Polyphenylene sulfide-based magnetic materials, their production methods and uses

Abstract

The present application provides polyphenylene sulfide-based magnetic materials, methods for their manufacture and uses. [Means] The polyphenylene sulfide-based magnetic material includes linear polyphenylene sulfide, magnetic powder, phenyl silicone resin, hyperbranched polyphenylene sulfide, and a lubricant. The present application adds phenyl silicone resin to increase the binding strength of the magnetic powder to the polyphenylene sulfide at high temperatures, adds hyperbranched polyphenylene sulfide to modify the structure of the linear polyphenylene sulfide, improving the strength and toughness of the polyphenylene sulfide-based magnetic material, and adds a lubricant to improve fluidity, resulting in a polyphenylene sulfide-based magnetic material characterized by high strength, good toughness, and good fluidity.

Description

[Technical Field]

[0001] This application relates to the technical field of injection-molded magnetic materials, for example, polyphenylene sulfide-based magnetic materials, their manufacturing methods and uses. [Background technology]

[0002] Injection-molded magnets are an important category of bonded magnets. They boast advantages such as high dimensional accuracy, excellent mechanical properties, and the ability to produce complex-shaped, multi-polar magnetized magnets. They are widely used in a variety of applications, including home appliances, automobiles, communication devices, gauges, computers, and office equipment. Injection-molded magnetic materials are typically obtained by blending magnetic powder, polymer adhesives, and additives in a specific ratio, followed by granulation. To ensure magnetic performance, injection-molded magnets require a high magnetic powder loading (mass fraction generally greater than 82%, sometimes as high as 90%). This can lead to degradation of the molding performance and mechanical properties of injection-molded magnetic materials, limiting their use. Polyphenylene sulfide (PS) materials, in particular, have the disadvantage of being more brittle than nylon materials. High powder loadings exacerbate this defect, making the final injection-molded magnet more susceptible to problems such as brittle cracking during application, significantly impacting their application. Currently, there are few reports on toughening in the field of polyphenylene sulfide injection molding magnetic materials, and generally, the toughness of the material can only be improved by using elastomer-modified polyphenylene sulfide. In polyphenylene sulfide injection molding magnetic composite materials, the compatibility between polyphenylene sulfide and elastomer is poor, which tends to cause problems such as weak bonding strength of the composite and poor uniformity.

[0003] CN105885415A discloses a method for producing a toughened polyphenylene sulfide / ferrite composite material. The specific steps of the method include first using polyphenylene sulfide as a matrix resin, granulating a toughener and a lubricant together in a twin-screw extruder to produce a multi-functional masterbatch, and then kneading and granulating ferrite magnetic powder treated with a coupling agent together with the multi-functional masterbatch in a twin-screw extruder to obtain a toughened polyphenylene sulfide / ferrite composite material, in which the toughener is any one or a combination of at least two of ternary ethylene propylene diene rubber, ethylene-octene copolymer, maleic anhydride-grafted ternary ethylene propylene diene rubber, and maleic anhydride-grafted ethylene-octene copolymer. The method of this technical solution first prepares a multifunctional masterbatch, which allows the components to be well dispersed and contributes to improving the processability of the polyphenylene sulfide / ferrite composite material. Second, the toughness of the composite material is effectively improved by using an elastomer as a toughener, resulting in a significantly improved toughness of the polyphenylene sulfide / ferrite composite material, as well as good processability and magnetic performance. However, as a toughener, the elastomer has a high viscosity, which improves the toughness of the material, but at the same time reduces the fluidity and strength of the material, resulting in poor magnetic performance.

