 1.15 molar equivalents of acetic anhydride relative to the total hydroxyl groups possessed by all raw material monomers of the liquid crystal polymer.

[0035] The reaction temperature for melt polymerization is preferably in the range of the melting point to (melting point + 70)°C, more preferably in the range of (melting point + 20)°C to (melting point + 50)°C.

[0036] The melt polymerization is preferably carried out in the presence of a catalyst without a solvent. As the catalyst, a conventionally known catalyst for polymer polymerization can be used. Examples of the catalyst include metal salt catalysts such as potassium acetate, magnesium acetate, stannous acetate, lead acetate, sodium acetate, tetrabutyl titanate, and antimony trioxide, nitrogen-containing heterocyclic compounds such as N-methylimidazole, and organic compound catalysts. The amount of catalyst used is not particularly limited, but is preferably the total number of moles of monomers × (10 to 100) mg / mol.

[0037] When performing solid-state polymerization, the polymer obtained by melt polymerization may be cooled and solidified, and then pulverized into powder or flakes. Alternatively, the polymer strands obtained by melt polymerization may be pelletized. The reaction temperature for solid-state polymerization is preferably the melting point or lower, and is preferably (melting point - 30)°C to (melting point - 10)°C. Solid-state polymerization may be performed with stirring, or may be performed in a stationary state without stirring.

[0038] The polymerization reactor is not particularly limited, but a reactor generally used for reactions of high-viscosity fluids is preferably used. Examples of such reactors include stirred tank-type polymerization reactors having stirrers with stirring blades of various shapes, such as anchor-type, multi-stage-type, spiral belt-type, and spiral shaft-type, or modified versions of these, as well as mixing devices generally used for kneading resins, such as kneaders, roll mills, and Banbury mixers.

[0039] (First non-liquid crystal polymer) The first non-liquid crystal polymer is a resin other than the above-mentioned liquid crystal polymer, and is not particularly limited, and any conventionally known non-liquid crystal polymer can be used. In a preferred embodiment of the present invention, the first non-liquid crystal polymer preferably contains at least one selected from the group consisting of polyether, polyamide, polysulfone, polyimide, polyimideamide, and polyetherketone, and more preferably contains at least one of polyether and polyamide.

[0040] In the present invention, it is preferable to use polyphenylene ether as the polyether. In the present invention, conventionally known polyphenylene ethers can be used as the polyphenylene ether. Polyphenylene ether (PPE) is a compound having a polyphenylene ether chain in the molecule. The polyphenylene ether of the present invention also includes its modified product, modified polyphenylene ether (m-PPE). The modified polyphenylene ether of the present invention also includes an alloy of polyphenylene ether (PPE) with other synthetic resins. Examples of other synthetic resins include polystyrene (PS), polyphenylene sulfide (PPS), polypropylene (PP), polyamide (PA), and polyacetal (POM).

[0041] The amount of the first non-liquid crystal polymer in the polymer alloy, relative to 100 parts by mass of the total of the first liquid crystal polymer and the first non-liquid crystal polymer, is preferably 0.1 parts by mass or more, more preferably 1 part by mass or more, even more preferably 3 parts by mass or more, and even more preferably 5 parts by mass or more, and the upper limit is preferably 50 parts by mass or less, more preferably 45 parts by mass or less, even more preferably 40 parts by mass or less, and even more preferably 35 parts by mass or less. If the amount of the first non-liquid crystal polymer in the polymer alloy is within the above numerical range, it becomes easier to impart desired physical properties to the polymer alloy.

[0042] (Compatibilizer) The compatibilizer is a reaction product of a second liquid crystal polymer having a reactive group at its terminal and a second non-liquid crystal polymer having a reactive group capable of reacting with the reactive group at the terminal of the second liquid crystal polymer. The reaction method and reaction conditions are not particularly limited and can be appropriately set depending on the type of reactive group of the second liquid crystal polymer and the type of reactive group of the second non-liquid crystal polymer. For example, a reaction product can be obtained by a polymerization reaction (melt polymerization, solid-state polymerization) between the raw material monomer of the second liquid crystal polymer and the second non-liquid crystal polymer.

[0043] From the viewpoint of improving the mechanical properties of the molded article, the compatibilizer preferably has a cyclic acid anhydride group. Examples of the cyclic acid anhydride group include at least one selected from the group consisting of maleic anhydride, succinic anhydride, phthalic anhydride, and glutaric anhydride. In a preferred embodiment of the present invention, the cyclic acid anhydride group may be introduced into the reaction product by reacting the reaction product obtained by reacting the second liquid crystal polymer with the second non-liquid crystal polymer with a compound having a cyclic acid anhydride group. Alternatively, the cyclic acid anhydride group may be introduced into the reaction product in the same step as the polymerization reaction by adding a compound having a cyclic acid anhydride group to the reaction system of the raw material monomers of the second liquid crystal polymer and the second non-liquid crystal polymer.

