Polyarylene sulfide resin composition and molded article made thereof

Abstract

The present invention provides a polyarylene sulfide resin composition that can suppress outgassing and has excellent toughness, and a molded article made therefrom. [Solution] A polyarylene sulfide resin composition characterized by containing (A) 3 to 50 parts by weight of an olefin copolymer (component B) containing epoxy groups, wherein the melt flow rate (MFR) measured under conditions of 190°C and a 2.16 kg load is 15 g / 10 min or more, per 100 parts by weight of polyarylene sulfide resin (component A).

Description

Technical Field

[0001] The present invention relates to a polyarylene sulfide resin composition capable of suppressing the generation of outgas and having excellent toughness, and a molded product made therefrom.

Background Art

[0002] Polyarylene sulfide resin is an engineering plastic excellent in chemical resistance, heat resistance, mechanical properties, etc. Therefore, polyarylene sulfide resin is widely used as electrical and electronic parts, vehicle-related parts, aircraft parts, and housing equipment parts. In recent years, in electronic devices such as digital cameras and tablets, with the miniaturization of products, the thickness of the product casings used has been decreasing, and in vehicle-related parts such as automobiles, the electrification of self-propelled vehicles such as hybrid vehicles and electric vehicles aimed at weight reduction of vehicles and reduction of fossil fuels due to energy conservation has been progressing.

[0003] However, polyarylene sulfide resin has a problem of being inferior in toughness represented by impact resistance compared to other engineering plastics. In order to solve this problem, generally, a method of blending various elastomers is known. In particular, for example, an olefin-based copolymer containing an epoxy group disclosed in Patent Document 1 is often blended for the purpose of improving impact resistance because of its excellent compatibility with polyarylene sulfide resin. On the other hand, the blending of the olefin-based copolymer component increases the outgas of the polyarylene sulfide composition and deteriorates the mold deposit property during molding, leading to an increase in the frequency of complicated mold cleaning operations.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] The object of the present invention is to provide a polyarylene sulfide resin composition that can suppress outgassing and has excellent toughness, and a molded article made therefrom. [Means for solving the problem]

[0006] As a result of diligent research, the inventors discovered that the above problem could be solved by blending a specific olefin copolymer with polyarylene sulfide resin, leading to the present invention. That is, the present invention is as follows.

[0007] 1. A polyarylene sulfide resin composition characterized by containing 3 to 50 parts by weight of (B) an olefin copolymer containing epoxy groups, wherein the melt flow rate (MFR) measured under conditions of 190°C and a 2.16 kg load is 15 g / 10 min or more, per 100 parts by weight of (A) a polyarylene sulfide resin (component A). 2. The polyarylene sulfide resin composition according to item 1 above, characterized in that component B is a copolymer of α-olefin and a glycidyl ester of an α,β-unsaturated carboxylic acid. 3. The polyarylene sulfide resin composition according to item 1 or 2 above, characterized in that component B contains 15% by weight or more of constituent units derived from glycidyl esters of α,β-unsaturated carboxylic acids. 4. A molded article made from a polyarylene sulfide resin composition as described in any of items 1 to 3 above. [Effects of the Invention]

[0008] According to the present invention, it is possible to provide a polyarylene sulfide resin composition and a molded article made therefrom that can suppress outgassing and have excellent toughness. Molded articles made from the polyarylene sulfide resin composition of the present invention can be suitably used, for example, in electrical and electronic components, vehicle-related parts, aircraft parts, industrial machinery parts, office automation equipment parts, and housing equipment parts. [Modes for carrying out the invention]

[0009] Hereinafter, the details of the present invention will be described.

[0010] <Component A: Polyarylene sulfide resin> The polyarylene sulfide resin used as component A in the present invention is not particularly limited, and a conventionally known polyarylene sulfide resin can be used.

[0011] Examples of the polyarylene sulfide resin include those composed of, as its structural units, for example, p-phenylene sulfide units, m-phenylene sulfide units, o-phenylene sulfide units, phenylene sulfide sulfone units, phenylene sulfide ketone units, phenylene sulfide ether units, diphenylene sulfide units, substituent-containing phenylene sulfide units, branched-structure-containing phenylene sulfide units, etc. Among them, those containing 70 mol% or more, particularly 90 mol% or more of p-phenylene sulfide units are preferable, and further, poly(p-phenylene sulfide) is more preferable.

