Poly(arylene sulfide) resin composition and molded article thereof

Abstract

Provided are: a poly(arylene sulfide) resin composition capable of attaining both high tracking resistance and excellent strength; and a molded article of the poly(arylene sulfide) resin composition.　The poly(arylene sulfide) resin composition comprises (A) a poly(arylene sulfide) resin, (B) talc, and (C) a fibrous inorganic filler, wherein the talc (B) has an average particle diameter of 10-25 μm, the content of the talc (B) is 60-235 parts by mass per 100 parts by mass of the poly(arylene sulfide) resin (A), the content of the fibrous inorganic filler (C) is 15-190 parts by mass per 100 parts by mass of the poly(arylene sulfide) resin (A), and the total content of the talc (B) and the fibrous inorganic filler (C) is 75-350 parts by mass per 100 parts by mass of the poly(arylene sulfide) resin (A).

Description

Polyarylene sulfide resin composition and molded article thereof

[0001] The present disclosure relates to a polyarylene sulfide resin composition and a molded article thereof.

[0002] Polyarylene sulfide resins, typified by polyphenylene sulfide resins, are widely used in electrical and electronic equipment component materials, automotive component materials, chemical equipment component materials, etc., due to their excellent heat resistance, mechanical properties, chemical resistance, dimensional stability, and flame retardancy. However, polyarylene sulfide resins have inferior tracking resistance compared to other engineering plastics such as polyamide resins. Techniques for improving the tracking resistance of polyarylene sulfide resins include adding magnesium hydroxide to the polyarylene sulfide resin and adding talc to the polyarylene sulfide resin (e.g., Patent Documents 1 and 2).

[0003] JP 2001-288363 A JP 2003-171552 A

[0004] However, when a large amount of magnesium hydroxide or talc is added to a polyarylene sulfide resin composition, the molded product becomes brittle and does not have sufficient strength.

[0005] An object of the present disclosure is to provide a polyarylene sulfide resin composition that can achieve both high tracking resistance and excellent strength, and a molded article thereof.

[0006] The present inventors have found that by using talc having a predetermined average particle size, it is easy to maintain excellent strength and improve tracking resistance even when a large amount of talc is blended into a polyarylene sulfide resin composition, and have completed the present disclosure.

[0007] The present disclosure includes the following aspects: [1] A polyarylene sulfide resin composition comprising: (A) a polyarylene sulfide resin; (B) talc; and (C) a fibrous inorganic filler, wherein the average particle size of the (B) talc is 10 to 25 μm, the content of the (B) talc is 60 to 235 parts by mass per 100 parts by mass of the (A) polyarylene sulfide resin, the content of the (C) fibrous inorganic filler is 15 to 190 parts by mass per 100 parts by mass of the (A) polyarylene sulfide resin, and the total content of the (B) talc and the (C) fibrous inorganic filler is 75 to 350 parts by mass per 100 parts by mass of the (A) polyarylene sulfide resin.

[10] A molded article comprising the polyarylene sulfide resin composition according to the above item "1."

[0008] According to the present disclosure, it is possible to provide a polyarylene sulfide resin composition that can achieve both high tracking resistance and excellent strength, and a molded article thereof.

[0009] An embodiment of the present disclosure will be described in detail below. However, the scope of the present disclosure is not limited to the embodiment described herein, and various modifications can be made without departing from the spirit of the present disclosure. Each aspect disclosed in this specification can be combined with any other feature disclosed in this specification. When multiple upper and lower limit values ​​are described for a specific parameter, any of these upper and lower limit values ​​can be combined to form a suitable numerical range. The lower and / or upper limit values ​​of a numerical range described in this disclosure are numerical values ​​within that range and may be replaced with numerical values ​​shown in the examples. When multiple numerical ranges are described for multiple parameters, any numerical range can be adopted for each parameter and combined as desired. The expression "X to Y" indicating a numerical range means "X or more and Y or less." If a specific description described for one embodiment also applies to other embodiments, that description may be omitted in other embodiments.

[0010] [Polyarylene sulfide resin composition] The polyarylene sulfide resin composition according to this embodiment (hereinafter also simply referred to as "resin composition") contains (A) a polyarylene sulfide resin, (B) talc, and (C) a fibrous inorganic filler.

[0011] <(A) Polyarylene sulfide resin> (A) Polyarylene sulfide resin is a resin having a repeating unit represented by the following general formula (I): -(Ar-S)- (I) (where Ar represents an arylene group).

[0012] The arylene group is not particularly limited, and examples thereof include a p-phenylene group, an m-phenylene group, an o-phenylene group, a substituted phenylene group, a p,p'-diphenylene sulfone group, a p,p'-biphenylene group, a p,p'-diphenylene ether group, a p,p'-diphenylene carbonyl group, a naphthalene group, etc. The (A) polyarylene sulfide resin can be a homopolymer using the same repeating unit among the repeating units represented by the general formula (I) above, or a copolymer containing different repeating units.

[0013] As the homopolymer, one having a p-phenylene group as the arylene group and a p-phenylene sulfide group as a repeating unit is preferred. This is because homopolymers having a p-phenylene sulfide group as a repeating unit have extremely high heat resistance and exhibit high strength, high rigidity, and high dimensional stability over a wide temperature range. By using such homopolymers, molded articles with excellent physical properties can be obtained.

[0014] As the copolymer, a combination of two or more different arylene sulfide groups among the above-mentioned arylene group-containing arylene sulfide groups can be used. Among these, a combination containing a p-phenylene sulfide group and an m-phenylene sulfide group is preferred from the viewpoint of obtaining a molded product with high physical properties such as heat resistance, moldability, and mechanical properties. A polymer containing 70 mol% or more of p-phenylene sulfide groups is more preferred, and a polymer containing 80 mol% or more is even more preferred. The polyarylene sulfide resin (A) having phenylene sulfide groups is a polyphenylene sulfide resin (PPS resin). The polyarylene sulfide resin (A) may be used alone or in combination of two or more types.