[0004] CN106317874A discloses a high-performance polyphenylene sulfide / ferrite magnetic composite material and a manufacturing method thereof. The manufacturing method includes the steps of coupling nano-order ferrite and micron-order ferrite powder with a coupling agent, and then feeding the resulting mixture together with polyphenylene sulfide resin, lubricant, etc. in an extruder equipped with an ultrasonic dispersing device to granulate the resulting mixture, thereby obtaining the high-performance polyphenylene sulfide / ferrite magnetic composite material. The high-performance polyphenylene sulfide / ferrite magnetic composite material of this technical proposal is made by adding nano-sized ferrite powder to micron-sized ferrite magnetic powder, thereby increasing the strength of the high-performance polyphenylene sulfide / ferrite magnetic composite material, making it easy to mold and process. The product has high mechanical strength, high temperature resistance, corrosion resistance, and excellent magnetic performance. The production process is simple and suitable for industrial production. While the addition of nano-sized ferrite is beneficial for improving the magnet filling rate, the addition of nano-sized ferrite increases the specific surface area of ​​the magnetic powder as a whole, increasing the amount of polymer needed to encapsulate the magnetic powder and reducing the flowability of the magnet at the same magnetic powder blend ratio. At the same time, problems such as aggregation between the nano-sized ferrite particles are likely to occur, which will affect the final magnet performance.

[0005] Injection molding magnetic materials, especially anisotropic injection molding magnets, require alignment during the injection molding process to achieve high performance. The fluidity of the injection molding magnetic material is an important factor, and poor fluidity will affect the performance of the injection molding magnet.

[0006] Therefore, there is a need to develop polyphenylene sulfide-based magnetic materials that have high strength, high toughness, and good flowability. Summary of the Invention [Problem to be solved by the invention]

[0007] The following is a summary of the subject matter described in detail herein. This summary does not limit the scope of the claims.

[0008] The present application provides a polyphenylene sulfide-based magnetic material, its manufacturing method and use, which has the characteristics of high strength, high toughness and good flowability. [Means for solving the problem]

[0009] In aspect 1, the present application provides: The composition includes linear polyphenylene sulfide, magnetic powder, phenyl silicone resin, hyperbranched polyphenylene sulfide, and a lubricant. A polyphenylene sulfide-based magnetic material is provided.

[0010] In this application, the addition of hyperbranched polyphenylene sulfide improves the crystalline structure of linear polyphenylene sulfide and enhances the mechanical properties of polyphenylene sulfide-based magnetic materials. Furthermore, the added hyperbranched polyphenylene sulfide molecules assume a spherical shape, acting as a plasticizer and improving the toughness of the linear polyphenylene sulfide matrix material and the toughness of the polyphenylene sulfide-based magnetic material. The phenyl silicone resin and polyphenylene sulfide are highly compatible, effectively enhancing the bonding strength between the magnetic powder and polyphenylene sulfide. The addition of a high-temperature-resistant lubricant improves the fluidity of the polyphenylene sulfide-based magnetic material.

[0011] In one embodiment, the melt flow rate of the linear polyphenylene sulfide is 500 to 3000 g / 10 min, for example, 500 g / 10 min, 800 g / 10 min, 1000 g / 10 min, 1500 g / 10 min, 1800 g / 10 min, 2000 g / 10 min, 2500 g / 10 min, 2800 g / 10 min, or 3000 g / 10 min, and is preferably 1500 to 2500 g / 10 min.

[0012] In this application, the melt flow rate is tested in accordance with ISO1133, and the test conditions are 316°C and 5 kg.

[0013] In one embodiment, the magnetic powder comprises ferrite magnetic powder and / or rare earth magnetic powder.

[0014] In one embodiment, the ferrite powder comprises strontium ferrite powder and / or barium ferrite powder.

[0015] In one embodiment, the rare earth magnetic powder comprises rare earth samarium iron nitrogen magnetic powder.

[0016] In one embodiment, the phenylsilicone resin comprises a phenylsilicone resin comprising an ethoxy group and a methyl group.

[0017] In this application, the ethoxy- and methyl-containing phenyl silicone resin contains a phenyl group, an ethoxy group, and a methyl group in the same molecule. The ethoxy group has high activity, reacts with magnetic particles, and further enhances the bonding strength between the magnetic particles and polyphenylene sulfide. The phenyl group provides fairly high compatibility between the phenyl silicone resin and polyphenylene sulfide, further enhancing the bonding strength between the magnetic particles and polyphenylene sulfide. The methyl group structure provides a certain degree of lubricity, effectively improving the flowability of the magnetic particles.

[0018] In one embodiment, the hyperbranched polyphenylene sulfide is obtained by polymerization of dichlorobenzenethiol or dichlorothiophenol monomers, and its preparation method can be found in the relevant literature.