[0012] The weight average molecular weight of the polyarylene sulfide resin is not particularly limited, but from the viewpoint of obtaining more excellent toughness, 30,000 g / mol or more is preferable, and 35,000 g / mol or more is more preferable. Also, regarding the upper limit, from the viewpoint of melt fluidity, 70,000 g / mol or less is preferable, and 65,000 g / mol or less is more preferable.

[0013] <Component B: Olefin copolymer> The olefin copolymer used as component B of the present invention is preferably an olefin copolymer containing an epoxy group, and more preferably a copolymer of an α-olefin and a glycidyl ester of an α,β-unsaturated carboxylic acid. Examples of α-olefins include ethylene, propylene, 1-butene, 1-pentene, 1-hexene, and 1-octene, with ethylene being particularly preferred. Two or more of these α-olefins can also be used. Examples of glycidyl esters of α,β-unsaturated carboxylic acids include glycidyl acrylate, glycidyl methacrylate, and glycidyl ethacrylate. Furthermore, these copolymers may be copolymerized with α,β-unsaturated carboxylic acids and their alkyl esters, such as acrylic acid, methacrylic acid, methyl acrylate, methyl methacrylate, butyl acrylate, and butyl methacrylate, as well as acrylonitrile, styrene, etc.

[0014] Component B is preferably an olefin copolymer containing 15% by weight or more of structural units derived from glycidyl esters of α,β-unsaturated carboxylic acids. A content of 17% by weight or more is more preferable. If the content is less than 15% by weight, outgassing may increase. There is no particular upper limit for the content, but it is preferably 40% by weight or less.

[0015] Component B must have a melt flow rate (MFR) of 15 g / 10 min or more, preferably 17 g / 10 min or more, and more preferably 20 g / 10 min or more, measured under conditions of 190°C and a 2.16 kg load. If the MFR is less than 15 g / 10 min, component B will not be sufficiently dispersed during extrusion mixing, the reaction with the polyarylene sulfide resin will not proceed, and outgassing will increase. There is no particular upper limit to the MFR, but it is preferably 500 g / 10 min or less, and more preferably 150 g / 10 min or less.

[0016] The content of component B is 3 to 50 parts by weight, preferably 4 to 30 parts by weight, and more preferably 5 to 20 parts by weight, per 100 parts by weight of component A. If the content is less than 3 parts by weight, sufficient toughness cannot be obtained, and if it exceeds 50 parts by weight, outgassing increases.

[0017] <Other ingredients> The polyarylene sulfide resin composition of the present invention may contain other thermoplastic resins to the extent that it does not contradict the spirit of the present invention, and may optionally contain additives such as antioxidants, impact modifiers, plasticizers, inorganic fillers, flame retardants, colorants, light stabilizers, heat stabilizers, antistatic agents, antiblocking agents, lubricants, dispersants, flow modifiers, mold release agents, and crystal nucleating agents.

[0018] <Method for producing polyarylene sulfide resin composition> Any method can be used to produce the polyarylene sulfide resin composition of the present invention. For example, one method involves pre-mixing each component and optionally other components, then melt-kneading and pelletizing them. Means of pre-mixing include a Nauter mixer, V-type blender, Henschel mixer, mechanochemical apparatus, and extruder mixer. Granulation may also be performed during pre-mixing using an extruder granulator or briquetting machine if necessary. After pre-mixing, the mixture is melt-kneaded in a melt-kneader, such as a vented twin-screw extruder, and pelletized using equipment such as a pelletizer. Other melt-kneaders include a Banbury mixer, kneading rolls, and a constant-temperature stirring vessel, but a vented twin-screw extruder is preferred. Alternatively, each component and optionally other components may be supplied independently to a melt-kneader, such as a twin-screw extruder, without pre-mixing.