[0015] Polyarylene sulfide resins are generally known to have molecular structures that are substantially linear and have no branching or crosslinking structures, and structures that have branches or crosslinking structures, depending on the production method, and either type is effective in the present embodiment.

[0016] (A) Polyarylene sulfide resin at 310°C and a shear rate of 1200 sec －１ From the viewpoint of improving moldability and toughness, the melt viscosity measured by is preferably 3 to 250 Pa·s, more preferably 5 to 150 Pa·s, and even more preferably 8 to 80 Pa·s.

[0017] The temperature-drop crystallization temperature (Tc) of the (A) polyarylene sulfide resin is preferably 215°C to 260°C, more preferably 220°C to 250°C, and particularly preferably 230°C to 240°C. By setting the temperature-drop crystallization temperature (Tc) of the (A) polyarylene sulfide resin to 215°C or higher, the strength of the molded article can be more easily increased. Furthermore, by setting the temperature-drop crystallization temperature (Tc) to 260°C or lower, the moldability of the resin composition can be more easily increased.

[0018] The temperature-decreasing crystallization temperature (Tc) is defined as the exothermic peak temperature associated with crystallization observed when the (A) polyarylene sulfide resin is heated to 340°C by a differential scanning calorimeter, melted, and then cooled at a rate of 10°C / min. As a method for increasing the temperature-decreasing crystallization temperature (Tc) of the (A) polyarylene sulfide resin, a method using a washing treatment after polymerization is preferred because it is simple in terms of process, but is not necessarily limited to this method. An example of a washing treatment method is a method in which the polymer after polymerization is washed with an acidic aqueous solution of appropriate acidity. In this case, examples of the acid used as the acidic aqueous solution include inorganic acids such as hydrochloric acid, sulfuric acid, and ammonium chloride; saturated fatty acids such as acetic acid, formic acid, propionic acid, butyric acid, valeric acid, and caproic acid; unsaturated fatty acids such as acrylic acid, crotonic acid, and oleic acid; aromatic carboxylic acids such as benzoic acid, phthalic acid, and salicylic acid; dicarboxylic acids such as oxalic acid, maleic acid, and fumaric acid; methanesulfonic acid and paratoluenesulfonic acid; and among these, hydrochloric acid, acetic acid, and ammonium chloride are preferred. Furthermore, before and after washing with the acidic aqueous solution, washing with an organic solvent such as acetone or water may be performed as necessary. For example, when the temperature-lowering crystallization temperature (Tc) of the (A) polyarylene sulfide resin is low, the temperature-lowering crystallization temperature (Tc) of the (A) polyarylene sulfide resin can be increased by washing the resin with the above-mentioned compound (e.g., acetic acid, ammonium chloride, etc.).

[0019] The method for producing the (A) polyarylene sulfide resin is not particularly limited, and it can be produced by a conventionally known production method. For example, it can be produced by synthesizing a low-molecular-weight polyarylene sulfide resin and then polymerizing it at high temperature in the presence of a known polymerization aid to increase the molecular weight. It may also be produced by blending multiple types of polyarylene sulfide resins. In this case, it can also be produced by combining polyarylene sulfide resins with different melt viscosities. When combining polyarylene sulfide resins with different melt viscosities, it is preferable that the melt viscosity of the resulting resin be within the above range.

[0020] Polyarylene sulfide resins produced by a general polymerization method are usually washed several times with an organic solvent such as water or acetone to remove by-product impurities, etc. As described above, in one embodiment, the polyarylene sulfide resin (A) may then be further washed with acetic acid, ammonium chloride, etc.

[0021] In one embodiment, the content of the (A) polyarylene sulfide resin in the total amount (100% by mass) of the resin composition can be, but is not limited to, 10 to 50% by mass, 15 to 50% by mass, or 15 to 45% by mass.

[0022] In one embodiment, the content of the (A) polyarylene sulfide resin in the total amount (100% by mass) of thermoplastic resins contained in the resin composition is preferably more than 50% by mass, more preferably 70% by mass or more, even more preferably 80% by mass or more, even more preferably 90% by mass or more, and may be 100% by mass. In one embodiment, when the resin composition contains an (E) elastomer described below, the total content of the (A) polyarylene sulfide resin and the (E) elastomer in the total amount (100% by mass) of thermoplastic components contained in the resin composition is preferably more than 50% by mass, more preferably 70% by mass or more, even more preferably 80% by mass or more, even more preferably 90% by mass or more, and may be 100% by mass.

[0023] <(B) Talc> The resin composition contains (B) talc. By containing (B) talc, the tracking resistance of the molded article tends to be improved. Talc is a magnesium silicate hydrate (3MgO.4SiO ２ ・H ２ Talc is a type of silicate mineral composed mainly of (B) talc. Talc generally contains other impurities, but the type and amount of impurities vary depending on the origin of the talc ore, and in this embodiment, the origin of the talc ore is not limited. (B) Talc may be used alone or in combination of two or more types.

[0024] The average particle size of (B) talc is 10 to 25 μm, preferably 12 to 25 μm, more preferably 13 to 25 μm, even more preferably 14 to 25 μm, still more preferably 14 to 20 μm, and particularly preferably 14 to 18 μm. In this specification, the average particle size refers to the volume-based average particle size (D50) measured by a laser diffraction / scattering method.

[0025] It has been surprisingly found that by setting the average particle size of (B) talc within the above range, both tensile strength and flexural strength are more likely to be improved than when talc with a smaller or larger average particle size is used. As a result, even when a large amount of talc is blended into the resin composition to improve tracking resistance (for example, when more than 60 parts by mass, or even 100 parts by mass or more, per 100 parts by mass of (A) polyarylene sulfide resin is blended), high strength can be maintained. As a result, a polyarylene sulfide resin composition can be obtained that can achieve both high tracking resistance and excellent strength. The mechanism behind this is not yet clear. For example, it is thought that by setting the average particle size of (B) talc within the above range, dispersibility in the resin composition is improved, but this is not limited to this. In one embodiment, it has been found that a resin composition containing (B) talc having the above average particle size is likely to have high strength and flexural modulus. A resin composition with a high flexural modulus has excellent rigidity in addition to tracking resistance and strength.