[0019] In one embodiment, the weight average molecular weight of the hyperbranched polyphenylene sulfide is 15,000 to 30,000, for example, 15,000, 16,000, 18,000, 20,000, 21,000, 23,000, 25,000, 28,000, or 30,000.

[0020] In one embodiment, the lubricant comprises a high temperature resistant amide-based lubricant.

[0021] In the present application, the high-temperature resistant amide-based lubricant means a lubricant whose weight loss rate at 350°C for 10 minutes is less than 10%.

[0022] In one embodiment, the linear polyphenylene sulfide is present in an amount of 10 to 18 parts by mass, for example, 10 parts, 11 parts, 12 parts, 13 parts, 14 parts, 15 parts, 16 parts, 17 parts, or 18 parts, based on 100 parts by total mass of the polyphenylene sulfide-based magnetic material.

[0023] In one embodiment, the magnetic powder is present in an amount of 80 to 100 parts by mass, for example, 80 parts, 82 parts, 85 parts, 87 parts, 88 parts, 90 parts, 92 parts, 95 parts, or 100 parts, and is preferably present in an amount of 80 to 88 parts.

[0024] In one embodiment, the phenyl silicone resin is present in an amount of 0.3 to 0.6 parts by mass, such as 0.3 parts, 0.35 parts, 0.4 parts, 0.45 parts, 0.5 parts, 0.55 parts, or 0.6 parts.

[0025] In one embodiment, the hyperbranched polyphenylene sulfide is present in an amount of 1 to 4 parts by mass, such as 1 part, 1.5 parts, 2 parts, 2.5 parts, 3 parts, 3.5 parts, or 4 parts.

[0026] In one embodiment, the lubricant is present in an amount of 0.5 to 1.0 parts by mass, such as 0.5 parts, 0.6 parts, 0.7 parts, 0.8 parts, 0.9 parts, or 1.0 parts.

[0027] In a second aspect, the present application provides a method for producing the polyphenylene sulfide-based magnetic material according to the first aspect, comprising: Step (1) of mixing magnetic powder with a phenyl silicone resin to obtain surface-treated magnetic powder; and step (2) mixing the surface-treated magnetic powder obtained in step (1), linear polyphenylene sulfide, hyperbranched polyphenylene sulfide, and a lubricant, and granulating the mixture to obtain a polyphenylene sulfide-based magnetic material. A method of manufacture is provided.

[0028] In one embodiment, the mixing described in step (1) is mixing magnetic powder with a phenyl silicone resin diluted with a solvent.

[0029] In one embodiment, the solvent comprises ethyl acetate and / or ethyl formate.

[0030] In one embodiment, the mass ratio of the phenyl silicone resin to the solvent is 1:3 to 1:6, such as 1:3, 1:3.5, 1:4, 1:4.5, 1:5, 1:5.5, or 1:6.

[0031] In one embodiment, the mixing temperatures in step (1) and step (2) are each independently 80 to 120°C, such as 80°C, 85°C, 90°C, 95°C, 100°C, 102°C, 105°C, 110°C, 115°C, or 120°C.

[0032] In one embodiment, the mixing times described in step (1) and step (2) are each independently 30 to 60 minutes, such as 30 minutes, 35 minutes, 40 minutes, 45 minutes, 50 minutes, 55 minutes, or 60 minutes.

[0033] In one embodiment, the granulation equipment described in step (2) is a twin-screw extruder.

[0034] In one embodiment, the granulation temperature is 290 to 310°C, for example, 290°C, 293°C, 295°C, 298°C, 300°C, 302°C, 305°C, 307°C, 309°C, or 310°C.

[0035] In a third aspect, the present application provides a use of the polyphenylene sulfide-based magnetic material according to the first aspect in an injection-molded magnet. [Effects of the Invention]

[0036] Compared to the related art, the present application has the following beneficial effects:

[0037] This application describes a polyphenylene sulfide-based magnetic material manufactured by compounding linear polyphenylene sulfide, magnetic powder, phenylsilicone resin, hyperbranched polyphenylene sulfide, and a lubricant. The addition of phenylsilicone resin enhances the bonding strength of the magnetic powder to the polyphenylene sulfide at high temperatures. The addition of hyperbranched polyphenylene sulfide finely modifies the structure of the linear polyphenylene sulfide, improving the strength and toughness of the polyphenylene sulfide-based magnetic material. The addition of a lubricant improves fluidity. The resulting polyphenylene sulfide-based magnetic material has high strength, good toughness, and good fluidity. The polyphenylene sulfide-based magnetic material has a melt flow rate of 48 to 420 g / 10 min, a tensile strength of 58 to 88 MPa, an elongation at break of 0.7% to 1.8%, and a flexural strength of 89 to 138 MPa.