[0044] The compatibilizer has a second liquid crystal polymer portion that improves the affinity with the first liquid crystal polymer, which is a raw material for the polymer alloy, and a second non-liquid crystal polymer portion that improves the affinity with the first non-liquid crystal polymer, which is a raw material for the polymer alloy. Therefore, by adding the compatibilizer when kneading the first liquid crystal polymer and the first non-liquid crystal polymer, the affinity between them is improved, macrophase separation is suppressed, and a polymer alloy can be produced that can produce molded products with excellent mechanical properties.

[0045] The compatibilizer preferably has liquid crystallinity. Since polymers having the same liquid crystal phase are generally compatible with each other, the addition of a compatibilizer having liquid crystallinity improves the affinity with the first liquid crystal polymer compared to a compatibilizer without liquid crystallinity, making it easier to produce a polymer alloy that can produce a molded product with superior mechanical properties regardless of the type of the first non-liquid crystal polymer.

[0046] The amount of the compatibilizer in the polymer alloy is preferably 0.1 parts by mass or more, more preferably 1 part by mass or more, even more preferably 2 parts by mass or more, and even more preferably 3 parts by mass or more, relative to 100 parts by mass of the total of the first liquid crystal polymer and the first non-liquid crystal polymer, and the upper limit is preferably 40 parts by mass or less, more preferably 30 parts by mass or less, even more preferably 20 parts by mass or less, and even more preferably 15 parts by mass or less. If the amount of the compatibilizer in the polymer alloy is within the above numerical range, the effect of improving the affinity for the first liquid crystal polymer and the first non-liquid crystal polymer can be obtained, and a polymer alloy can be produced that can produce a molded product with excellent mechanical properties.

[0047] (Second liquid crystal polymer) The second liquid crystal polymer used in the reaction product has a reactive group at its terminal. The reactive group at the terminal of the liquid crystal polymer preferably contains at least one selected from the group consisting of a carboxy group, a hydroxy group, an amide group, an acetyl group, and an amino group, and more preferably contains a carboxy group. In one embodiment of the present invention, these reactive groups can be introduced into the terminal of the liquid crystal polymer by polymerization using raw material monomers having these reactive groups.

[0048] In a preferred embodiment of the present invention, the second liquid crystal polymer preferably contains a structural unit (I) derived from a hydroxycarboxylic acid, and may further contain a structural unit (II) derived from a diol and a structural unit (III) derived from a dicarboxylic acid, and may further contain a structural unit (IV) derived from an aromatic monomer having two functional groups (excluding the structural units (I) to (III)). Each structural unit is as described in detail for the first liquid crystal polymer.

[0049] In a preferred embodiment of the present invention, the first liquid crystal polymer and the second liquid crystal polymer preferably contain the same type of structural units. By containing the same type of structural units, the effect of improving affinity by adding a compatibilizer can be more effectively achieved. For example, if the first liquid crystal polymer contains structural units derived from a hydroxycarboxylic acid, the second liquid crystal polymer preferably also contains structural units derived from a hydroxycarboxylic acid.

[0050] (Second non-liquid crystal polymer) The second non-liquid crystal polymer is a resin other than the liquid crystal polymer described above, and has a reactive group capable of reacting with the reactive group at the terminal of the second liquid crystal polymer. The reactive group of the second non-liquid crystal polymer preferably includes at least one selected from the group consisting of a carboxy group, a hydroxy group, an amide group, an acetyl group, and an amino group, and more preferably includes a hydroxy group.

[0051] The non-liquid crystal polymer is preferably an amorphous polymer. Examples of amorphous polymers having a reactive group include polyphenylene ether, polyvinyl alcohol, amorphous polyarylate, poly(meth)acrylate, and polycarbonate. Among these, polyphenylene ether having a hydroxy group at the polymer terminal is preferred. As explained above in (First non-liquid crystal polymer), the polyphenylene ether of the present invention also includes modified polyphenylene ether (m-PPE), which is a modified product thereof. These amorphous polymers may be used alone or in combination of two or more.

[0052] The non-liquid crystal polymer may also include another polymer that is compatible with the amorphous polymer having a reactive group, such as polystyrene and polystyrene-hydrogenated polybutadiene (SEBS).

[0053] The amount of the second non-liquid crystal polymer in the compatibilizer is preferably 1 part by mass or more, more preferably 3 parts by mass or more, even more preferably 5 parts by mass or more, and even more preferably 10 parts by mass or more, relative to 100 parts by mass of the second liquid crystal polymer, and the upper limit is preferably 50 parts by mass or less, more preferably 45 parts by mass or less, even more preferably 40 parts by mass or less, and even more preferably 35 parts by mass or less. If the amount of the second non-liquid crystal polymer in the compatibilizer is within the above numerical range, the effect of improving affinity for the first liquid crystal polymer and the first non-liquid crystal polymer can be obtained, and a polymer alloy can be produced that can produce a molded product with excellent mechanical properties.

[0054] [Molded products] The molded article according to the present invention contains the above-mentioned polymer alloy. By containing the above-mentioned polymer alloy, the molded article has excellent mechanical properties.

[0055] (filler) The molded article may further contain a filler. Examples of fillers include carbon fiber, graphite, glass fiber, talc, mica, glass flakes, clay, sericite, calcium carbonate, calcium sulfate, calcium silicate, silica, alumina, aluminum hydroxide, calcium hydroxide, graphite, potassium titanate, titanium oxide, fluorocarbon resin fiber, fluorocarbon resin, barium sulfate, and various whiskers. These fillers may be used alone or in combination of two or more.

