Polyarylene Sulfide Molded Articles with High Tensile Strength
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Solution Overview
Problem
Molded articles made from polyarylene sulfide and reinforcing fibers face challenges in achieving high tensile strength while maintaining moldability and productivity, due to low interfacial bondability and insufficient tensile elongation of the polyarylene sulfide, which limits their application as alternatives to metal materials.
Innovation Solution
A molded article comprising 10-40% reinforcing fibers and 60-90% polyarylene sulfide matrix resin, with specific conditions such as strand tensile strength of 1.5-5.5 GPa, fiber length of 0.4-10 mm, tensile elongation of 1.5-10%, and interfacial shear strength of 20 MPa or more, to enhance tensile strength and moldability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the tensile elongation of polyarylene sulfide is improved to enhance dynamic characteristics, then the tensile strength of the molded article is improved, but the melt viscosity increases and moldability is impaired
Solution Approach 1:
The patent changes the chemical structure parameters of polyarylene sulfide by introducing specific aromatic rings (naphthalene, anthracene, phenanthrene units) to achieve optimal balance between tensile elongation and melt viscosity. This structural modification allows the resin to maintain high tensile elongation (2-10%) while keeping melt viscosity at manageable levels for injection molding
Solution Approach 2:
The patent creates a composite system by combining modified polyarylene sulfide with specific reinforcing fibers (glass fibers, carbon fibers, or aramid fibers) to achieve synergistic effects. The fiber reinforcement provides additional tensile strength while the modified resin matrix ensures good interfacial bonding and processability
2Strength
If the interfacial bondability between polyarylene sulfide and reinforcing fibers is improved to utilize the reinforcing effect, then the tensile strength is improved, but the complexity of the molding material increases
Solution Approach 1:
The patent applies preliminary surface treatment to reinforcing fibers before combining them with polyarylene sulfide. The fibers are treated with silane coupling agents or oxidizing agents to create surface groups that enhance chemical bonding with the resin, ensuring strong interfacial adhesion before the molding process begins
Solution Approach 2:
The patent introduces coupling agents as intermediary substances between the reinforcing fibers and polyarylene sulfide matrix. These coupling agents (such as silane-based agents) form chemical bridges that improve interfacial bonding, allowing effective stress transfer from the matrix to the fibers without requiring overly complex material formulations
3Strength
If the tensile elongation of polyarylene sulfide is increased to achieve high tensile strength, then the dynamic characteristics are improved, but the productivity decreases due to higher process temperature requirements
Solution Approach 1:
The patent modifies the chemical structure of polyarylene sulfide by controlling the molar ratios of aromatic rings and sulfide groups, as well as the mass average molecular weight (10,000-100,000). These parameter changes optimize the balance between tensile elongation and melt viscosity, allowing processing at standard temperatures without sacrificing mechanical properties
Solution Approach 2:
The patent introduces local structural variations in the polyarylene sulfide chain by incorporating specific aromatic units (naphthalene, anthracene, phenanthrene) at controlled proportions. This local structural optimization enhances tensile elongation in specific regions of the polymer chain while maintaining overall processability
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(b)
Figure 3
AI summary
Provided are a molded article including: 10 to 40% by mass of reinforcing fibers (A); and 60 to 90% by mass of a matrix resin (B) mainly including a polyarylene sulfide, the molded article satisfying the following conditions (I) to (IV) and having a tensile strength of 240 MPa or more in a main orientation direction of the reinforcing fibers (A) in the molded article; and a molding material for producing the molded article. (I) The strand tensile strength of the reinforcing fibers (A) is 1.5 to 5.5 GPa. (II) The number average fiber length of the reinforcing fibers (A) is 0.4 to 10 mm. (III) The tensile elongation of the matrix resin (B) is 1.5 to 10%. (IV) The interfacial shear strength between the reinforcing fibers (A) and the matrix resin (B) is 20 MPa or more.