[0038] Other aspects may be understood upon reading and understanding the detailed description. DETAILED DESCRIPTION OF THE INVENTION

[0039] The technical solution of the present application will be further described below through specific embodiments. Those skilled in the art should understand that the above examples are only for understanding the present application and should not be considered as specifically limiting the present application.

[0040] All "parts" referred to below are "parts by mass". [Example]

[0041] This example provides a polyphenylene sulfide-based magnetic material and a method for producing the same. The polyphenylene sulfide-based magnetic material contained 13 parts of linear polyphenylene sulfide (Shinwasei PPS11200F, with a melt flow rate of 2000 g / 10 min measured at 316°C and 5 kg in accordance with ISO 1133), 85 parts of magnetic powder (strontium ferrite magnetic powder with an average particle size D50 of 1.9 μm measured by the Fischer air permeability method), 0.5 parts of phenyl silicone resin (2531E), 1 part of hyperbranched polyphenylene sulfide (weight average molecular weight 20,000), and 0.5 parts of lubricant (high-temperature resistant lubricant MPK-03, purchased from Kyoeisha Chemical).

[0042] The hyperbranched polyphenylene sulfide was produced in hexamethylphosphortriamide using 2,4-dichlorobenzenethiol as a raw material and potassium hydroxide as a catalyst, with reference to the method for producing hyperbranched polyphenylene sulfide disclosed in Xu RL, Liu HW, Shi W F. Photofluorescence of hyperbranched poly(phenylene sulfide)[J]. Journal of Polymer Science, Part B. Polymer Physics, 2006(5):44.

[0043] The polyphenylene sulfide-based magnetic material was prepared as follows.

[0044] (1) 0.5 parts of phenyl silicone resin was dissolved and diluted with 3 parts of ethyl acetate, then mixed with 85 parts of magnetic powder and blended at high speed at 100°C for 50 minutes to volatilize the diluted ethyl acetate solution, thereby obtaining surface-treated magnetic powder.

[0045] (2) The surface-treated magnetic powder obtained in step (1), 13 parts of linear polyphenylene sulfide, 1 part of hyperbranched polyphenylene sulfide, and 0.5 parts of lubricant were mixed for 30 minutes, extruded in a twin-screw extruder, and granulated at a granulation temperature of 300°C to obtain the polyphenylene sulfide-based magnetic material. [Example]

[0046] This example provides a polyphenylene sulfide-based magnetic material and a method for producing the same. The polyphenylene sulfide-based magnetic material contains 18 parts of linear polyphenylene sulfide (Shinwasei PPS Powder 10300, with a melt flow rate of 2500 g / 10 min measured at 316°C and 5 kg in accordance with ISO 1133), 80 parts of magnetic powder (barium ferrite magnetic powder, with an average particle size D50 of 2 μm measured by the Fischer air permeability method), 0.6 parts of phenyl silicone resin (2531E), 1 part of hyperbranched polyphenylene sulfide (weight average molecular weight 30,000), and 0.4 parts of lubricant (high-temperature resistant lubricant MPK-03, purchased from Kyoeisha Chemical).

[0047] The hyperbranched polyphenylene sulfide was produced in hexamethylphosphortriamide using 2,4-dichlorobenzenethiol as a raw material and potassium hydroxide as a catalyst, with reference to the method for producing hyperbranched polyphenylene sulfide disclosed in Xu RL, Liu HW, Shi W F. Photofluorescence of hyperbranched poly(phenylene sulfide)[J]. Journal of Polymer Science, Part B. Polymer Physics, 2006(5):44.

[0048] The polyphenylene sulfide-based magnetic material was prepared as follows.

[0049] (1) 0.6 parts of phenyl silicone resin was dissolved and diluted with 4 parts of ethyl acetate, then mixed with 80 parts of magnetic powder and blended at high speed for 60 minutes at 80°C to volatilize the diluted ethyl acetate solution, thereby obtaining surface-treated magnetic powder.

