CN1974672A - 液晶聚合物混合物和含该混合物的组合物 - Google Patents

液晶聚合物混合物和含该混合物的组合物 Download PDF

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Publication number
CN1974672A
CN1974672A CNA2006101647211A CN200610164721A CN1974672A CN 1974672 A CN1974672 A CN 1974672A CN A2006101647211 A CNA2006101647211 A CN A2006101647211A CN 200610164721 A CN200610164721 A CN 200610164721A CN 1974672 A CN1974672 A CN 1974672A
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liquid crystalline
crystalline polymers
crystalline polymer
polymer blends
liquid
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寺田浩昭
浅原素纪
加藤博行
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Ueno Seiyaku Oyo Kenkyujo KK
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Ueno Technology Co Ltd
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Publication of CN1974672A publication Critical patent/CN1974672A/zh
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    • C09K19/00—Liquid crystal materials
    • C09K19/04—Liquid crystal materials characterised by the chemical structure of the liquid crystal components, e.g. by a specific unit
    • C09K19/38—Polymers
    • C09K19/3833—Polymers with mesogenic groups in the side chain
    • C09K19/3838—Polyesters; Polyester derivatives
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Abstract

本发明提供一种液晶聚合物混合物，其由混合具有延伸模量为20－32GPa和用差示扫描量热计测定的熔点为250－330℃的液晶聚合物(A)，和用差示扫描量热计测定的熔点为大于等于190℃且小于250℃的液晶聚合物(B)得到，其中所述液晶聚合物(A)和所述液晶聚合物(B)的重量比在50∶50至90∶10的范围。液晶聚合物混合物和含所述液晶聚合物混合物的液晶聚合物混合物组合物都显示优良的机械性能如延伸模量，和在低温下有优良的模制操作性。本发明的液晶聚合物混合物和液晶聚合物混合物组合物适宜生产具有高结合强度的焊接品。

Description

液晶聚合物混合物和含该混合物的组合物
技术领域
本发明涉及一种液晶聚合物混合物，该混合物显示了高延伸模量和优良的模制流动性和在低温下优良的模制加工性能，和涉及一种含该混合物的液晶聚合物混合组合物。
背景技术
热塑性的液晶聚合物(以下称为液晶聚合物或LCP)具有良好的性质，包括耐热性、机械性能，如硬度、耐化学性和尺寸精确度。由于这些性能，LCPs不仅应用于生产模型制品，也用于多种产品，包括纤维和薄膜。特别是个人电脑和移动电话使用高集成器件，并且希望将尺寸较小、更薄和更小的部件技术用于它们。在信息通信领域有时需要很薄的部件。由于LCPs的优良性能，LCPs的消耗已经增长。