[0026] The shape of the talc (B) is not limited and may be plate-like or granular, but plate-like is preferred from the viewpoint that the strength of the molded product is likely to be higher. Examples of plate-like talc (B) include those whose shapes are plate-like, flat-like, or scaly, as published by manufacturers in catalogs, etc.

[0027] The talc (B) may be surface-treated with various commonly known surface treatment agents such as epoxy compounds, isocyanate compounds, silane compounds, titanate compounds, and fatty acids. The surface treatment can improve adhesion to the polyarylene sulfide resin (A). It is preferable to apply the surface treatment agent to the talc (B) in advance to perform surface treatment or convergence treatment before preparing the material.

[0028] The content of (B) talc is 60 to 235 parts by mass, preferably 70 to 200 parts by mass, more preferably 80 to 180 parts by mass, even more preferably 90 to 160 parts by mass, still more preferably 100 to 140 parts by mass, and particularly preferably 110 to 130 parts by mass, relative to 100 parts by mass of (A) polyarylene sulfide resin. By setting the content of (B) talc within the above range, it is easier for the molded product to achieve both high tracking resistance and excellent strength.

[0029] <(C) Fibrous Inorganic Filler> The resin composition contains (C) a fibrous inorganic filler. By containing (C) a fibrous inorganic filler, the strength of the molded article is likely to be higher and the tracking resistance is likely to be higher. As a result, it is easier to achieve both high tracking resistance and excellent strength.

[0030] Examples of materials for the (C) fibrous inorganic filler include glass fiber, zinc oxide fiber, titanium oxide fiber, wollastonite, silica fiber, silica-alumina fiber, zirconia fiber, boron nitride fiber, silicon nitride fiber, boron fiber, and potassium titanate fiber, and it is preferable to use one or more of these. Among these, it is more preferable to include glass fiber. Hollow fibers can also be used as the (C) fibrous inorganic filler for the purpose of reducing the specific gravity of the resin composition, etc.

[0031] The (C) fibrous inorganic filler may be surface-treated with various commonly known surface treatment agents such as epoxy compounds, isocyanate compounds, silane compounds, titanate compounds, and fatty acids. The surface treatment can improve adhesion to the (A) polyarylene sulfide resin. It is preferable to apply the surface treatment agent to the (C) fibrous inorganic filler to perform surface treatment or convergence treatment before preparing the material.

[0032] Examples of the (C) fibrous inorganic filler include fibrous inorganic fillers whose cross-sectional shape perpendicular to the longitudinal direction of the fiber is circular, elliptical, semicircular, cocoon-shaped (an ellipse with a portion of its longitudinal direction recessed inward), rectangular, or similar shapes. From the viewpoint of suppressing an increase in the melt viscosity of the resin composition and improving moldability, it is preferable that the cross-sectional shape perpendicular to the longitudinal direction of the fiber is elliptical, semicircular, cocoon-shaped (an ellipse with a portion of its longitudinal direction recessed inward), rectangular, or similar shapes.

[0033] The (C) fibrous inorganic filler has a diameter ratio (hereinafter simply referred to as "diameter ratio"), which is the ratio of the major axis to the minor axis in a cross section perpendicular to the longitudinal direction, but is not limited thereto. It is preferably 3.0 or more, more preferably 3.0 to 10.0, even more preferably 3.5 to 8.0, even more preferably 3.8 to 7.0, and particularly preferably 3.8 to 6.0. By setting the diameter ratio of the (C) fibrous inorganic filler within the above range, an increase in the melt viscosity of the resin composition can be suppressed, thereby improving moldability. Furthermore, when the resin composition contains the (D) alkoxysilane described below, using a (C) fibrous inorganic filler having the above diameter ratio allows the (C) fibrous inorganic filler and the (D) alkoxysilane to act synergistically, thereby further increasing the strength of the resin composition.

[0034] The "major diameter of a cross section perpendicular to the longitudinal direction" is the longest linear distance in a cross section perpendicular to the longitudinal direction of the fiber, and the "minor diameter of a cross section perpendicular to the longitudinal direction" is the longest linear distance perpendicular to the major diameter in the cross section. The diameter difference ratio refers to the diameter difference ratio of the initial shape (shape before melt-kneading). The diameter difference ratio can be calculated using a scanning electron microscope and image processing software, and is the arithmetic average value measured for any 10 pieces of (C) fibrous inorganic filler. The diameter difference ratio can also be the manufacturer's value (value published by the manufacturer in a catalog, etc.).

[0035] The major axis of the cross section perpendicular to the longitudinal direction of the (C) fibrous inorganic filler is preferably 10 to 40 μm, more preferably 20 to 30 μm. The minor axis of the cross section perpendicular to the longitudinal direction of the (C) fibrous inorganic filler is preferably 1 to 20 μm, more preferably 3 to 15 μm. The major axis and minor axis of the cross section perpendicular to the longitudinal direction can both be calculated using a scanning electron microscope and image processing software, and are taken as the arithmetic average values ​​measured for 10 pieces of (C) fibrous inorganic filler. In addition, the major axis and minor axis of the cross section perpendicular to the longitudinal direction can both be manufacturer values ​​(values ​​published by the manufacturer in a catalog, etc.)

[0036] From the viewpoint of easily increasing the strength of molded articles, the average fiber length of the (C) fibrous inorganic filler is preferably 0.01 to 3.5 mm, more preferably 0.05 to 3.5 mm, even more preferably 0.1 to 3.5 mm, and particularly preferably 0.5 to 3 mm, as the average fiber length (cut length) before melt-kneading into the resin composition. The average fiber length can be calculated using a scanning electron microscope and image processing software, and is the arithmetic average value measured for 1,000 pieces of (C) fibrous inorganic filler. The average fiber length can also be determined by the manufacturer (a value published by the manufacturer in a catalog, etc.).