[0050] (2) The surface-treated magnetic powder obtained in step (1), 18 parts of linear polyphenylene sulfide, 1 part of hyperbranched polyphenylene sulfide, and 0.4 parts of lubricant were mixed for 60 minutes, extruded in a twin-screw extruder, and granulated at a granulation temperature of 310°C to obtain the polyphenylene sulfide-based magnetic material. [Example]

[0051] This example provides a polyphenylene sulfide-based magnetic material and a method for producing the same. The polyphenylene sulfide-based magnetic material contained 10 parts of linear polyphenylene sulfide (Shinwasei PPS 34100, with a melt flow rate of 1500 g / 10 min measured at 316°C and 5 kg in accordance with ISO 1133), 88 parts of magnetic powder (rare earth samarium iron nitrogen magnetic powder with an average particle size D50 of 2.2 μm measured by the Fischer air permeability method), 0.3 parts of phenyl silicone resin (2531E), 1 part of hyperbranched polyphenylene sulfide (weight average molecular weight 15000), and 0.7 parts of lubricant (high-temperature resistant lubricant MPK-03, purchased from Kyoeisha Chemical).

[0052] The hyperbranched polyphenylene sulfide was produced in hexamethylphosphortriamide using 2,4-dichlorobenzenethiol as a raw material and potassium hydroxide as a catalyst, with reference to the method for producing hyperbranched polyphenylene sulfide disclosed in Xu RL, Liu HW, Shi W F. Photofluorescence of hyperbranched poly(phenylene sulfide)[J]. Journal of Polymer Science, Part B. Polymer Physics, 2006(5):44.

[0053] The polyphenylene sulfide-based magnetic material was prepared as follows.

[0054] (1) 0.3 parts of phenyl silicone resin was dissolved and diluted with 6 parts of ethyl acetate, then mixed with 88 parts of magnetic powder and blended at high speed at 120°C for 30 minutes to volatilize the diluted ethyl acetate solution, thereby obtaining surface-treated magnetic powder.

[0055] (2) The surface-treated magnetic powder obtained in step (1), 10 parts of linear polyphenylene sulfide, 1 part of hyperbranched polyphenylene sulfide, and 0.7 parts of lubricant were mixed for 50 minutes, extruded in a twin-screw extruder, and granulated at a granulation temperature of 290°C to obtain the polyphenylene sulfide-based magnetic material. [Example]

[0056] This example provides a polyphenylene sulfide-based magnetic material and a manufacturing method thereof. The only difference from Example 1 is that the mass parts of the linear polyphenylene sulfide are adjusted to 12 parts and the mass parts of the hyperbranched polyphenylene sulfide are adjusted to 2 parts; the other raw materials, amounts used, and manufacturing method are the same as those of Example 1. [Example]

[0057] This example provides a polyphenylene sulfide-based magnetic material and a manufacturing method thereof. The only difference from Example 1 is that the mass parts of the linear polyphenylene sulfide are adjusted to 11 parts and the mass parts of the hyperbranched polyphenylene sulfide are adjusted to 3 parts; the other raw materials, amounts used, and manufacturing method are the same as those of Example 1. [Example]

[0058] This example provides a polyphenylene sulfide-based magnetic material and a manufacturing method thereof. The only difference from Example 1 is that the mass parts of the linear polyphenylene sulfide are adjusted to 10 parts and the mass parts of the hyperbranched polyphenylene sulfide are adjusted to 4 parts; the other raw materials, amounts used, and manufacturing method are the same as those of Example 1. [Example]

[0059] This example provides a polyphenylene sulfide-based magnetic material and a manufacturing method thereof. The only difference from Example 1 is that the mass parts of the linear polyphenylene sulfide are adjusted to 13.5 parts and the mass parts of the hyperbranched polyphenylene sulfide are adjusted to 0.5 parts; the other raw materials, amounts used, and manufacturing method are the same as those of Example 1. [Example]