近来，需要空调机的室内设备尺寸更小，并且希望将尺寸更小、更薄和更小的部件技术用于室内设备，如横向气流风扇。常规地，如丙烯酸苯乙烯树脂的塑性材料已经用于生产横向气流风扇。但是丙烯酸苯乙烯树脂不适于厚度为0.8mm或更薄的部件。很难通过注模法用所述树脂完全填充用于这么薄的部件的模具。此外，用丙烯酸苯乙烯制成的横向气流风扇由于部件的弯曲容易变形。而且，需要横向气流风扇的高速旋转来补偿由于室内设备尺寸的减小而带来的风量的降低。为了生产小尺寸的横向气流风扇，技术期望有一种具有高延伸模量和能抵抗高速旋转的高机械强度的材料。认为LCPs有希望作为能解决由于部件的尺寸减小而引起的问题并能显示高机械强度的材料。
在各种液晶聚合物中，在分子链中包括一定量6-氧基-2萘甲酰基重复单元的液晶聚酯酰胺显示高延伸模量(日本专利申请Laid Open No.Sho.57-172921相当于US4330457和日本专利申请Laid Open No.Sho.61-51032，在此引入这些内容作为参考)。然而，具有高延伸模量的液晶聚合物可通常显示高熔体粘度和低流动性能，因此不适于生产具有薄部件的模制品。
此外，LCPs具有高熔点，需要比通常用于生产横向气流风扇的树脂材料如丙烯酸苯乙烯更高的工艺温度。因此，如果用这些LCPs制成的部件要进行二次加工如焊接，很难获得具有足够的结合强度的连接产品。
因此，希望LCPs在模制流动性和延伸模量之间有适当的平衡，且在低温下有极好模制操作性。由这种LCPs制成的部件可容易地进行二次加工操作，如焊接。
为了改善具有高延伸模量的LCPs的流动性，例如，已经建议用包括液晶聚酯酰胺的聚合物混合物，如日本专利申请Laid Open No.Sho.57-172921相当于US4330457和日本专利申请Laid Open No.Sho.61-51032中公开的，和包括整个芳香族液晶聚酯聚合物混合物(参见日本专利申请Laid Open No.Sho.61-120851相当于US4567227)。但是所述聚合物混合物需要在2502或更高的温度下进行操作，在低温下显示的可加工性不好。聚合物混合物的模制流动性也不令人满意。此外，由于其高加工温度，聚合物混合物的可焊接性不好，不适于生产小尺寸的横向气流风扇。
发明内容
发明概述
本发明的一个目的是提供一种液晶聚合物材料，其适于生产模制品，如用于空调机的室内设备的横向气流风扇，并且显示了优良的机械性能，如高延伸模量，在低温下有优良的模制操作性和优良的流动性。
本发明提供一种液晶聚合物混合物，其通过结合(A)延伸模量为20-32GPa和用差示扫描量热计测定的熔点为250-330℃的液晶聚合物，和(B)差示扫描量热计测定的熔点大于等于190℃且小于250℃的液晶聚合物得到，其中所述液晶聚合物(A)和所述液晶聚合物(B)的重量比在50∶50至90∶10的范围。
优选地，本发明的液晶聚合物混合物的差示扫描量热计测定的熔点为大于等于200℃且小于250℃。
本发明的液晶聚合物混合物显示了优良的机械性能，对于模制有优良的流动性能和在低温下有优良的模制操作性。本发明的液晶聚合物混合物的模制部件具有优良的焊接性。
在说明书和权利要求书中，术语“液晶聚合物混合物”意为通过结合上面定义的液晶聚合物(A)和(B)以使所述液晶聚合物(A)与(B)的重量比在50∶50至90∶10的范围而获得的聚合物混合物。本发明液晶聚合物混合物基本上由液晶聚合物(A)和液晶聚合物(B)组成。
在说明书和权利要求书中，术语“液晶聚合物混合组合物”意为包括上面定义的液晶聚合物混合物和如填料、增强剂等其他成分的组合物。
附图说明
图1描述了用作超声波焊接试样的共用结合处。
优选实施方式的详述
首先，描述包含在本发明液晶聚合物混合物中的液晶聚合物(A)。
液晶聚合物(A)为液晶聚酯或液晶聚酯酰胺，其显示各向异性的熔融相，本领域中的技术员称作为热致液晶聚合物。
液晶聚合物(A)的各向异性的熔融相可以通过常规的用正交光偏振器的偏振光系统的方法确定。更具体的，可以在氮气氛围下用Leitz’s偏光显微镜观察Leitz’s热台上的样品。
用于本发明的液晶聚合物(A)没有特别的限定，可以是任何具有延伸模量为20-32GPa和用差示扫描量热计测定的熔点为250-330℃的液晶聚合物。优选地，聚合物(A)的延伸模量为24-32GPa，熔点为250-310℃。更优选，聚合物(A)的熔点为250-290℃。
用于本发明的液晶聚合物(A)由一种或多种液晶聚酯和/或液晶聚酯酰胺组成。当用两种或两种以上的聚合物时，可将它们分别与液晶聚合物(B)结合，或在与液晶聚合物(B)混合之前将它们熔混在一起。如果液晶聚合物(A)包括两种或两种以上的树脂，树脂混合物应当具有在上述定义范围内的延伸模量和熔点。
延伸模量的测定：
树脂的延伸模量根据有Instron 5567的ASTM D638用ASTM4型试样在室温、移动速度为5mm/s下测定。
熔点的测定：