[0056] The content of the filler in the molded article is preferably 1% by mass or more and 70% by mass or less, more preferably 5% by mass or more and 60% by mass or less, even more preferably 10% by mass or more and 50% by mass or less, and even more preferably 15% by mass or more and 45% by mass or less, based on the total amount of the molded article. When two or more fillers are contained, it is preferable that the total content thereof is within the above range. If the content of the filler in the molded article is within the above range, it is preferable because a molded article having excellent mechanical properties can be obtained.

[0057] (other resins) The molded article may further contain other resins in addition to the polymer alloys described above, provided that the resin does not deviate from the spirit of the present invention. Examples of such resins include polyester resins such as polyethylene terephthalate, polyethylene naphthalate, polyarylate, polycyclohexylene dimethylene terephthalate, and polybutylene terephthalate; polyolefin resins such as polyethylene and polypropylene; cycloolefin polymers; vinyl resins such as polyvinyl chloride; (meth)acrylic resins such as polyacrylate, polymethacrylate, and polymethyl methacrylate; imide resins such as polyacetal resins, polyamide resins, polyimides, and polyetherimides; polystyrene resins such as polystyrene, high-impact polystyrene, AS resin, and ABS resin; thermosetting resins such as epoxy resins; cellulose resins, polyether ether ketone resins, fluororesins, and polycarbonate resins. These resins may be used alone or in combination of two or more.

[0058] The content of the resin other than the polymer alloy in the molded article is preferably 5 parts by mass or more and preferably 20 parts by mass or less based on the non-liquid crystal polymer introduced into the system.

[0059] (Other additives) The molded article may contain other additives, such as colorants, dispersants, plasticizers, antioxidants, curing agents, flame retardants, heat stabilizers, ultraviolet absorbers, antistatic agents, and surfactants, within the scope of the present invention.

[0060] The shape of the molded product is not particularly limited and may be changed appropriately depending on the application, and may be, for example, a plate, sheet, film, fiber, powder, or the like.

[0061] The molded article can be produced by a conventionally known molding method using a mixture containing the above-mentioned polymer alloy and, if desired, fillers, other resins, other additives, etc. The mixture can be obtained by melt-kneading the above-mentioned polymer alloy, etc. using a Banbury mixer, kneader, single-screw or twin-screw extruder, etc. In addition, examples of molding methods for molded articles include press molding, foam molding, injection molding, melt spinning, solution spinning, calendar molding, and punch molding.

[0062] [Electrical and electronic components] The electric / electronic component according to the present invention comprises a molded article (e.g., a fibrous molded article or an injection-molded article) containing a polymer alloy. Examples of electric / electronic components comprising the molded article include antennas used in electronic devices and communication devices such as ETC, GPS, wireless LAN, and mobile phones, high-speed transmission connectors, CPU sockets, circuit boards, flexible printed circuit boards (FPCs), laminated circuit boards, millimeter-wave and quasi-millimeter-wave radars such as collision prevention radars, RFID tags, capacitors, inverter components, insulating films, cable covering materials, insulating materials for secondary batteries such as lithium-ion batteries, and speaker diaphragms. [Example]

[0063] The present invention will be described in more detail below with reference to examples, but the present invention is not limited to these examples.

[0064] [Test Example 1] <First Example of Liquid Crystal Polymer Production> A polymerization vessel equipped with a stirring blade was charged with 27 mol% 6-hydroxy-2-naphthoic acid (HNA) and 73 mol% p-hydroxybenzoic acid (HBA) as raw material monomers for the first liquid crystal polymer, and magnesium acetate and potassium acetate were added as catalysts. Subsequently, the polymerization vessel was subjected to three cycles of vacuum decompression and nitrogen injection, after which acetic anhydride (1.05 molar equivalents relative to the hydroxyl groups) was further added, the temperature was raised to 160°C, and the acetylation reaction was carried out under reflux for 1.5 hours.

[0065] After the acetylation was completed, the polymerization vessel, which had been in a state of acetic acid distillation, was heated to 320°C at a rate of 0.5°C / min. During this time, acetic acid as a by-product was distilled off as the esterification reaction progressed. After reaching 320°C, the vessel was stirred for 20 minutes, and then the system was depressurized while maintaining the temperature at 320°C to promote the distillation of acetic acid as a by-product. In this state, the pressure was gradually reduced to 200 hPa over 20 minutes. After that, the viscosity of the polymer was measured based on the power consumption and torque of the agitator. -1 When the viscosity reached approximately 20 Pa·s, the polymer was extracted and cooled to solidify. If the target viscosity was not reached after maintaining the pressure at 200 hPa for more than an hour, the pressure was further reduced to 10 hPa. After the reaction, the amount of acetic acid distilled was measured and found to be 99-100% of the theoretical reaction standard. The obtained polymer was allowed to cool naturally at room temperature and then crushed to a size that could pass through a sieve with 2.0 mm openings, yielding the first liquid crystal polymer A.