[0037] The average fiber length of the (C) fibrous inorganic filler in the molded article is preferably 50 to 1,000 μm, more preferably 100 to 900 μm, from the viewpoint of further increasing the strength of the molded article. The average fiber length of the (C) fibrous inorganic filler in the molded article can be calculated by heating the molded article at 600° C. for 3 to 5 hours, incinerating the residue, dispersing 3 mg of the residue in a 5% polyethylene glycol aqueous solution, stirring thoroughly, transferring 10 mL to a Petri dish, and using an image measuring device to calculate the arithmetic average value measured for 1,000 pieces of (C) fibrous inorganic filler.

[0038] The content of the (C) fibrous inorganic filler is 15 to 190 parts by mass, preferably 20 to 180 parts by mass, more preferably 30 to 160 parts by mass, even more preferably 40 to 150 parts by mass, still more preferably 50 to 130 parts by mass, and particularly preferably 50 to 120 parts by mass, relative to 100 parts by mass of the (A) polyarylene sulfide resin. By setting the content of the (C) fibrous inorganic filler within the above range, the strength of the molded article is likely to be higher and the tracking resistance is likely to be higher.

[0039] <Total Content of (B) Talc and (C) Fibrous Inorganic Filler> The total content of (B) talc and (C) fibrous inorganic filler is 75 to 350 parts by mass, preferably 80 to 330 parts by mass, more preferably 90 to 300 parts by mass, even more preferably 100 to 280 parts by mass, still more preferably 120 to 250 parts by mass, and particularly preferably 150 to 230 parts by mass, per 100 parts by mass of (A) polyarylene sulfide resin. By setting the total content of (B) talc and (C) fibrous inorganic filler within the above range, the strength of the molded article is likely to be higher and the tracking resistance is likely to be higher.

[0040] As described later, the resin composition may contain fillers other than (B) talc and (C) fibrous inorganic filler as needed, but from the viewpoint of more easily achieving both high tracking resistance and excellent strength, the total content of (B) talc and (C) fibrous inorganic filler in the total amount (100 mass%) of the filler is preferably 50 mass% or more, more preferably 80 mass% or more, and even more preferably 90 mass% or more. In one embodiment, the filler consists only of (B) talc and (C) fibrous inorganic filler.

[0041] <Other Fillers> The resin composition may contain other fillers, if necessary, in addition to (B) talc and (C) fibrous inorganic filler. Examples of other inorganic fillers include organic fillers, powdery granular inorganic fillers other than talc (granular), and plate-like inorganic fillers other than talc (plate-like).

[0042] Examples of organic fillers include polyester fibers, polyamide fibers, fluorine fibers, and ebonite powder. Examples of granular inorganic fillers include carbon black; silica, quartz powder, glass beads, glass powder, silicates such as calcium silicate, aluminum silicate, and diatomaceous earth; metal oxides such as iron oxide, titanium oxide, zinc oxide, and alumina; metal carbonates such as calcium carbonate and magnesium carbonate; metal sulfates such as calcium sulfate and barium sulfate; and silicon carbide, silicon nitride, boron nitride, and various metal powders. Examples of plate-like inorganic fillers include glass flakes, mica, kaolin, clay, alumina, and various metal foils. The average particle size (D50) of the granular inorganic filler and plate-like inorganic filler is not limited and can be, for example, 0.1 to 100 μm. The other fillers may be used alone or in combination of two or more.

[0043] The content of the other fillers is not limited, and can be, for example, 0 to 50 parts by mass, or can be less than 40 parts by mass, relative to 100 parts by mass of the (A) polyarylene sulfide resin. In one embodiment, when other fillers are contained, from the viewpoint of the strength and tracking resistance of the molded article, the total content of the (B) talc, (C) fibrous inorganic filler, and other fillers is preferably 75 to 350 parts by mass relative to 100 parts by mass of the (A) polyarylene sulfide resin.

[0044] <(D) Alkoxysilane Compound> The resin composition may contain a (D) alkoxysilane compound. By containing the (D) alkoxysilane compound, the strength of the molded article tends to be increased. In one embodiment, the (D) alkoxysilane compound preferably has one or more groups selected from an epoxy group, an amino group, a vinyl group, a (meth)acrylic group, an isocyanate group, and a mercapto group.

[0045] In one embodiment, the alkoxysilane compound (D) is preferably represented by the following formula (II): １ ｎ Si(OR ２ ) ４－ｎ (II) In formula (II), R １ is an alkyl group having 1 to 18 (preferably 1 to 10) carbon atoms and having an epoxy group, an amino group, a vinyl group, a (meth)acrylic group, an isocyanate group, or a mercapto group, and R ２ is an alkyl group having 1 to 4 carbon atoms, and n is an integer of 1 to 3.

[0046] Examples of the alkoxysilane compound (D) include alkoxysilanes such as epoxyalkoxysilanes, aminoalkoxysilanes, vinylalkoxysilanes, (meth)acrylicalkoxysilanes, isocyanatealkoxysilanes, and mercaptoalkoxysilanes, and it is preferable to include one or more of these. The number of carbon atoms in the alkoxy group is preferably 1 to 10, and particularly preferably 1 to 4.

[0047] Examples of epoxyalkoxysilanes include γ-glycidoxypropyltrimethoxysilane, β-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, and γ-glycidoxypropyltriethoxysilane.

[0048] Examples of aminoalkoxysilanes include γ-aminopropyltrimethoxysilane, γ-aminopropyltriethoxysilane, γ-aminopropylmethyldimethoxysilane, γ-aminopropylmethyldiethoxysilane, N-(β-aminoethyl)-γ-aminopropyltrimethoxysilane, N-phenyl-γ-aminopropyltrimethoxysilane, γ-diallylaminopropyltrimethoxysilane, and γ-diallylaminopropyltriethoxysilane.

[0049] Examples of vinylalkoxysilanes include vinyltrimethoxysilane, vinyltriethoxysilane, and vinyltris(β-methoxyethoxy)silane.