用差示扫描量热计Exstar 6000(Seiko Instruments Inc.，Chiba，Japan)或相同类型的DSC装置。将检测的LCP样品以20℃/分钟的速率加热，记录吸热峰(Tm1)。然后，LCP样品在比Tm1高20-50℃的温度下保持10分钟。然后将样品以20℃/分钟的速率冷却至室温，然后以相同的速率再次加热。最后步骤中得到的吸热峰记为熔点。
用于本发明的液晶聚合物(A)可以是半芳香的液晶聚合物，其在分子链中含有脂肪基，或完全芳香液晶聚合物，其分子链由芳香基组成。在这些液晶聚合物中，由于其阻燃性和优良的机械性能，优选完全芳香液晶聚合物。
液晶聚合物(A)中的重复单元的例子为芳香羟羰基，芳香二羰基，芳香二氧基，芳香氨氧基、芳香氨羰基，芳香二氨基，芳香羟二羰基和脂肪二氧基重复单元。
由上述的重复单元形成的液晶聚合物可根据聚合物的结构组分和组分的比率和分配次序包括赋予或不赋予各向异性的熔融相的两种聚合物。将用于本发明的液晶聚合物(A)限定为显示各向异性的熔融相的那些聚合物。
提供芳香羟羰基重复单元的单体例子为对羟基苯甲酸、间羟基苯甲酸、邻羟基苯甲酸、6-羟基-2-萘甲酸、5-羟基-2-萘甲酸、3-羟基-2-萘甲基、4’-羟苯基-4-苯甲酸、3’-羟苯基-4-苯甲酸、4’-羟苯基-3-苯甲酸、和其烷基、烷氧基或卤素取代的衍生物和形成酯的衍生物，如其酰基衍生物、酯衍生物和酰卤。上述中，就控制所得液晶聚合物混合物的性能和熔点而言，优选对羟基苯甲酸和6-羟基-2-萘甲酸。
提供芳香二羰基重复单元的单体例子为芳基二羧酸，如对苯二甲酸、间苯二甲酸、2，6-萘二羧酸、1，6-萘二羧酸、2，7-萘二羧酸、1，4-萘二羧酸、4，4’-二羧基联苯，和其烷基、烷氧基和卤素取代的衍生物和形成酯的衍生物，如其酯衍生物和酸卤化物。上述中，就控制所得液晶聚合物混合物的机械性能、耐热性、熔点和模制性能而言，优选对苯二甲酸和2，6-萘二羧酸。
提供芳香二氧基重复单元的单体例子为芳香二醇，如对苯二酚、间苯二酚、2，6-二羟萘、2，7-二羟萘、1，6-二羟萘、1，4-二羟萘、4，4’-二羟联苯、3，3’-二羟联苯、3，4’-二羟联苯、4，4’-二羟二苯醚，和烷基、烷氧基或卤素取代的衍生物，和形成酯的衍生物，如其酰基衍生物。上述中，就所得液晶聚合物混合物在聚合过程中的优良反应性和优良的性能而言，优选对苯二酚和4，4’-二羟联苯。
提供芳香氨氧基重复单元的单体例子为芳香羟胺，如对氨基苯酚、间氨基苯酚、4-氨基-1-萘酚、5-氨基-1-萘酚、8-氨基-2-萘酚、4-氨基-4’-羟基联苯、和烷基、烷氧基或卤素取代的衍生物，和形成酯的衍生物，如其酰基衍生物以及形成酰胺的衍生物，如其N-酰基衍生物。
提供芳香氨羰基重复单元的单体例子为芳香氨基羧酸，如对氨基苯甲酸、间氨基苯甲酸、6-氨基-2-萘甲酸、和烷基、烷氧基或卤素取代的衍生物，和形成酯的衍生物，如其酰基衍生物、酯衍生物和酸卤化物以及形成酰胺的衍生物，如其N-酰基衍生物。
提供芳香二氨基重复单元的单体例子为芳香二胺，如对苯二胺、间苯二胺、1，5-二氨基萘、1，8-二氨基萘，和烷基、烷氧基或卤素取代的衍生物，和形成酰胺的衍生物，如其N-酰基衍生物。
提供芳香氧二羰基重复单元的单体例子为羟基芳香二羧酸，如3-羟基-2，7-萘二羧酸、4-羟基间苯二甲酸、5-羟基间苯二甲酸、和其烷基、烷氧基或卤素取代的衍生物，和形成酯的衍生物，如其酰基衍生物、酯衍生物和酰卤。
提供脂肪二氧基重复单元的单体例子为脂肪二醇，如乙二醇、1，4-丁二醇、1，6-己二醇、和其酰基衍生物。此外，含脂肪二氧基重复单元的液晶聚合物可由含脂肪二氧基重复单元的聚酯如聚对苯二甲酸乙二醇酯或聚对苯二甲酸丁二醇酯与上述芳香氧基羧酸、芳香二羧酸、芳香二醇、芳香羟胺、芳香氨羧酸、芳香二胺或其酰基衍生物、酯衍生物或酸卤化物反应得到。
如果硫酯键不损害本发明的目的，用于本发明的液晶聚合物(A)可有硫酯键。提供硫酯键单体的例子有巯基芳香羧酸、芳香二硫醇和羟基芳香硫醇。这些另外的单体的添加比例优选不超过基于提供芳香氧羰基、芳香二羰基、芳香二氧基、芳香氨氧基、芳香二氨基、芳香氧二羰基和脂肪二氧基重复单元的单体总量的10mol％。
上述中，用于本发明优选的液晶聚合物(A)为含下面通式(I)所示的6-氧基-2-萘甲酰基重复单元的那些聚合物。
当液晶聚合物(A)含通式(I)表示的重复单元时，所述重复单元在液晶聚合物(A)中的比例优选为基于聚合物(A)重复单元总量的50-80mol％，更优选50-70mol％，最优选50-65mol％。
根据本发明，从高延伸模量和良好的操作性的角度考虑，由下述重复单元组成的液晶聚合物(A-1)别优选作为LCP(A)：
