Long Fiber-Reinforced Polyarylene Sulfide Resin Blow Molding
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Solution Overview
Problem
Polyarylene sulfide resin molded articles lack sufficient impact resistance and moldability for large-sized components due to high melt fluidity and terminal carboxy groups, limiting their application in harsh environments such as automobile engines.
Innovation Solution
A long fiber-reinforced polyarylene sulfide resin composition with fibers exceeding 5 mm in length is dry-blended with the resin and melted to produce blow-molded hollow articles, enhancing mechanical strengths and moldability through improved draw-down resistance and thickness uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If polyarylene sulfide resin is used for blow molding, then heat resistance and chemical resistance are improved, but impact resistance and moldability deteriorate due to high melt fluidity and terminal carboxy groups
Solution Approach 1:
The patent uses a composite material system consisting of polyarylene sulfide resin combined with long glass fibers (5-20 mm) and a specific coupling agent. This composite structure provides both the heat resistance of the PAS resin and the impact resistance of the fiber reinforcement, while the coupling agent ensures proper interfacial bonding to maintain mechanical strength.
Solution Approach 2:
The patent controls the melt flow rate of the polyarylene sulfide resin within a specific range (10-100 g/10 min at 316°C) and limits the terminal carboxy group content to 0.1-5 mmol/g. By adjusting these parameters, the resin achieves optimal balance between heat resistance, moldability, and impact resistance for blow molding applications.
2Temperature
If polyarylene sulfide resin is used for blow molding, then heat resistance is improved, but thickness uniformity and draw-down resistance deteriorate due to high melt fluidity
Solution Approach 1:
The patent specifies controlling the melt flow rate to 10-100 g/10 min at 316°C and terminal carboxy groups to 0.1-5 mmol/g. These parameter controls regulate the melt viscosity and draw-down behavior during extrusion blow molding, ensuring uniform wall thickness while maintaining the inherent heat resistance of the PAS resin.
3Strength
If fiber reinforcing material is added to improve impact resistance, then mechanical strength is improved, but moldability deteriorates due to increased draw-down and thickness unevenness
Solution Approach 1:
The patent specifies using long glass fibers with a length of 5-20 mm, which provides sufficient impact resistance while maintaining moldability. The fiber length is optimized to balance reinforcement effectiveness with ease of processing during extrusion blow molding, avoiding excessive draw-down and thickness variation.
Solution Approach 2:
The patent uses a coupling agent to improve the interfacial bonding between the glass fibers and the polyarylene sulfide resin matrix. This localized enhancement at the fiber-matrix interface ensures effective stress transfer and maintains mechanical strength while allowing the use of long fibers that would otherwise compromise moldability.
4Strength
If long glass fibers are used to improve impact resistance, then mechanical strength is improved, but processing difficulty increases due to high melt viscosity
Solution Approach 1:
The patent controls the melt flow rate within 10-100 g/10 min at 316°C, which corresponds to an optimal viscosity range for processing long fiber-reinforced compositions. This parameter control ensures the melt has sufficient viscosity to maintain fiber orientation and structural integrity, yet remains processable during extrusion and blow molding operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The approach results in polyarylene sulfide resin molded articles with improved impact resistance and heat resistance, suitable for harsh environments, while maintaining excellent moldability and inner-surface smoothness.
Implementation Method 1
heating at a temperature not lower than a melting point of the polyarylene sulfide resins to melt the polyarylene sulfide resins
Implementation Method 2
heating at a temperature not lower than a melting point of the polyarylene sulfide resins to melt the polyarylene sulfide resins
Data Source
AI summary
To provide a polyarylene sulfide (PAS) resin composition and a PAS resin molded article that are excellent in mechanical strengths such as impact resistance while maintaining excellent heat resistance of the PAS resin, and methods for producing the PAS resin composition and the PAS resin molded article. Specifically, provided are a method for producing a long fiber-reinforced PAS resin molded article, the method including obtaining a long fiber-reinforced PAS resin composition containing a PAS resin and a fiber reinforcing material having a fiber length of more than 5 mm, subsequently subjecting the resin composition and a PAS resin to dry blending, and subsequently subjecting the dry-blended substance to melting and subsequently to melt-molding; the long fiber-reinforced PAS resin composition; and a method for producing the long fiber-reinforced PAS resin composition.