[0019] <About molded products> The molded article obtained by using the polyarylene sulfide resin composition of the present invention can be obtained by molding the pellets produced as described above. Preferably, it can be obtained by injection molding or extrusion molding. In injection molding, not only ordinary molding methods but also injection compression molding, injection press molding, gas assist injection molding, foam molding (including the method of injecting a supercritical fluid), insert molding, in-mold coating molding, adiabatic mold molding, rapid heating and cooling mold molding, two-color molding, multi-color molding, sandwich molding, and ultra-high speed injection molding can be mentioned. Also, either a cold runner system or a hot runner system can be selected for molding. In extrusion molding, a molded article can be obtained by extruding a round bar and then cutting it into a disc shape, or by extruding a thick sheet and then punching it into a predetermined shape.

Examples

[0020] The present invention will be further described below with reference to examples. Unless otherwise specified, parts in the examples are parts by weight and % is % by weight. The evaluation was carried out by the following methods.

[0021] [Evaluation of Polyarylene Sulfide Resin Composition] (1) Tensile Elongation at Break After drying the pellets obtained by the following method at 130 °C for 7 hours, a multi-purpose test piece type A1 was produced by an injection molding machine (EC130SXII-4Y manufactured by Toshiba Machine Co., Ltd.) under the conditions of a cylinder temperature of 300 °C and a mold temperature of 140 °C, and the tensile elongation at break was measured by a method conforming to ISO527. The larger this value, the more excellent the toughness of the polyarylene sulfide resin composition. (2) Outgassing Amount Using TG8121 manufactured by Rigaku, 5 to 10 mg of the pellets obtained by the following method were heated from room temperature to 320 °C at a rate of 20 °C / 10 min in a nitrogen atmosphere. After the temperature rise, it was held for 30 minutes, and the weight loss ratio (%) during this period was measured. The smaller this value, the less the outgassing amount.

[0022] [Examples 1 to 3, Comparative Examples 1 to 3] According to the addition amounts shown in Table 1, Component A and Component B were supplied to a twin-screw extruder from the first supply port. Here, the first supply port refers to the supply port at the base. The extrusion was carried out using a vented twin-screw extruder with a diameter of 30 mm Φ (manufactured by Nippon Steel Works, Ltd.: TEX30α-31.5BW-2V). After melting and kneading at a screw rotation speed of 200 rpm, a discharge rate of 20 kg / h, and a vacuum degree of 3 kPa at the vent to form a strand, the strand was cut by a pelletizer to obtain pellets. The extrusion temperature was 300 °C.

[0023] Each component with the symbol notation in Table 1 is as follows. <Component A> A-1: Polyphenylene sulfide resin (manufactured by Solvay: Ryton QA281N (product name)) <Component B> B-1: Ethylene glycidyl methacrylate copolymer [olefin copolymer having an epoxy group as a functional group] (manufactured by Sumitomo Chemical Co., Ltd.: Bondfast BF-30C (product name), MFR 30 g / 10 min, 19% by weight of the structural unit derived from the glycidyl ester of α,β-unsaturated carboxylic acid) B-2 (comparative example): Ethylene glycidyl methacrylate copolymer [olefin copolymer having an epoxy group as a functional group] (manufactured by Sumitomo Chemical Co., Ltd.: Bondfast BF-E (product name), MFR 3 g / 10 min, 12% by weight of the structural unit derived from the glycidyl ester of α,β-unsaturated carboxylic acid)

[0024]

Table 1

Claims

1. A polyarylene sulfide resin composition characterized by containing (A) 3 to 50 parts by weight of an olefin copolymer (component B) containing epoxy groups, wherein the melt flow rate (MFR) measured under conditions of 190°C and a 2.16 kg load is 15 g / 10 min or more, per 100 parts by weight of a polyarylene sulfide resin (component A).

2. The polyarylene sulfide resin composition according to claim 1, characterized in that component B is a copolymer of an α-olefin and a glycidyl ester of an α,β-unsaturated carboxylic acid.

3. The polyarylene sulfide resin composition according to claim 1 or 2, characterized in that component B contains 15% by weight or more of structural units derived from glycidyl esters of α,β-unsaturated carboxylic acids.

4. A molded article comprising the polyarylene sulfide resin composition according to claim 1 or 2.

Images