Figure A20061016472100101
其中，
Ar1和Ar2分别表示至少一个二价芳香基；
X表示O或NH；和
a、b和c表示液晶聚合物(A)中的重复单元的相对摩尔份数(mol％)并且满足下式：
50mol％≤a≤80mol％
10mol％≤b≤25mol％
10mol％≤c≤25mol％
a+b+c＝100mol％。
在液晶聚合物(A-1)中，优选满足下式的那些聚合物：
b＝c。
在用于本发明的液晶聚合物(A1)中，Ar1和Ar2的优选的例子为亚苯基、亚萘基、亚联苯基。更优选地，Ar1和Ar2都是亚苯基，最优选地，Ar1和Ar2都为对-亚苯基。
在用于本发明的液晶聚合物(A-1)中，X优选为NH。换言之，优选液晶聚酯酰胺。
描述包含在本发明液晶聚合物混合物中的液晶聚合物(B)。
液晶聚合物(B)为液晶聚酯或液晶聚酯酰胺，其显示各向异性的熔融相，本领域中的技术员称为热致液晶聚合物。
可以用与液晶聚合物(A)相同的方法确定液晶聚合物(B)各向异性的熔融相。
用于本发明的液晶聚合物(B)没有特别的限定，可以是任何具有用差示扫描量热计测定的熔点为大于等于190℃且小于250℃的液晶聚合物。优选地，聚合物(B)的熔点为200-240℃，更优选为210-230℃。
用于本发明的液晶聚合物(B)由一种或多种液晶聚酯和/或液晶聚酯酰胺组成。当用两种或两种树脂时，可以分别将它们与液晶聚合物(A)混合，或可在与液晶聚合物(A)结合之前将它们熔混在一起。如果液晶聚合物(B)包括两种或两种以上的树脂，树脂混合物应当具有在上述定义范围内的熔点。
可与用于液晶聚合物(A)相同的方法测定液晶聚合物(B)的熔点。
用于本发明的液晶聚合物(B)可以是分子链中含有脂肪基的半芳香液晶聚合物，或分子链由芳香基组成的完全芳香液晶聚合物。在这些液晶聚合物中，由于其阻燃性和优良的机械性能，优选完全芳香液晶聚合物。
液晶聚合物(B)中的重复单元的例子为芳香氧羰基，芳香二羰基，芳香二氧基，芳香氨氧基、芳香氨羰基，芳香二氨基，芳香氧二羰基和脂肪二氧基重复单元。
提供含于液晶聚合物(A)中的重复单元的上述单体例子可优选用于制备液晶聚合物(B)。
由上述的重复单元形成的液晶聚合物可根据聚合物的结构组分和组分的比率和分配次序包括赋予或不赋予各向异性的熔融相的两种聚合物。用于本发明的液晶聚合物(B)限为显示各向异性的熔融相的那些聚合物。
如果硫酯键不损害本发明的目的，用于本发明的液晶聚合物(B)可有硫酯键。提供硫酯键的单体的例子有巯基芳香羧酸、芳香二硫醇和羟基芳香硫醇。这些外的单体的添加比例优选不超过基于提供芳香氧羰基、芳香二羰基、芳香二氧基、芳香氨氧基、芳香氨羰基、芳香氧二羰基和脂肪二氧基重复单元的单体总量的10mol％。
根据本发明，从良好的机械性能和良好的可加工性的角度考虑，由下述重复单元组成的液晶聚合物(B-1)特别优选作为LCP(B)：
Figure A20061016472100121
其中，
Ar3和Ar4分别表示至少一个二价芳香基；和
p、q、r和s表示液晶聚合物(B)中的重复单元的相对摩尔份数(mol％)并且满足下式：
0.4≤q/p≤2.0
2mol％≤r≤15mol％
2mol％≤s≤15mol％
p+q+r+s＝100mol％。
在液晶聚合物(B-1)中，优选满足下式的那些聚合物：
r＝s。
使得到优选的液晶聚合物(B)具有低熔点和优良机械性能的混合重复单元的例子如下所示：
其中，
重复单元右下角的数字表示每个重复单元在液晶聚合物(B)中的mol％。
上述中，下面的重复单元的结合得到特别优选的液晶聚合物(B)：
Figure A20061016472100131
其中，
重复单元右下角的数字表示每个重复单元在液晶聚合物(B)中的mol％。
制备用于本发明的液晶聚合物(A)和(B)的方法不受限制，可以用本领域中已知的任何方法。例如，可以用常规的聚合方法，如熔融酸解和淤浆聚合法用于制备聚合物以得到上述单体组分中的酯和/或酰胺键。
优选用熔融酸解法制备液晶聚合物(A)和(B)。这种方法中，将单体加热得到熔融液，然后所述熔融液反应得到熔融聚合物。该方法的最后步骤可在真空下进行，以促进除去挥发性的副产物，如醋酸或水。
淤浆聚合法的特征在于单体在热交换流体中反应，以在热交换液体媒质中以悬浮液的形式得到固态聚合物。
不管是熔融酸解法还是淤浆聚合法，聚合单体可以是低酰基衍生物的形式，该酰基衍生物是在室温下酰化羟基和/或氨基得到。低的酰基可以优选有2-5个碳原子，更优选2-3个碳原子。乙酰化单体最优选用于反应。
单体的低酰基衍生物可以是那些预先分别酰化单体制备的，或可是那些通过在反应系统中在制备液晶聚合物时向单体加入如乙酸酐的酰化剂生产的。