[0066] The obtained polymer was heated and melted on the heating stage of a polarizing microscope (product name: ECLIPSE E600 POL) manufactured by Nikon Corporation equipped with a large cooling and heating stage for microscopes (product name: 10083L) manufactured by Japan High Tech Co., Ltd., and the liquid crystallinity was confirmed based on the presence or absence of optical anisotropy.

[0067] The melting point of the first liquid crystal polymer was measured using a differential scanning calorimeter (DSC). Specifically, the first liquid crystal polymer was heated from 30°C to 350-400°C at a rate of 10°C / min until completely melted, then cooled to 30°C at a rate of 10°C / min, and heated again at a rate of 10°C / min to the same temperature as in the first cycle. The temperature at the apex of the endothermic peak in the second cycle of the heating process was taken as Tm2, ​​and Tm2 was taken as the melting point (°C). As a result of the measurement, the melting point of the first liquid crystal polymer was 285°C.

[0068] <Production Example of Compatibilizer A> A polymerization vessel equipped with a stirring blade was charged with 27 mol% 6-hydroxy-2-naphthoic acid (HNA) and 73 mol% p-hydroxybenzoic acid (HBA) as raw material monomers for the second liquid crystal polymer. Furthermore, poly(2,6-dimethyl-1,4-phenylene ether) (containing terminal hydroxy groups, Mw: 6300, Mn: 2350, manufactured by SABIC, product name: SA120) as the second non-liquid crystal polymer, and magnesium acetate and potassium acetate as catalysts. The amount of the second non-liquid crystal polymer was 15.8 parts by mass per 100 parts by mass of the second liquid crystal polymer (total raw material monomers). Subsequently, the polymerization vessel was subjected to three cycles of vacuum decompression and nitrogen injection. Then, acetic anhydride (1.05 molar equivalents relative to the hydroxyl groups) was further added, and the temperature was raised to 160 °C. The acetylation reaction was carried out under reflux for 1.5 hours.

[0069] After the acetylation was completed, the polymerization vessel, which had been in a state of acetic acid distillation, was heated to 320°C at a rate of 0.5°C / min. During this time, acetic acid as a by-product was distilled off as the esterification reaction progressed. After reaching 320°C, the vessel was stirred for 20 minutes, and then the system was depressurized while maintaining the temperature at 320°C to promote the distillation of acetic acid as a by-product. In this state, the pressure was gradually reduced to 200 hPa over 20 minutes. After that, the viscosity of the polymer was measured based on the power consumption and torque of the agitator. -1The polymer was extracted when the viscosity exceeded 20 Pa·s and cooled to solidify. If the target viscosity was not reached after maintaining the pressure at 200 hPa for more than an hour, the pressure was further reduced to 10 hPa. After the reaction, the amount of acetic acid distilled was measured and found to be 99-100% of the theoretical reaction standard. The resulting polymer was allowed to cool naturally at room temperature and then crushed to a size that could pass through a 2.0 mm mesh sieve. The crushed polymer was then washed with toluene, a good solvent for the second non-liquid crystal polymer (SA120), to remove any unreacted second non-liquid crystal polymer (SA120) remaining in the polymer. The washed solid was then dried and the toluene was removed to obtain compatibilizer A. Compatibilizer A was heated and melted on the heating stage of a polarizing microscope manufactured by Nikon Corporation (product name: ECLIPSE E600 POL) equipped with a large cooling and heating stage for microscopes manufactured by Japan High Tech (product name: 10083L). Optical anisotropy was confirmed, and it was therefore determined that compatibilizer A had liquid crystallinity.

[0070] <Example of polymer alloy manufacturing> (Example 1-1) 70 parts by mass of the first liquid crystal polymer produced above, 30 parts by mass of a modified polyphenylene ether resin (an alloy of poly(2,6-dimethyl-1,4-phenylene oxide) and polystyrene ((PPE / PS), manufactured by Global Polyacetal Corporation, product name: Iupiace AH60)) as a first non-liquid crystal polymer, and 5 parts by mass of the compatibilizer A produced above were kneaded at 340°C using a twin-screw kneader (Labo Plastomill Micro, small extrusion segment 2D15W, manufactured by Toyo Seiki Seisakusho, Ltd.) to obtain a polymer alloy.

[0071] (manufacturing of molded products) The obtained polymer alloy was heated and melted at 310°C using an injection molding machine and injected into a mold at a temperature of 80°C to prepare a bending test piece of 80 mm (flow direction) x 12 mm x 2 mm (thickness).

[0072] (Example 1-2) A polymer alloy was obtained in the same manner as in Example 1-1, except that the blending amount of compatibilizer A was changed to 10 parts by mass in the production of the polymer alloy. Next, a bending test piece was prepared using the obtained polymer alloy in the same manner as in Example 1-1.

[0073] (Comparative Example 1-1) A polymer blend was obtained in the same manner as in Example 1-1, except that the compatibilizer A was not added in the production of the polymer alloy. Next, a bending test piece was prepared using the obtained polymer blend in the same manner as in Example 1-1.

[0074] (Reference example 1-1) The above-prepared compatibilizer A was kneaded alone at 340°C using a twin-screw kneader. Next, bending test pieces were prepared using the obtained kneaded product in the same manner as in Example 1-1.