[0060] This example provides a polyphenylene sulfide-based magnetic material and a manufacturing method thereof. The only difference from Example 1 is that the linear polyphenylene sulfide (Shinwasei PPS11200F) is replaced with the same mass of linear polyphenylene sulfide (Shinwasei 3450, with a melt flow rate of 500 g / 10 min measured at 316°C and 5 kg in accordance with ISO 1133). The other raw materials, amounts used, and manufacturing method are the same as those in Example 1. [Example]

[0061] This example provides a polyphenylene sulfide-based magnetic material and a manufacturing method thereof. The only difference from Example 1 is that the linear polyphenylene sulfide (Shinwasei PPS11200F) is replaced with the same mass of linear polyphenylene sulfide (Shinwasei 10500, with a melt flow rate of 3000 g / 10 min measured at 316°C and 5 kg in accordance with ISO 1133). The other raw materials, amounts used, and manufacturing method are the same as those in Example 1. [Example]

[0062] This example provides a polyphenylene sulfide-based magnetic material and a manufacturing method thereof. The only difference from Example 1 is that the hyperbranched polyphenylene sulfide (weight average molecular weight 20,000) is replaced with the same mass of hyperbranched polyphenylene sulfide (weight average molecular weight 40,000). The other raw materials, amounts used, and manufacturing method are the same as those in Example 1. [Example]

[0063] This example provides a polyphenylene sulfide-based magnetic material and a manufacturing method thereof. The only difference from Example 1 is that the mass parts of the phenyl silicone resin are adjusted to 0.1 parts and the mass parts of linear polyphenylene sulfide are adjusted to 13.4 parts. The other raw materials, amounts used, and manufacturing method are the same as those of Example 1. [Example]

[0064] This example provides a polyphenylene sulfide-based magnetic material and a manufacturing method thereof. The only difference from Example 1 is that the mass parts of the phenyl silicone resin are adjusted to 1 part and the mass parts of linear polyphenylene sulfide are adjusted to 12.5 parts. The other raw materials, amounts used, and manufacturing method are the same as those of Example 1. [Comparative Example 1]

[0065] This comparative example provides a polyphenylene sulfide-based magnetic material and its manufacturing method. The only differences from Example 1 are that no phenyl silicone resin is added, the mass parts of linear polyphenylene sulfide are adjusted to 13.5 parts, the manufacturing method does not include step (1), and the surface-treated magnetic powder in step (2) is replaced with 85 parts of magnetic powder. The other raw materials, amounts used, and manufacturing method are the same as those in Example 1. Comparative Example 2

[0066] This comparative example provides a polyphenylene sulfide-based magnetic material and a manufacturing method thereof. The only difference from Example 1 is that no hyperbranched polyphenylene sulfide was added and the mass parts of linear polyphenylene sulfide were adjusted to 14 parts; the other raw materials, amounts used, and manufacturing method were the same as those in Example 1. Comparative Example 3

[0067] This comparative example provides a polyphenylene sulfide-based magnetic material and its manufacturing method. The only difference from Example 5 is that the phenyl silicone resin is replaced with the same mass of silane coupling agent KH550. The other raw materials, amounts used, and manufacturing method are the same as those of Example 5. Comparative Example 4

[0068] This comparative example provides a polyphenylene sulfide-based magnetic material and its manufacturing method. The only difference from Example 5 is that the hyperbranched polyphenylene sulfide is replaced with the same mass of elastomeric polyurethane (weight average molecular weight 20,000, SP9324 from BASF, Germany). The other raw materials, amounts used, and manufacturing methods are the same as those of Example 5. Comparative Example 5

[0069] This comparative example provides a polyphenylene sulfide-based magnetic material and its manufacturing method. The only differences from Example 5 are that the phenyl silicone resin is replaced with the same mass of silane coupling agent KH550, the hyperbranched polyphenylene sulfide is replaced with the same mass of elastomer polyurethane (weight average molecular weight 20,000, BASF SP9324, Germany), no lubricant is added, and the mass parts of the magnetic powder are 85.5 parts; the other raw materials, amounts used, and manufacturing methods are the same as those of Example 5.

[0070] The polyphenylene sulfide-based magnetic materials according to the examples and comparative examples were subjected to the following performance tests.

[0071] (1) Flowability: In accordance with ISO1133, the melt flow rate of the examples and comparative examples in each group was tested at 330°C and a pressure of 10 kg.