不管是熔融酸解法还是淤浆聚合法，如果需要，可以在反应中用催化剂。
催化剂的例子包括有机锡化合物，如二烷基锡氧化物(如二丁基氧化锡)和二芳基氧化锡；有机钛化合物，如二氧化钛，三氧化锑，烷氧硅酸钛和醇化钛；羧酸的碱金属或碱土金属盐，如醋酸钾；无机酸盐(如K2SO4)；如Lewis酸(如BF3)和气态酸催化剂，例如卤化氢(如HCl)。
当使用催化剂时，向反应中加入的催化剂的量优选为单体总量的10-1000ppm，更优选20-300ppm。
液晶聚合物(A)和液晶聚合物(B)可从聚合物反应容器以熔融态获得，并处理得到粒状、片状或粉状。
本发明的液晶聚合物混合物通过结合液晶聚合物(A)和液晶聚合物(B)得到，使得聚合物(A)和聚合物(B)的重量比为50∶50至90∶10。本发明的液晶聚合物混合物可通过用捏合机器捏合聚合物(A)和聚合物(B)的混合物得到，所述捏合机器如班伯里密炼机(Banbury mixer)、捏合机、单螺杆挤出机、双螺杆挤出机等。
液晶聚合物(A)和液晶聚合物(B)的重量比为50∶50至90∶10，优选60∶40至90∶10，更优选70∶30至90∶10，最优选80∶20至90∶10。
当液晶聚合物(A)的量占液晶聚合物混合物总重量的90wt％以上，液晶聚合物混合物将在低温下没有足够的流动性或可加工性。另一方面，当其量小于50wt％时，液晶聚合物混合物将没有足够的机械性能，如延伸模量。
所得本发明的液晶聚合物混合物的由差示扫描量热计测定的熔点为200-270℃，优选大于等于200℃且小于250℃。
本发明的液晶聚合物混合物显示良好的流动性，在低温下有良好的模制可加工性，和良好的机械性能，如延伸模量。
本发明进一步提供一种包括本发明液晶聚合物混合物和其他组分的液晶聚合物混合组合物。
本发明的液晶聚合物混合组合物可以是由在本发明液晶聚合物混合物中混合一种或多种无机和/或有机填料得到的那些。
无机和/或有机填料的例子可包括玻璃纤维、硅铝纤维、氧化铝纤维、碳纤维、钛酸钾纤维、硼酸铝纤维、芳族聚酸胺纤维、滑石、云母、石墨、硅灰石、白云石、粘土、玻璃片、玻璃珠、玻璃气球、碳酸钙、硫酸钡和氧化钛。其中，由于物理性质和价格的良好平衡，优选玻璃纤维。
本发明的液晶聚合物混合组合物中无机和/或有机填料的加入量为每100份液晶聚合物(A)和液晶聚合物(B)总重量中加入0.1-200重量份，优选1-100重量份。
本发明的液晶聚合物混合组合物中如果需要，可进一步添加一种或多种通常用于树脂组合物的添加剂。例如，可混入模制润滑剂如高级脂肪酸，高级脂肪酯、高级脂肪酰胺、高级脂肪酸金属盐、聚硅氧烷和碳氟树脂；着色剂，如颜料和染料；抗氧化剂；热稳定剂；UV吸收剂；抗静电剂；和表面活性剂。这里所用术语“高级”基表示10-25个碳原子的基。
如高级脂肪酸、高级脂肪酯、高级脂肪酸金属盐或碳氟型表面活性剂的模制润滑剂可在颗粒进行模制处理前加入到液晶聚合物混合物或液晶聚合物混合组合物中，从而使添加剂粘附于颗粒的外表面。
如果其他树脂成分不损害本发明的目的，则本发明的液晶聚合物混合组合物可包括一种或多种其他的树脂成分，该树脂成分可以在与本发明液晶聚合物混合物相同的温度范围内进行例如模制的加工。其他树脂成分的例子包括热塑树脂如聚酰胺、聚酯、聚缩醛、聚苯醚和其变性衍生物、聚砜、聚醚砜、聚醚酰亚胺和聚酰胺酰亚胺、和热固性树脂如酚醛树脂、环氧树脂和聚亚胺树脂。其他树脂成分的量没有限制，可根据想要的性质确定。通常，这种其他树脂加到液晶聚合物混合组合物中的量为每100份液晶聚合物(A)和液晶聚合物(B)的总重量加入0.1-100重量份，优选0.1-80重量份。
本发明的液晶聚合物混合物组合物可通过向本发明的液晶聚合物混合物中加入无机和/或有机填料、添加剂和其他树脂组分，再用捏合机器将混合物捏合得到，所述捏合机器如班伯里密炼机(Banbury mixer)、捏合机、单螺杆挤出机、双螺杆挤出机等。
可以在液晶聚合物(A)和液晶聚合物(B)通过熔融捏合期间或之后，将无机和/或有机填料、添加剂和其他树脂组分添加到本发明的液晶聚合物混合物中。
本发明的液晶聚合物混合组合物可用常规的方法操作得到模制品、薄膜、薄片、粘合型纺织品等。例如，优选用注模或压出技术。
特别地，本发明的液晶聚合物混合物和液晶聚合物混合组合物显示极好的模制流动性，它们适宜用于生产用于有很薄部件的空调机的室内设备横向气流风扇或其组件，如厚度薄至0.8mm或更薄。
本发明的液晶聚合物混合物和液晶聚合物混合物组合物具有低熔点和在低温下有优良的模制加工性，因此它们可用二次加工如焊接进行有效处理。
本发明进一步提供一种生产具有结合处的模制品的方法，包括结合由模制本发明的液晶聚合物混合物或液晶聚合物混合组合物得到的多于一种组分的步骤，其中结合步骤通过超声波焊接、振动焊接、高频焊接、电磁感应焊接、脉冲焊接或旋转焊接进行。