[0075] <Mechanical property measurements> (Measurement of bending strength, bending modulus, bending elongation) For each bending test piece obtained above, the bending strength (MPa), bending modulus (GPa), and bending elongation (%) were measured at room temperature using a universal testing machine (Strograph VG, manufactured by Toyo Seiki Co., Ltd.) in accordance with JIS K7171 under the conditions of indenter radius = support table radius = 5.0 mm, support distance 50 mm, and test speed 2 mm / min. The average values ​​of N = 5 measurements for each bending test piece are shown in Table 1.

[0076] [Table 1]

[0077] From the results in Table 1, it was found that by adding a compatibilizer A (Reference Example 1-1) with lower mechanical properties than the polymer blend of Comparative Example 1-1 to a liquid crystal polymer and a first non-liquid crystal polymer, a polymer alloy with superior mechanical properties to the polymer blend of Comparative Example 1-1 could be produced (Examples 1-1 to 1-2). Although the flexural strength of Reference Example 1-1 itself was low, the examples containing this low-strength component had higher strength than the comparative examples, indicating that compatibilizer A functioned as a compatibilizer between the first liquid crystal polymer and the first non-liquid crystal polymer. Furthermore, the improvement in physical properties due to the addition of this compatibilizer was achieved by mixing the compatibilizer and liquid crystal polymer in one step, without the need to separately mix them to create a masterbatch in advance.

[0078] [Test Example 2] <Production Example of Compatibilizer B> A polymerization vessel equipped with a stirring blade was charged with 27 mol% 6-hydroxy-2-naphthoic acid (HNA) and 73 mol% p-hydroxybenzoic acid (HBA) as raw material monomers for the second liquid crystal polymer. Furthermore, poly(2,6-dimethyl-1,4-phenylene ether) (containing terminal hydroxy groups, Mw: 47600, Mn: 17300, manufactured by SABIC Corporation, product name: NORYLPPO630) was charged as a second non-liquid crystal polymer, and magnesium acetate and potassium acetate were added as catalysts. The amount of the second non-liquid crystal polymer was 15.8 parts by mass per 100 parts by mass of the second liquid crystal polymer (total raw material monomers). Subsequently, the polymerization vessel was subjected to three cycles of vacuum decompression and nitrogen injection. Then, acetic anhydride (1.05 molar equivalents relative to the hydroxyl groups) was further added, and the temperature was raised to 160 °C. The acetylation reaction was carried out under reflux for 1.5 hours.

[0079] After the acetylation was completed, the polymerization vessel, which had been in a state of acetic acid distillation, was heated to 320°C at a rate of 0.5°C / min. During this time, acetic acid as a by-product was distilled off as the esterification reaction progressed. After reaching 320°C, the vessel was stirred for 20 minutes, and then the system was depressurized while maintaining the temperature at 320°C to promote the distillation of acetic acid as a by-product. In this state, the pressure was gradually reduced to 200 hPa over 20 minutes. After that, the viscosity of the polymer was measured based on the power consumption and torque of the agitator. -1The polymer was extracted when the viscosity reached approximately 20 Pa·s and cooled to solidify. If the target viscosity was not reached after maintaining the pressure at 200 hPa for more than an hour, the pressure was further reduced to 10 hPa. After the reaction, the amount of acetic acid distilled was measured and found to be 99-100% of the theoretical reaction standard. The resulting polymer was allowed to cool naturally at room temperature, then crushed to a size that could pass through a sieve with 2.0 mm openings to obtain compatibilizer B. As with compatibilizer A, optical anisotropy was confirmed for compatibilizer B, and it was therefore determined to have liquid crystallinity.

[0080] <Production Example of Compatibilizer C> Compatibilizer C was obtained in the same manner as in the production example of compatibilizer B, except that the temperature was raised from room temperature to 250°C under reduced pressure of 100 kPa in a vacuum oven (Yamato Scientific Co., Ltd., square vacuum dryer DP23), and then the temperature was maintained at 250°C for 6 hours to carry out solid-state polymerization. Compatibilizer C was confirmed to have optical anisotropy in the same manner as compatibilizer A, and was therefore determined to have liquid crystallinity.

[0081] <Example of polymer alloy manufacturing> Example 2-1 A polymer alloy was obtained in the same manner as in Example 1-1, except that the compatibilizer A was changed to the compatibilizer B in the production of the polymer alloy. Next, a bending test piece was prepared using the obtained polymer alloy in the same manner as in Example 1-1.

[0082] (Example 2-2) A polymer alloy was obtained in the same manner as in Example 2-1, except that the blending amount of compatibilizer B in the production of the polymer alloy was changed to 10 parts by mass. Next, a bending test piece was prepared using the obtained polymer alloy in the same manner as in Example 1-1.

[0083] (Example 2-3) A polymer alloy was obtained in the same manner as in Example 1-1, except that the compatibilizer A was changed to the compatibilizer C in the production of the polymer alloy. Next, a bending test piece was prepared using the obtained polymer alloy in the same manner as in Example 1-1.