[0072] (2) Mechanical properties: They were injection molded into dumbbell-shaped strength test specimens and short pieces at a temperature of 330°C, and then tested for tensile strength and elongation at break using an Instron 6633 universal testing machine in accordance with GB / T1040-1992, and for bending strength in accordance with GB / T9341-2008.

[0073] The test results are shown in Table 1.

[0074] [Table 1]

[0075] The test results in Table 1 show that the polyphenylene sulfide-based magnetic materials according to Examples 1 to 12 had melt flow rates of 48 to 420 g / 10 min, tensile strengths of 58 to 88 MPa, elongations at break of 0.7% to 1.8%, and flexural strengths of 89 to 138 MPa. A comparison of Example 1 with Examples 4 to 6 shows that the melt flow rate increased as the mass part of hyperbranched polyphenylene sulfide increased.

[0076] Compared to Example 1, when the mass part of hyperbranched polyphenylene sulfide was too small (Example 7), the polyphenylene sulfide-based magnetic material produced had a lower melt flow rate, poor fluidity, and reduced tensile strength and flexural strength. It was proven that the performance of polyphenylene sulfide-based magnetic materials produced using hyperbranched polyphenylene sulfide within a specific mass part range was better.

[0077] Compared to Example 1, when the melt flow rate of the linear polyphenylene sulfide was reduced (Example 8), the polyphenylene sulfide-based magnetic material produced had a lower melt flow rate and poor fluidity, and when the melt flow rate of the linear polyphenylene sulfide was increased (Example 9), the tensile strength and flexural strength decreased.It was proven that the performance of the polyphenylene sulfide-based magnetic material produced by selecting linear polyphenylene sulfide with a melt flow rate of 1500 to 2500 g / 10 min was better.

[0078] Compared to Example 1, when the weight-average molecular weight of the hyperbranched polyphenylene sulfide was too large (Example 10), the polyphenylene sulfide-based magnetic material produced had a lower melt flow rate, poor fluidity, and reduced tensile strength and flexural strength. It was demonstrated that the performance of polyphenylene sulfide-based magnetic materials produced using hyperbranched polyphenylene sulfide within a specific weight-average molecular weight range was better.

[0079] Compared to Example 1, when the part by mass of the phenyl silicone resin was too small (Example 11), the magnetic powder was not completely embedded, and the polyphenylene sulfide-based magnetic material produced had a lower melt flow rate, poor fluidity, and reduced tensile strength and flexural strength. When the part by mass of the phenyl silicone resin was too large (Example 12), the polyphenylene sulfide-based magnetic material produced had an increased viscosity, a lower melt flow rate, and poor fluidity. It was demonstrated that the performance of polyphenylene sulfide-based magnetic materials produced using phenyl silicone resins within a specific part by mass range was better.

[0080] Compared to Example 1, when no phenyl silicone resin was added (Comparative Example 1), the bonding strength between the magnetic powder and linear polyphenylene sulfide was poor, and the polyphenylene sulfide-based magnetic material produced had a lower melt flow rate and lower tensile strength and bending strength.

[0081] Compared with Example 1, when no hyperbranched polyphenylene sulfide was added (Comparative Example 2), the polyphenylene sulfide-based magnetic material produced had a lower melt flow rate, and lower tensile strength and bending strength.

[0082] Compared to Example 5, when the phenyl silicone resin was replaced with the same mass of silane coupling agent KH550 (Comparative Example 3), the polyphenylene sulfide-based magnetic material produced had a lower melt flow rate, and lower tensile strength and flexural strength. This is because the melting point of polyphenylene sulfide is high, and the granulation temperature exceeds 300°C, at which temperature ordinary silane coupling agents are prone to decomposition and inactivation, ultimately causing a deterioration in the performance of the polyphenylene sulfide-based magnetic material.

[0083] Compared with Example 5, when the hyperbranched polyphenylene sulfide was replaced with the same mass of elastomeric polyurethane (Comparative Example 4), the produced polyphenylene sulfide-based magnetic material had a lower melt flow rate and lower tensile strength and flexural strength.