在本发明的说明书和权利要求书中，术语“模制品”表示用本发明的液晶聚合物混合物或液晶聚合物混合组合物通过焊接结合或不焊接结合制成的产品。该术语表示通过用二次加工如焊接结合两种或两种以上的组分得到产品，和不经二次加工得到的产品。
术语“组分”表示由本发明液晶聚合物混合物或液晶聚合物混合组合物经结合或不结合形成的部件，该结合使之构成一个完整的产品，且其进行二次加工得到完整的产品。
为了结合由模制本发明的液晶聚合物混合物或液晶聚合物混合组合物得到的两种或两种以上的组分，适宜用焊接机，如超声波焊接机、高频焊接机、电磁感应焊接机、脉冲焊接机、振动焊接机和旋转焊接机。
这些结合方法(焊接方法)在下面简要的描述。
<超声波焊接>
在该方法中，超声波静电能量转换成机械振动能量，使在需焊接的树脂部件的结合表面产生磨擦热，从而可将它们焊接在一起。
<高频焊接>
在该方法中，通过高频辐射的方法使需焊接的部件内部产生电介质热，从而可将它们焊接在一起。
<电磁感应焊接>
在该方法中，将放置在需焊接的部件结合部位的金属或磁性材料有选择的加热，从而使部件间接加热，可将它们能焊接在一起。
<脉冲焊接>
在该方法中，用压垫的方法将部件加压，然后将置于压垫顶部的镍铬丝带瞬间加热至软化或熔融所述部件，从而可将它们焊接在一起。
<振动焊接>
在该方法中，将需焊接的两个部件都置于压力下，将其中一个水平振动以在焊接表面上产生磨擦热，从而可将部件焊接在一起。
<旋转焊接>
在该方法中，将圆筒形的模制部件置于压力下，使产品在高速下旋转以产生磨擦热，使部件焊接。
在上述结合/焊接方法中，从大型或形状复杂的产品的焊接性能的角度考虑，本发明特别优选超声波焊接、振动焊接或旋转焊接。
本发明的液晶聚合物混合物和液晶聚合物混合物组合物熔点低，适宜生产具有高机械强度的焊接模制品。
此外，本发明液晶聚合物混合物和液晶聚合物混合组合物形成的组分可容易地进行二次操作，甚至在它们具有很薄或细致的部件的情况下，这是由于它们的优良模制流动性和在低温下优良的模制加工性能。通过结合组分于由本发明液晶聚合物混合物或液晶聚合物混合组合物制成的横向气流风扇，可以生产很薄和很小的空调室内设备的横向气流风扇等。
具体实施方式
根据下面的实施例进一步描述本发明。
实施例
在实施例中，用下面的缩写。
BON6：6-羟基-2-萘甲酸
POB：对-羟基苯甲酸
AcPAP：对-乙酰基氨基苯酚
HQ：对苯二酚
TPA：对苯二甲酸
合成实施例1
LCP-I(液晶聚合物(A))的合成
将BON6、AcPAP和TPA以表1所示比例加入到装有扭矩计搅动设备和冷凝器的反应容器中，单体总量为5mol。然后将0.2g(相对于单体总量为227ppm)醋酸钾和相对于单体的羟基总量(摩尔)的1.030倍摩尔的醋酸酐加入到容器中。混合物在下面的条件下聚合。
表1：合成实施例1，单体比
  BON6   AcPAP   TPA
  g   565   151   166
  mol％   60   20   20
在氮氛围下，用1小时以上将混合物从室温加热至150℃，在150℃保持60分钟，然后快速加热至240℃，蒸馏掉副产物醋酸，并在该温度下保持60分钟。然后用3小时以上将混合物加热至335℃，并用60分钟以上将压力降至30mmHg。当扭矩变成预定的水平，聚合反应结束。将所得的聚合物从容器移出，用粉碎机粉碎得到LCP颗粒。结果，蒸馏出的醋酸接近理论量。
所得液晶聚合物的DSC测定熔点为280℃。
将得到的液晶聚合物颗粒在130℃下干燥4小时，然后用注射模型成形机UH1000-100(Nissei Plastic Industrial Co.，Ltd.，Japan)在料筒温度320℃模头温度70℃下生产LCP-I的试样。试样的延伸模量为27GPa。
合成实施例2
LCP-II(液晶聚合物(B))的合成
将BON6、POB、HQ和TPA以表2所示比例加入到装有扭矩计搅动设备和冷凝器的反应容器中，单体总量为5mol。然后将0.05g(相对于单体总量为63ppm)醋酸钾和相当于单体的羟基总量(摩尔)的1.025倍摩尔的醋酸酐加入到容器中。混合物在下面的条件下聚合。
表2：合成实施例2，单体比
  BON6   POB   HQ   TPA
  g   386   297   44   67
  mol％   41   43   8   8
在氮氛围下，用1小时以上将混合物从室温加热至150℃，在150℃保持30分钟，然后快速加热至210℃，蒸馏掉副产物醋酸，并在该温度下保持30分钟。然后用3小时以上将混合物加热至335℃，并用30分钟以上将压力降至20mmHg。当扭矩变成预定的水平，聚合反应结束。将所得的聚合物从容器移出，用粉碎机粉碎得到LCP颗粒。结果，蒸馏出的醋酸接近理论量。