[0084] (Examples 2-4) A polymer alloy was obtained in the same manner as in Example 2-3, except that the blending amount of compatibilizer C in the production of the polymer alloy was changed to 10 parts by mass. Next, a bending test piece was prepared using the obtained polymer alloy in the same manner as in Example 1-1.

[0085] (Reference example 2-1) The compatibilizer B produced above was kneaded at 340°C using a twin-screw kneader. Next, bending test pieces were prepared using the obtained kneaded product in the same manner as in Example 1-1.

[0086] (Reference example 2-2) The compatibilizer C produced above was kneaded at 340°C using a twin-screw kneader. Next, bending test pieces were prepared using the obtained kneaded product in the same manner as in Example 1-1.

[0087] <Mechanical property measurements> (Measurement of bending strength, bending modulus, bending elongation) The bending strength (MPa), bending modulus (GPa), and bending elongation (%) of each of the bending test pieces obtained above were measured in the same manner as in Test Example 1. The measurement results are shown in Table 2. The results of Comparative Example 1-1 are also shown in Table 2.

[0088] (Measurement of Izod impact strength) For each of the bending test pieces obtained above and in Comparative Example 1-1, an IT-type impact tester (manufactured by Toyo Seiki Seisakusho Co., Ltd.) was used in accordance with JIS K7110. A pendulum with a weight of 5.5 J and a pendulum tip radius of 0.8 mm was released from a lifting angle of 150° at room temperature and applied to the edge of the test piece fixed in a cantilevered manner at a pendulum impact speed of 3.5 m / s, and the Izod impact strength (kJ / m 2 ) was measured. The average values ​​of N=5 measurements for each composition are shown in Table 2.

[0089] [Table 2]

[0090] The results in Table 2 show that even when compatibilizers B and C, which change the type of the second non-liquid crystal polymer used as the raw material for the compatibilizer, are used, polymer alloys with superior mechanical properties to the polymer blends of the comparative examples can be produced (Examples 2-1 to 2-4). As with the results in Table 1, the function of the compatibilizer was confirmed. In addition to flexural strength, an increase in impact strength due to the addition of the compatibilizer was also confirmed.

[0091] [Test Example 3] <Production Example of Compatibilizer D> A polymerization vessel equipped with a stirring blade was charged with 27 mol% 6-hydroxy-2-naphthoic acid (HNA) and 73 mol% p-hydroxybenzoic acid (HBA) as raw material monomers for the second liquid crystal polymer. Furthermore, poly(2,6-dimethyl-1,4-phenylene ether) (containing terminal hydroxy groups, Mw: 6300, Mn: 2350, manufactured by SABIC, product name: SA120) as the second non-liquid crystal polymer, and magnesium acetate and potassium acetate as catalysts. The amount of the second non-liquid crystal polymer was 23.7 parts by mass per 100 parts by mass of the second liquid crystal polymer (total raw material monomers). Subsequently, the polymerization vessel was vacuum-decompressed and nitrogen-injected three times, after which acetic anhydride (1.05 molar equivalents relative to the hydroxyl groups) was further added, the temperature was raised to 160 °C, and the acetylation reaction was carried out under reflux for 1.5 hours.

[0092] After the acetylation was completed, the polymerization vessel, which had been in a state of acetic acid distillation, was heated to 320°C at a rate of 0.5°C / min. During this time, acetic acid as a by-product was distilled off as the esterification reaction progressed. After reaching 320°C, the vessel was stirred for 20 minutes, and then the system was depressurized while maintaining the temperature at 320°C to promote the distillation of acetic acid as a by-product. In this state, the pressure was gradually reduced to 200 hPa over 20 minutes. After that, the viscosity of the polymer was measured based on the power consumption and torque of the agitator. -1The polymer was extracted when the viscosity exceeded 20 Pa·s and cooled to solidify. If the target viscosity was not reached after maintaining the pressure at 200 hPa for more than an hour, the pressure was further reduced to 10 hPa. After the reaction, the amount of acetic acid distilled was measured and found to be 99–100% of the theoretical reaction ratio. The resulting polymer was allowed to cool naturally at room temperature and then crushed to a size that could pass through a 2.0 mm mesh sieve. The crushed polymer was then washed with toluene, a good solvent for the second non-liquid crystal polymer (SA120), to remove any unreacted second non-liquid crystal polymer (SA120) remaining in the polymer. The washed solid was then dried and the toluene was removed to obtain compatibilizer D. Compatibilizer D was confirmed to have optical anisotropy in the same manner as compatibilizer A, and was therefore deemed to have liquid crystallinity.

[0093] <Production Example of Compatibilizer E> The above-prepared compatibilizer D, maleic anhydride, and peroxidizer (2,5-dimethyl-2,5-di(t-butylperoxide)hexyne-3 (NOF Corporation, trade name: Perhexyne 25B) were kneaded and reacted in a twin-screw kneader (Toyo Seiki Seisaku-sho, Laboplastomill Micro, small extrusion segment 2D15W). The resulting pellets were cooled to room temperature and crushed to a size that would pass through a 2.0 mm mesh sieve. This yielded compatibilizer E, a maleic acid-modified version of compatibilizer D. As a result, the methyl groups in the polyphenylene ether moiety in compatibilizer D were modified with maleic anhydride. Note that the blend amount of maleic anhydride and the blend amount of peroxidizer were 1 part by mass per 100 parts by mass of compatibilizer D, and 0.25 parts by mass per 100 parts by mass of compatibilizer D. Optical anisotropy of compatibilizer E was confirmed in the same manner as for compatibilizer A, and therefore it was determined to have liquid crystallinity.