[0050] Examples of (meth)acrylalkoxysilanes include γ-acryloxypropyltriethoxysilane, γ-acryloxypropyltrimethoxysilane, γ-methacryloxypropyltriethoxysilane, γ-methacryloxypropyltrimethoxysilane, γ-methacryloxypropylmethyldimethoxysilane, and γ-methacryloxypropylmethyldiethoxysilane.

[0051] Examples of the isocyanate alkoxysilane include γ-isocyanate propyl triethoxysilane and γ-isocyanate propyl trimethoxysilane.

[0052] Examples of mercaptoalkoxysilanes include γ-mercaptopropyltrimethoxysilane and γ-mercaptopropyltriethoxysilane.

[0053] Of these, epoxyalkoxysilane and aminoalkoxysilane are more preferred, and γ-aminopropyltriethoxysilane is particularly preferred.

[0054] The content of the (D) alkoxysilane compound is preferably 0.1 to 10 parts by mass, more preferably 0.2 to 8 parts by mass, even more preferably 0.3 to 5 parts by mass, and even more preferably 0.5 to 3 parts by mass, relative to 100 parts by mass of the (A) polyarylene sulfide resin. By setting the content of the (D) alkoxysilane compound within the above range, the strength of the molded article tends to be increased. As described above, the (B) talc and the (C) fibrous inorganic filler may be surface-treated with a silane compound such as an alkoxysilane compound, but the content thereof is not included in the content of the (D) alkoxysilane compound.

[0055] <(E) Elastomer> The resin composition may contain an (E) elastomer. By containing the (E) elastomer, tracking resistance is likely to be high even when the content of (B) talc is lower than the above-mentioned range. As a result, high tracking resistance and excellent strength are more likely to be compatible.

[0056] Examples of the (E) elastomer include olefin-based elastomers, styrene-based elastomers, polyester-based elastomers, polyamide-based elastomers, and urethane-based elastomers, and it is preferable to contain one or more selected from the group consisting of these. From the viewpoints of extrusion processability and tracking resistance of molded articles, it is more preferable to contain an olefin-based elastomer. The (E) elastomer may be used alone or in combination of two or more types.

[0057] Olefin elastomers include homopolymers and copolymers of α-olefins, such as ethylene, propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 4-methyl-1-pentene, 4-methyl-1-hexene, 1-nonene, and 1-decene.

[0058] The olefin-based elastomer may have a reactive functional group. Examples of olefin-based elastomers having a reactive functional group include acid-modified elastomers modified with acids or acid anhydrides such as (meth)acrylic acid or maleic anhydride; elastomers using copolymerizable monomers having glycidyl groups or epoxy groups (glycidyl (meth)acrylate, etc.); and epoxy-modified elastomers obtained by epoxidizing the unsaturated bonds of elastomers. Specific examples of olefin-based elastomers having a reactive functional group include those containing, in addition to structural units derived from α-olefins, structural units derived from glycidyl esters of α,β-unsaturated acids. In one embodiment, from the viewpoint of improving moldability, olefin-based elastomers that do not have reactive functional groups or have a low content of reactive functional groups are preferred.

[0059] Preferred examples of the olefin-based elastomer include, but are not limited to, an ethylene-propylene copolymer, an ethylene-butene copolymer, an ethylene-octene copolymer, an ethylene-propylene-butene copolymer, an ethylene-propylene-diene copolymer, an ethylene-ethyl acrylate copolymer, an ethylene-vinyl acetate copolymer, an ethylene-glycidyl methacrylate copolymer, etc. In one embodiment, from the viewpoint of extrusion processability, the (E) elastomer preferably contains one or more selected from an ethylene-propylene copolymer, an ethylene-butene copolymer, an ethylene-octene copolymer, an ethylene-propylene-butene copolymer, and an ethylene-propylene-diene copolymer, and more preferably contains an ethylene-octene copolymer.

[0060] Examples of styrene-based elastomers include, but are not limited to, block copolymers composed of a polymer block mainly composed of a vinyl aromatic compound such as styrene and a polymer block mainly composed of an unhydrogenated and / or hydrogenated conjugated diene compound.

[0061] Examples of polyester elastomers include, but are not limited to, block copolymers having an aromatic polyester such as polyethylene terephthalate or polybutylene terephthalate as a hard segment and a polyether such as polyethylene glycol or polytetramethylene glycol, or an aliphatic polyester such as polyethylene adipate, polybutylene adipate or polycaprolactone as a soft segment.

[0062] Examples of polyamide elastomers include, but are not limited to, block copolymers having nylon 6, nylon 66, nylon 11, nylon 12, or the like as hard segments and polyether or aliphatic polyester as soft segments.

[0063] Examples of urethane-based elastomers include, but are not limited to, block copolymers having a polyurethane as a hard segment obtained by reacting a diisocyanate such as 4,4'-diphenylmethane diisocyanate, 4,4'-dicyclohexylmethane diisocyanate, tolylene diisocyanate, or hexamethylene diisocyanate with a glycol such as ethylene glycol or tetramethylene glycol, and a polyether such as polyethylene glycol, polypropylene glycol, or polytetramethylene glycol, or an aliphatic polyester such as polyethylene adipate, polybutylene adipate, or polycaprolactone as a soft segment.

[0064] From the viewpoint of easily improving tracking resistance even when the content of (B) talc is lower within the above-mentioned range, the content of the (E) elastomer is preferably 1 to 150 parts by mass, more preferably 5 to 100 parts by mass, and even more preferably 5 to 50 parts by mass relative to 100 parts by mass of the (A) polyarylene sulfide resin. In one embodiment, the content of the elastomer may be 5 to 30 parts by mass, 5 to 20 parts by mass, or 8 to 14 parts by mass relative to 100 parts by mass of the (A) polyarylene sulfide resin.

[0065] In one embodiment, when the resin composition contains the (D) alkoxysilane compound and / or the (E) elastomer, the total content of the (A) polyarylene sulfide resin, (B) talc, (C) fibrous inorganic filler, and the (D) alkoxysilane compound and / or the (E) elastomer is preferably 70% by mass or more, more preferably 80 to 100% by mass, even more preferably 95 to 100% by mass, and particularly preferably 98 to 100% by mass, based on the total amount (100% by mass) of the resin composition.