[0084] Compared to Example 5, when the phenyl silicone resin was replaced with the same mass of silane coupling agent KH550, the hyperbranched polyphenylene sulfide was replaced with the same mass of elastomeric polyurethane, and no lubricant was added (Comparative Example 5), the polyphenylene sulfide-based magnetic material produced had a lower melt flow rate and lower tensile strength and flexural strength.

[0085] The present application has described the polyphenylene sulfide-based magnetic material of the present application, its manufacturing method and use through the above examples, but the applicant declares that the present application is not limited to the above examples, i.e., it does not mean that the present application must be carried out depending on the above examples. Those skilled in the art should understand that any improvements to the present application, equivalent substitution of each raw material of the product of the present application, addition of auxiliary components, selection of specific forms, etc. are all within the protection scope and disclosure of the present application.

Claims

1. The composition includes linear polyphenylene sulfide, magnetic powder, phenyl silicone resin, hyperbranched polyphenylene sulfide, and a lubricant. Polyphenylene sulfide-based magnetic material.

2. The melt flow rate of the linear polyphenylene sulfide is 500 to 3000 g / 10 min, and preferably 1500 to 2500 g / 10 min.

2. The polyphenylene sulfide-based magnetic material of claim 1.

3. The magnetic powder includes ferrite magnetic powder and / or rare earth magnetic powder.

3. The polyphenylene sulfide-based magnetic material according to claim 1 or 2.

4. The ferrite magnetic powder includes strontium ferrite magnetic powder and / or barium ferrite magnetic powder.

4. The polyphenylene sulfide-based magnetic material of claim 3.

5. The rare earth magnetic powder includes rare earth samarium iron nitrogen magnetic powder.

5. A polyphenylene sulfide-based magnetic material according to claim 3 or 4.

6. The phenyl silicone resin includes a phenyl silicone resin containing an ethoxy group and a methyl group. The polyphenylene sulfide-based magnetic material according to any one of claims 1 to 5.

7. The hyperbranched polyphenylene sulfide is obtained by polymerization of dichlorobenzenethiol or dichlorothiophenol monomers. The polyphenylene sulfide-based magnetic material according to any one of claims 1 to 6.

8. The weight average molecular weight of the hyperbranched polyphenylene sulfide is 15,000 to 30,000. A polyphenylene sulfide-based magnetic material according to any one of claims 1 to 7.

9. The lubricant comprises a high-temperature resistant amide-based lubricant. A polyphenylene sulfide-based magnetic material according to any one of claims 1 to 8.

10. the linear polyphenylene sulfide is 10 to 18 parts by mass, based on 100 parts of the total mass of the polyphenylene sulfide-based magnetic material; Preferably, the magnetic powder is present in an amount of 80 to 100 parts by mass, more preferably 80 to 88 parts by mass; Preferably, the phenyl silicone resin is 0.3 to 0.6 parts by weight, Preferably, the hyperbranched polyphenylene sulfide is 1 to 4 parts by mass, Preferably, the lubricant is present in an amount of 0.5 to 1.0 parts by weight. A polyphenylene sulfide-based magnetic material according to any one of claims 1 to 9.

11. A method for producing the polyphenylene sulfide-based magnetic material according to any one of claims 1 to 10, comprising the steps of: Step (1) of mixing magnetic powder with a phenyl silicone resin to obtain surface-treated magnetic powder; and step (2) mixing the surface-treated magnetic powder obtained in step (1), linear polyphenylene sulfide, hyperbranched polyphenylene sulfide, and a lubricant, followed by granulation, to obtain a polyphenylene sulfide-based magnetic material. Manufacturing method.

12. The mixing described in step (1) is mixing magnetic powder with a phenyl silicone resin diluted with a solvent; The method of claim 11.

13. The solvent comprises ethyl acetate and / or ethyl formate. The method of claim 12.

14. the mass ratio of the phenyl silicone resin to the solvent is 1:3 to 1:6; Preferably, the temperature of mixing described in step (1) and step (2) is each independently 80 to 120°C; Preferably, the mixing times described in step (1) and step (2) are each independently 30 to 60 minutes; Preferably, the granulation equipment described in step (2) is a twin-screw extruder; Preferably, the granulation temperature is 290 to 310°C. The method according to any one of claims 11 to 13.

15. Use of the polyphenylene sulfide-based magnetic material according to any one of claims 1 to 10 in an injection-molded magnet.

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