[0094] <Production example of compatibilizer F> Compatibilizer F was obtained in the same manner as in the production example of compatibilizer E, except that the blending amount of maleic anhydride was changed to 10 parts by mass per 100 parts by mass of compatibilizer D. As with compatibilizer A, optical anisotropy was confirmed for compatibilizer F, and it was therefore determined to have liquid crystallinity.

[0095] <Example of polymer alloy manufacturing> Example 3-1 In producing the polymer alloy, a polyamide (manufactured by Solvay, trade name: Amodel A-8002) was used as the first non-liquid crystal polymer, and the compatibilizer A was changed to the compatibilizer D. The polymer alloy was obtained in the same manner as in Example 1-3. Next, a bending test piece was prepared using the obtained polymer alloy in the same manner as in Example 1-1.

[0096] (Example 3-2) A polymer alloy was obtained in the same manner as in Example 1-3, except that the compatibilizer A was changed to the compatibilizer E in the production of the polymer alloy. Next, a bending test piece was prepared using the obtained polymer alloy in the same manner as in Example 1-1.

[0097] (Example 3-3) A polymer alloy was obtained in the same manner as in Example 3-2, except that the blending amount of compatibilizer E in the production of the polymer alloy was changed to 20 parts by mass. Next, a bending test piece was prepared using the obtained polymer alloy in the same manner as in Example 1-1.

[0098] (Examples 3-4) A polymer alloy was obtained in the same manner as in Example 1-3, except that the compatibilizer A was changed to the compatibilizer F in the production of the polymer alloy. Next, a bending test piece was prepared using the obtained polymer alloy in the same manner as in Example 1-1.

[0099] (Examples 3-5) A polymer alloy was obtained in the same manner as in Example 3-4, except that the blending amount of compatibilizer F was changed to 20 parts by mass in the production of the polymer alloy. Next, a bending test piece was prepared using the obtained polymer alloy in the same manner as in Example 1-1.

[0100] (Comparative Example 3-1) A polymer blend was obtained in the same manner as in Example 3-1, except that compatibilizer D was not added in the production of the polymer alloy.

[0101] <Mechanical property measurements> (Measurement of bending strength, bending modulus, bending elongation) For each of the bending test pieces obtained above, the bending strength (MPa), bending modulus (GPa), and bending elongation (%) were measured in the same manner as in Test Example 2. The measurement results are shown in Table 3.

[0102] [Table 3]

[0103] The results in Table 3 show that by using a compatibilizer with liquid crystallinity, it is possible to produce polymer alloys with better mechanical properties than the polymer blends of the comparative examples, even for a first non-liquid crystal polymer that is not PPE (Examples 3-1 to 3-5). In particular, by using compatibilizers E and F that had been modified with maleic anhydride, the mechanical properties of polymer alloys using polyamides with amine groups at their terminals could be further improved (Examples 3-2 to 3-5).

[0104] [Test Example 4] <Production example of compatibilizer G> Compatibilizer G was obtained in the same manner as in the production example of compatibilizer E, except that compatibilizer A was used as the raw material compatibilizer and the amount of peroxidizer blended was changed to 0.1 parts by mass per 100 parts by mass of compatibilizer A. Optical anisotropy of compatibilizer G was confirmed in the same manner as compatibilizer A, and it was therefore determined to have liquid crystallinity.

[0105] <Example of polymer alloy manufacturing> (Example 4-1) A polymer alloy was obtained in the same manner as in Example 1-1, except that the compatibilizer A was changed to the compatibilizer G in the production of the polymer alloy. Next, a bending test piece was prepared using the obtained polymer alloy in the same manner as in Example 1-1.

[0106] (Example 4-2) A polymer alloy was obtained in the same manner as in Example 4-1, except that the blending amount of compatibilizer G was changed to 7.5 parts by mass in the production of the polymer alloy. Next, a bending test piece was prepared using the obtained polymer alloy in the same manner as in Example 1-1.

[0107] (Example 4-3) A polymer alloy was obtained in the same manner as in Example 4-1, except that the blending amount of the compatibilizer G was changed to 10 parts by mass in the production of the polymer alloy. Next, a bending test piece was prepared using the obtained polymer alloy in the same manner as in Example 1-1.

[0108] (Example 4-4) 70 parts by mass of the first liquid crystal polymer produced above, 30 parts by mass of polyamide (manufactured by Solvay, trade name: Amodel A-8002) as a first non-liquid crystal polymer, 10 parts by mass of the compatibilizer A produced above, 1 part by mass of maleic anhydride, and 0.1 parts by mass of a peroxidizer (2,5-dimethyl-2,5-di(t-butylperoxide)hexyne-3, manufactured by NOF Corporation, trade name: Perhexyne 25B) were kneaded at 340°C using a twin-screw kneader (Toyo Seiki Seisakusho, Labo Plastomill Micro, small extrusion segment 2D15W) to obtain a polymer alloy. Next, a bending test piece was prepared using the obtained polymer alloy in the same manner as in Example 1-1.