所得液晶聚合物的DSC测定熔点为218℃。
将得到的液晶聚合物颗粒在130℃下干燥4小时，然后用注射模型成形机UH1000-100(Nissei Plastic Industrial Co.，Ltd.，Japan)在料筒温度320℃模头温度70℃下生产LCP-II的试样。试样的延伸模量为12GPa。
合成实施例3
LCP-III的合成
将POB和BON6以表3所示比例加入到装有扭矩计搅动设备和冷凝器的反应容器中，单体总量为5mol。然后将0.05g(相对于单体总量为67ppm)醋酸钾和相对于单体的羟基总量(摩尔)的1.025倍摩尔的醋酸酐加入到容器中。混合物在下面的条件下聚合。
表3：合成实施例3，单体比
  POB   BON6
  g   504   254
  mol％   73   27
在氮氛围下，用1小时以上将混合物从室温加热至150℃，在150℃保持30分钟，然后快速加热至210℃，蒸馏掉副产物醋酸，并在该温度下保持30分钟。然后用3小时以上将混合物加热至325℃，并用30分钟以上将压力降至20mmHg。当扭矩变成预定的水平，聚合反应结束。将所得的聚合物从容器移出，用粉碎机粉碎得到LCP颗粒。结果，蒸馏出的醋酸接近理论量。
所得液晶聚合物的DSC测定熔点为280℃。
将得到的液晶聚合物颗粒在130℃下干燥4小时，然后用注射模型成形机UH1000-100(Nissei Plastic Industrial Co.，Ltd.Japan)在料筒温度320℃模头温度70℃下生产LCP-III的试样。试样的延伸模量为13GPa。
实施例1
LCP-I(A)、LCP-II(B)和玻璃纤维(T-747 Nippon Electric Glass Co.，Ltd.，Japan)以重量比49∶21∶30(LCP-I(A)与LCP-II(B)的重量比为70∶30)混合，在320℃下熔融捏合，然后用Twin-Screw Extruder(TEX 30，The Japan SteelWorks，LTD.，Tokyo，Japan)挤压得到液晶聚合物混合组合物的颗粒。将所得颗粒在130℃下干燥4小时，然后用UH1000-100(Nissei Plastic Industrial Co.，Ltd.，Japan)在料筒温度320℃、模头温度70℃下模制得到用于的超声波焊接测试的具有如图1所示剪切焊头形的试样，和用于测定延伸模量的试样。
将前述试样用超声波焊接机(BRANSON 950M，Emerson Japan，Ltd.，Japan)在下面的条件下焊接得到结合的产品。
所得的结合产品的结合强度通过用Instron Corporation #5567评估为在结合表面垂直方向5mm/秒的拉伸率下的分裂力。液晶聚合物混合组合物的熔点、延伸模量和由液晶聚合物混合组合物形成的结合产品的结合强度如表4所示。
<超声波焊接条件>
振动：20KHz
喇叭(Hom)：锥形喇叭，TIN，3/4英寸直径
焊接时间：80m秒
保持时间：0.5秒
实施例2
除了LCP-I(A)、LCP-II(B)和玻璃纤维以如表4所示的重量比(LCP-I(A)与LCP-II(B)的重量比为80∶20)混合外，用与实施例1相同的方法得到液晶聚合物混合组合物。
液晶聚合物混合组合物的熔点、延伸模量和由液晶聚合物混合组合物形成的结合产品的结合强度如表4所示。
实施例3
除了LCP-I(A)、LCP-II(B)和玻璃纤维以如表4所示的重量比(LCP-I(A)与LCP-II(B)的重量比为60∶40)混合外，用与实施例1相同的方法得到液晶聚合物混合组合物。
液晶聚合物混合组合物的熔点、延伸模量和由液晶聚合物混合组合物形成的结合产品的结合强度如表4所示。
比较实施例1
除了LCP-I(A)和玻璃纤维以如表4所示重量比混合外，用与实施例1相同的方法得到液晶聚合组合物。
液晶聚合物混合组合物的熔点、延伸模量和由液晶聚合物混合组合物形成的结合产品的结合强度如表4所示。
比较实施例2
除了LCP-I(A)、LCP-III和玻璃纤维以如表4所示重量比混合外，用与实施例1相同的方法得到液晶聚合物组合物。
液晶聚合物组合物的熔点、延伸模量和由液晶聚合物组合物形成的结合产品的结合强度如表4所示。
比较实施例3
除了LCP-II(B)和玻璃纤维以如表4所示重量比混合和在230℃下熔融捏合外，用与实施例1相同的方法得到液晶聚合物组合物。
液晶聚合物组合物的熔点、延伸模量和由液晶聚合物组合物形成的结合产品的结合强度如表4所示。
比较实施例4