[0066] <Other Additives, etc.> The resin composition may contain known additives generally added to thermoplastic resins and thermosetting resins to impart desired properties according to the intended purpose, as long as the effects of the present invention are not impaired. Examples of additives include burr inhibitors, release agents, lubricants, plasticizers, flame retardants, colorants such as dyes and pigments, crystallization accelerators, crystal nucleating agents, various antioxidants, heat stabilizers, weather resistance stabilizers, and corrosion inhibitors. Examples of release agents include polyethylene wax, fatty acid esters, fatty acid amides, etc. Examples of crystal nucleating agents include boron nitride, kaolin, carbon black, and carbon nanotubes. Examples of corrosion inhibitors include zinc oxide and zinc carbonate. The content of the additives may be 5% by mass or less based on the total amount (100% by mass) of the resin composition.

[0067] The resin composition may contain magnesium hydroxide from the viewpoint of easily improving tracking resistance. Magnesium hydroxide is represented by the chemical formula Mg(OH) ２ Preferably, the magnesium hydroxide has a high purity and contains 80% by mass or more of an inorganic substance represented by the formula (I). From the viewpoint of facilitating enhanced tracking resistance, the volume-based average particle size (D50) of the magnesium hydroxide measured by a laser diffraction / scattering method is preferably 0.01 to 1.5 μm, more preferably 0.05 to 1.0 μm, and even more preferably 0.1 to 0.8 μm.

[0068] The resin composition according to this embodiment can have high tracking resistance even if it does not contain magnesium hydroxide or if the content of magnesium hydroxide is small. In one embodiment, the content of magnesium hydroxide may be less than 50 parts by mass, may be 0 to 30 parts by mass, or may be 0 to 5 parts by mass, relative to 100 parts by mass of the polyarylene sulfide resin (A). In one embodiment, the resin composition does not need to contain magnesium hydroxide.

[0069] In addition to the above components, the resin composition may also contain a small amount of other auxiliary thermoplastic resin components depending on the purpose. The other thermoplastic resin used here may be any resin stable at high temperatures. Examples include aromatic polyesters composed of aromatic dicarboxylic acids and diols or oxycarboxylic acids, such as polyethylene terephthalate and polybutylene terephthalate; polyamides, polycarbonates, ABS, polyphenylene oxide, polyalkyl acrylates, polysulfones, polyethersulfones, polyetherimides, polyether ketones, fluororesins, liquid crystal polymers, and cyclic olefin copolymers. Two or more of these thermoplastic resins may also be mixed and used. The content of the other thermoplastic resin components may be, for example, 20% by mass or less of the total amount (100% by mass) of the resin composition.

[0070] <Method for producing polyarylene sulfide resin composition> The method for producing the resin composition is not particularly limited, and the resin composition can be produced by melt-kneading the above-mentioned components by a known method. For example, any of a method in which the components are mixed and then kneaded and extruded in an extruder to prepare pellets, a method in which pellets with different compositions are first prepared, a predetermined amount of the pellets are mixed, and molded to obtain a molded product of the desired composition after molding, and a method in which one or more of the components are directly charged into a molding machine can be used.

[0071] The resin composition was heated at a temperature of 310°C and a shear rate of 1000 sec －１The melt viscosity measured by is preferably 150 to 400 Pa s, more preferably 180 to 390 Pa s, even more preferably 200 to 380 Pa s, and particularly preferably 230 to 350 Pa s. By setting the melt viscosity of the resin composition within the above range, moldability can be improved.

[0072] The resin composition according to this embodiment can achieve both high tracking resistance and excellent strength. In one embodiment, the resin composition has a comparative tracking index of preferably 450 V or more, more preferably 500 V or more, measured in accordance with UL746A. A resin composition having a comparative tracking index of 450 V or more has excellent tracking resistance. The comparative tracking index is determined by drying the resin composition at 140°C for 3 hours, and then preparing a flat test piece having dimensions of 50 mm x 70 mm x 3 mm thick by injection molding at a cylinder temperature of 320°C and a mold temperature of 150°C, and measuring the value of this test piece in accordance with UL746A.

[0073] In one embodiment, the resin composition has a tensile strength measured in accordance with ISO 527-1, 2 of preferably 90 MPa or more, more preferably 93 MPa or more, and even more preferably 95 MPa or more.

[0074] In one embodiment, the resin composition has a flexural strength measured in accordance with ISO178 of preferably 150 MPa or more, more preferably 153 MPa or more, and even more preferably 160 MPa or more.

[0075] In one embodiment, the resin composition also has excellent rigidity. In one embodiment, the resin composition has a flexural modulus measured in accordance with ISO 178 of preferably 19,000 MPa or more, more preferably 21,000 MPa or more, and even more preferably 22,000 MPa or more.

[0076] Test pieces used to measure tensile strength, flexural strength, and flexural modulus are prepared by drying pellets of the resin composition at 140° C. for 3 hours and then injection molding them at a cylinder temperature of 320° C. and a mold temperature of 150° C. The test piece used to measure tensile strength is an A-type test piece (width 10 mm, thickness 4 mmt) conforming to ISO 3167:2002, and the test piece used to measure flexural strength and flexural modulus is a test piece (width 10 mm, thickness 4 mmt) conforming to ISO 316.

[0077] The resin composition according to the present embodiment can achieve both high tracking resistance and excellent strength, and therefore can be preferably used for producing components that require tracking resistance and strength, such as insulating members for electric and electronic components, such as relays, switches, connectors, actuators, sensors, transformer bobbins, terminal blocks, covers, sockets, coils, and plugs.

[0078] [Molded Article] The molded article according to this embodiment contains the polyarylene sulfide resin composition described above. Since the molded article contains the polyarylene sulfide resin composition described above, it has high tracking resistance and excellent strength.