[0109] (Reference example 4-1) The compatibilizer G produced above was kneaded at 340°C using a twin-screw kneader. Using the obtained kneaded product, a bending test piece was prepared in the same manner as in Example 1-1.

[0110] <Mechanical property measurements> (Measurement of flexural modulus, flexural strength, and flexural elongation) For each of the bending test pieces of Examples 4-1 and 4-2 obtained above, the bending strength (MPa), bending modulus (GPa), and bending elongation (%) were measured in the same manner as in Test Example 1. The measurement results are shown in Table 4. The results of Comparative Example 3-1 are also shown in Table 4.

[0111] (Measurement of Izod impact strength) The bending test pieces of Examples 4-1 and 4-2 and Comparative Example 3-1 obtained above were subjected to the Izod impact strength (kJ / m 2 The measurement results are shown in Table 4.

[0112] (Measurement of weld strength) The kneaded products of Examples 4-2 to 4-3 and Comparative Example 3-1 obtained above were used to measure weld strength. First, using each kneaded product, molten polymer was poured into a mold measuring 80 mm (flow direction) × 15 mm × 0.5 mm (thickness) from both ends of the long side at the same time to prepare a test piece with a weld surface formed in the center of the long axis. Next, a three-point bending test was performed in which a pressing jig pressed the weld formed on the test piece, causing the test piece to break at the weld interface, and the strength of the weld interface was measured. The measurement results are shown in Table 4.

[0113] [Table 4] The results in Table 4 indicate that even if the types of the first non-liquid crystal polymer and the compatibilizer are changed and a small amount of the compatibilizer is added, a polymer alloy having superior mechanical properties to the polymer blend of the comparative example can be produced (Examples 4-1 to 4-2). Furthermore, even if the maleic acid modification treatment is simultaneously performed during the polymer alloy polymerization process instead of the maleic acid modification treatment of the compatibilizer itself in a separate kneading process, a polymer alloy having superior mechanical properties to the polymer blend of the comparative example can be produced (Example 4-3). Furthermore, it was found that the addition of a compatibilizer has the effect of increasing the strength of the weld interface.

Claims

1. a first liquid crystal polymer; a first non-liquid crystal polymer; a compatibilizer that is a reaction product of a second liquid crystal polymer having a terminal reactive group and a second non-liquid crystal polymer having a reactive group that can react with the terminal reactive group of the second liquid crystal polymer; A polymer alloy comprising:

2. 2. The polymer alloy according to claim 1, wherein the reactive group at the terminal of the second liquid crystal polymer comprises at least one selected from the group consisting of a carboxy group, a hydroxy group, an amide group, an acetyl group, and an amino group.

3. The polymer alloy according to claim 1 , wherein the first liquid crystal polymer has a melting point of 270° C. or higher.

4. The polymer alloy of claim 1 , wherein the second liquid crystal polymer comprises constitutional units derived from a hydroxycarboxylic acid.

5. 2. The polymer alloy according to claim 1, wherein the reactive group of the second non-liquid crystal polymer comprises at least one selected from the group consisting of a carboxy group, a hydroxy group, an amide group, an acetyl group, and an amino group.

6. The polymer alloy of claim 1 , wherein the second non-liquid crystal polymer comprises a polyphenylene ether.

7. The polymer alloy according to claim 1, wherein the blending amount of the second non-liquid crystal polymer is 1 part by mass or more and 50 parts by mass or less per 100 parts by mass of the second liquid crystal polymer.

8. The polymer alloy of claim 1 , wherein the compatibilizer has a cyclic acid anhydride group.

9. 9. The polymer alloy according to claim 8, wherein the cyclic acid anhydride group is at least one selected from the group consisting of a maleic anhydride group, a succinic anhydride group, a phthalic anhydride group, and a glutaric anhydride group.

10. The polymer alloy of claim 1 , wherein the first liquid crystal polymer comprises constitutional units derived from a hydroxycarboxylic acid.

11. 2. The polymer alloy of claim 1, wherein the first non-liquid crystal polymer comprises at least one selected from the group consisting of polyethers, polyamides, polysulfones, polyimides, polyimideamides, and polyetherketones.

12. The polymer alloy according to claim 1, wherein the amount of the compatibilizer is 0.1 parts by mass or more and 50 parts by mass or less per 100 parts by mass of the first liquid crystal polymer and the first non-liquid crystal polymer combined.

13. The polymer alloy according to claim 1, wherein the amount of the compatibilizer is 0.1 parts by mass or more and 20 parts by mass or less per 100 parts by mass of the first liquid crystal polymer and the first non-liquid crystal polymer combined.

14. The polymer alloy according to claim 1, wherein the amount of the first non-liquid crystal polymer is 0.1 parts by mass or more and 50 parts by mass or less per 100 parts by mass of the first liquid crystal polymer and the first non-liquid crystal polymer combined.

15. A molded article comprising the polymer alloy according to any one of claims 1 to 14.

16. An electric / electronic component comprising the molded article according to claim 15.

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