[0079] The method for producing the molded article is not limited, and any known method can be used. For example, the molded article can be produced by feeding the polyarylene sulfide resin composition described above into an extruder, melt-kneading the composition, and pelletizing the pellets, and then feeding the pellets into an injection molding machine equipped with a predetermined mold and injection molding the pellets.

[0080] The molded article according to the present embodiment has high tracking resistance and excellent strength, and therefore can be preferably used as a component requiring tracking resistance and strength. For example, the molded article may be an insulating component for an electric or electronic component such as a relay, a switch, a connector, an actuator, a sensor, a transformer bobbin, a terminal block, a cover, a socket, a coil, or a plug.

[0081] A non-limiting list of exemplary embodiments and combinations of exemplary embodiments of the present disclosure is disclosed below: [1] A polyarylene sulfide resin composition comprising: (A) a polyarylene sulfide resin, (B) talc, and (C) a fibrous inorganic filler, wherein the average particle size of the (B) talc is 10 to 25 μm, the content of the (B) talc is 60 to 235 parts by mass per 100 parts by mass of the (A) polyarylene sulfide resin, the content of the (C) fibrous inorganic filler is 15 to 190 parts by mass per 100 parts by mass of the (A) polyarylene sulfide resin, and the total content of the (B) talc and the (C) fibrous inorganic filler is 75 to 350 parts by mass per 100 parts by mass of the (A) polyarylene sulfide resin. [2] The polyarylene sulfide resin composition according to [1], which contains 0.1 to 10 parts by mass of an alkoxysilane compound (D) relative to 100 parts by mass of the polyarylene sulfide resin (A). [3] The polyarylene sulfide resin composition according to [1] or [2], which contains 1 to 150 parts by mass of an elastomer (E) relative to 100 parts by mass of the polyarylene sulfide resin (A). [4] The polyarylene sulfide resin composition according to any one of [1] to [3], wherein the fibrous inorganic filler (C) has a difference-in-diameter ratio, which is the ratio of the major axis to the minor axis in a cross section perpendicular to the longitudinal direction, of 3.0 or more. [5] The polyarylene sulfide resin composition according to any one of [1] to [4], wherein the alkoxysilane compound (D) has one or more groups selected from the group consisting of an epoxy group, an amino group, a vinyl group, a (meth)acrylic group, an isocyanate group, and a mercapto group. [6] The polyarylene sulfide resin composition according to any one of [1] to [5], wherein the elastomer (E) comprises an olefin-based elastomer, a styrene-based elastomer, a polyester-based elastomer, a polyamide-based elastomer, and a urethane-based elastomer. －１The polyarylene sulfide resin composition according to any one of [1] to [6], having a melt viscosity of 150 to 400 Pa·s as measured by a tensile strength test. [8] The polyarylene sulfide resin composition according to any one of [1] to [7], having a tensile strength of 90 MPa or more as measured in accordance with ISO 527-1, 2. [9] The polyarylene sulfide resin composition according to any one of [1] to [8], having a flexural strength of 150 MPa or more as measured in accordance with ISO 178.

[10] A molded article comprising the polyarylene sulfide resin composition according to any one of [1] to [9]. The configurations and combinations thereof in each embodiment are merely examples, and additions, omissions, substitutions, and other modifications of the configurations are possible as appropriate within the scope of the gist of the present disclosure. The present disclosure is not limited by the embodiments.

[0082] The present disclosure will be explained in more detail below by showing examples, but interpretation of the present disclosure is not limited to these examples.

[0083] [Materials] The materials used in the examples and comparative examples are as follows. <Polyarylene sulfide resin> PPS: polyphenylene sulfide resin, "Fortron KPS" manufactured by Kureha Corporation (melt viscosity: 30 Pa·s (shear rate: 1200 sec) －１ The melt viscosity of the PPS resin was measured as follows: Using a Capillograph manufactured by Toyo Seiki Seisakusho Co., Ltd., a flat die of 1 mmφ×20 mmL was used as a capillary, and the barrel temperature was 310°C, the shear rate was 1200 sec －１The melt viscosity of the PPS resin was measured at 340°C. The Tc of the PPS resin was measured as follows: Approximately 5 mg of the PPS resin was weighed out, and using a PerkinElmer DSC-8500 differential scanning calorimeter, the temperature was increased at a rate of 10°C / min, held at 340°C for 5 minutes, and then decreased at a rate of 10°C / min. The crystallization peak (exothermic peak) temperature was read from the resulting DSC chart to determine the Tc. <Talc> Talc-1: Talc, manufactured by Matsumura Sangyo Co., Ltd., "Crown Talc PO-U2", average particle size 15 μm Talc-2: Talc, manufactured by Matsumura Sangyo Co., Ltd., "Crown Talc Official PP", average particle size 14 μm Talc-3: Talc, manufactured by Matsumura Sangyo Co., Ltd., "Crown Talc ID-S", average particle size 15 μm Talc-4: Talc, manufactured by Matsumura Sangyo Co., Ltd., "Hi Filler #5000PA", average particle size 4 μm Talc-5: Talc, manufactured by Matsumura Sangyo Co., Ltd., "Crown Talc DR", average particle size 41 μm Talc-6: Talc, manufactured by Matsumura Sangyo Co., Ltd., "Hi Filler ID-PJS", average particle size 5 μm Talc-7: Talc, manufactured by Hayashi Kasei Co., Ltd., "UPN HS-T0.8", average particle size 5 μm <Fibrous inorganic fillers> GF-1: Glass fiber, manufactured by Nippon Electric Glass Co., Ltd., chopped strand ECS 03 T-717, average fiber length 3 mm, cross section nearly circular, major axis 13 μm, minor axis 13 μm, diameter ratio 1.0 GF-2: Glass fiber, manufactured by Nippon Electric Glass Co., Ltd., flat glass fiber ECS 03 T-760-FGF, average fiber length 3 mm, cross section oval, major axis 28 μm, minor axis 7 μm, diameter ratio 4.0 <Alkoxysilane compound> Alkoxysilane compound: γ-aminopropyltriethoxysilane, manufactured by Shin-Etsu Chemical Co., Ltd., "KBE-903P" <Elastomer> Elastomer: ethylene-octene copolymer, manufactured by Dow Chemical Japan, "Engage 8003"

[0084] [Examples 1 to 6, Comparative Examples 1 to 4] Using the above materials, a polyarylene sulfide resin, talc, and, as necessary, an alkoxysilane compound and an elastomer were dry-blended in the compositions and content ratios shown in Table 1. This was fed into a twin-screw extruder with a cylinder temperature of 320°C (glass fiber was added separately from the side feed section of the extruder) and melt-kneaded to obtain resin composition pellets of the examples and comparative examples.

[0085] [Measurements] The obtained resin composition pellets were used to measure the melt viscosity, tensile strength, flexural strength, flexural modulus, and comparative tracking index by the following methods. The results are shown in Table 1.

[0086] <Melt Viscosity> Using a Capillograph manufactured by Toyo Seiki Seisakusho Co., Ltd., a flat die of 1 mmφ×20 mmL was used as a capillary, and the barrel temperature was 310° C. and the shear rate was 1000 sec －１ The melt viscosity was measured at 100°C.

[0087] <Mechanical Properties> (Test Pieces) The resin composition pellets were dried at 140°C for 3 hours and then injection molded at a molding cylinder temperature of 320°C and a mold temperature of 150°C to prepare A-type test pieces (width 10 mm, thickness 4 mmt) in accordance with ISO 3167:93 as test pieces for tensile strength, and test pieces (width 10 mm, thickness 4 mmt) in accordance with ISO 316 as test pieces for flexural strength and flexural modulus.

[0088] (Tensile Strength) The tensile strength (MPa) of the above test pieces was measured in accordance with ISO 527-1 and 2. When the tensile strength was 90 MPa or more, the strength was evaluated as excellent.

[0089] (Flexural Strength) The flexural strength (MPa) of the test piece was measured in accordance with ISO 178. A flexural strength of 150 MPa or more was evaluated as excellent in strength.

[0090] (Flexural Modulus) The flexural modulus of the test piece was measured in accordance with ISO 178. When the flexural modulus was 19,000 MPa or more, the rigidity was evaluated as excellent, and when the flexural modulus was 21,000 MPa or more, the rigidity was evaluated as even better.

[0091] <Comparative Tracking Index (CTI)> After drying the resin composition pellets at 140°C for 3 hours, a 50mm x 70mm x 3mm thick plate test piece was prepared by injection molding at a cylinder temperature of 320°C and a mold temperature of 150°C. Using the above plate test piece and platinum electrodes, a voltage was applied while a 0.1% by mass aqueous ammonium chloride solution was dropped in accordance with UL746A, and the applied voltage (V: volts) at which tracking occurred on the test piece was measured. For the measurement, a tracking resistance tester "HAT-500-3" manufactured by Hitachi Chemical Co., Ltd. was used. A CTI of 450V or higher was evaluated as having excellent tracking resistance.

[0092]

[0093] As shown in Table 1, the resin compositions of Examples 1 to 6 had excellent tracking resistance and high values ​​for both tensile strength and flexural strength, achieving both high tracking resistance and excellent strength. Furthermore, the resin compositions of Examples 1 to 6 also had high flexural modulus values ​​and excellent rigidity. In contrast, the resin compositions of Comparative Examples 1 to 4, which used talc with an average particle size of less than 10 μm or talc with an average particle size of more than 25 μm, had low values ​​for both tensile strength and flexural strength, and were unable to achieve both high tracking resistance and excellent strength.

[0094] The polyarylene sulfide resin composition of the present embodiment can achieve both high tracking resistance and excellent strength, and therefore can be suitably used for members that require tracking resistance and strength, and has industrial applicability.

Claims

1. A polyarylene sulfide resin composition comprising: (A) a polyarylene sulfide resin; (B) talc; and (C) a fibrous inorganic filler; wherein the average particle size of the (B) talc is 10 to 25 μm; the content of the (B) talc is 60 to 235 parts by mass per 100 parts by mass of the (A) polyarylene sulfide resin; the content of the (C) fibrous inorganic filler is 15 to 190 parts by mass per 100 parts by mass of the (A) polyarylene sulfide resin; and the total content of the (B) talc and the (C) fibrous inorganic filler is 75 to 350 parts by mass per 100 parts by mass of the (A) polyarylene sulfide resin.

2. The polyarylene sulfide resin composition according to claim 1, which contains 0.1 to 10 parts by mass of (D) an alkoxysilane compound per 100 parts by mass of (A) the polyarylene sulfide resin.

3. A polyarylene sulfide resin composition according to claim 1 or 2, which contains 1 to 150 parts by mass of (E) elastomer per 100 parts by mass of (A) polyarylene sulfide resin.

4. A polyarylene sulfide resin composition according to claim 1 or 2, wherein the fibrous inorganic filler (C) has a diameter ratio, which is the ratio of the major axis to the minor axis in a cross section perpendicular to the longitudinal direction, of 3.0 or more.

5. A polyarylene sulfide resin composition according to claim 1 or 2, wherein the alkoxysilane compound (D) has one or more groups selected from the group consisting of an epoxy group, an amino group, a vinyl group, a (meth)acrylic group, an isocyanate group, and a mercapto group.

6. A polyarylene sulfide resin composition according to claim 1 or 2, wherein the elastomer (E) comprises an olefin-based elastomer, a styrene-based elastomer, a polyester-based elastomer, a polyamide-based elastomer, or a urethane-based elastomer.

7. Temperature 310℃ and shear rate 1000sec －１ 3. The polyarylene sulfide resin composition according to claim 1, wherein the melt viscosity measured by the method is 150 to 400 Pa·s.

8. The polyarylene sulfide resin composition according to claim 1 or 2, which has a tensile strength of 90 MPa or more as measured in accordance with ISO 527-1, 2.

9. The polyarylene sulfide resin composition according to claim 1 or 2, which has a flexural strength measured in accordance with ISO 178 of 150 MPa or more.

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

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