除了LCP-I(A)、LCP-II(B)和玻璃纤维以如表4所示重量比(液晶聚合物(A)与液晶聚合物(B)的重量比为30∶70)混合外，用与实施例1相同的方法得到液晶聚合物组合物。
液晶聚合物组合物的熔点、延伸模量和由液晶聚合物组合物形成的结合产品的结合强度如表4所示。
表4
  组合物(重量％)   熔点(℃)   延伸模量(GPa)  结合的机械强度(A)
  LCP-I(A)   LCP-II(B)   LCP-III   玻璃纤维
 实施例1   49   21   0   30   240   27  280
 实施例2   56   14   0   30   245   27  270
 实施例3   42   28   0   30   225   25  300
 比较实施例1 70 0 0 30 280 28 180
 比较实施例2 49 0 21 30 280 27 240
 比较实施例3   0   70   0   30   218   21  350
 比较实施例4   21   49   0   30   220   21  310
含30重量％玻璃纤维的本发明实施例1、实施例2和实施例3的液晶聚合物混合组合物显示高的延伸模量、低于250℃的熔点，和由超声波焊接得到的焊接的高机械强度。
由70重量％的LCP-I(液晶聚合物(A))和30重量％的玻璃纤维组成的比较实施例1的液晶聚合物组合物显示了高延伸模量。但是对比实施例1的液晶聚合物组合物显示了高熔点和由超声波焊接得到的焊接的低机械强度。
由LCP-I(液晶聚合物(A))、高熔点的LCP-III和玻璃纤维组成的比较实施例2的液晶聚合物组合物显示了高延伸模量。但是对比实施例2的液晶聚合物组合物显示了高熔点和相对较低的焊接机械强度。
由70重量％的LCP-II(液晶聚合物(B))和30重量％的玻璃纤维组成的比较实施例3的液晶聚合物组合物显示了低熔点和高结合机械强度。但是对比实施例3的液晶聚合物组合物显示了低的延伸模量。
含21重量％的LCP-I(液晶聚合物(A))、49重量％的LCP-II(液晶聚合物(B))和30重量％的玻璃纤维的比较实施例4的液晶聚合物组合物(液晶聚合物(A)与液晶聚合物(B)的比为30∶70)显示了低熔点和高结合机械强度。但是对比实施例4的液晶聚合物组合物显示的延伸模量低。

Claims (14)

1.一种液晶聚合物混合物，其通过结合下述成分得到：
(A)具有延伸模量为20-32GPa和用差示扫描量热计测定的熔点为250-330℃的液晶聚合物，和
(B)用差示扫描量热计测定的熔点为大于等于190℃且小于250℃的液晶聚合物，
其中所述液晶聚合物(A)和所述液晶聚合物(B)的重量比在50∶50至90∶10的范围。
2.根据权利要求1所述的液晶聚合物混合物，其中液晶聚合物混合物用差示扫描量热计测定的熔点为大于等于200℃且小于250℃。
3.根据权利要求1或2所述的液晶聚合物混合物，其中液晶聚合物(A)包括聚合物(A)的重复单元总量的50-80mol％的由下述通式(I)表示的重复单元，
4.根据权利要求3所述的液晶聚合物混合物，其中液晶聚合物(A)由下面的重复单元构成：
其中，
Ar1和Ar2分别表示至少一个二价芳香基；
X表示O或NH；和
a、b和c表示液晶聚合物(A)中的重复单元的相对摩尔份数(mol％)并且满足下式：
50mol％≤a≤80mol％
10mol％≤b≤25mol％
10mol％≤c≤25mol％
a+b+c＝100mol％。
5.根据权利要求4所述的液晶聚合物混合物，其中，Ar1和Ar2表示对亚苯基，X表示NH。
6.根据权利要求1-5任一项所述的液晶聚合物混合物，其中液晶聚合物(B)由下面的重复单元组成：
Figure A2006101647210003C1
其中，
Ar3和Ar4分别表示至少一个二价芳香基；和
p、q、r和s表示液晶聚合物(B)中的重复单元的相对摩尔份数(mol％)并且满足下式：
0.4≤q/p≤2.0
2mol％≤r≤15mol％
2mol％≤s≤15mol％
p+q+r+s＝100mol％。
7.根据权利要求6所述的液晶聚合物混合物，其中，液晶聚合物(B)由下面的重复单元构成：
其中，
重复单元右下角的数字表示每个重复单元在液晶聚合物(B)中的mol％。
8.一种液晶聚合物混合组合物，包括至少一种无机和/或有机填料，其量为每100重量份根据权利要求1-7任一项的液晶聚合物混合物加入0.1-200重量份。
9.根据权利要求8所述的液晶聚合物混合组合物，其中无机和/或有机填料为玻璃纤维。
10.一种通过模制根据权利要求1-7任一项的液晶聚合物混合物或权利要求8或9的液晶聚合物混合物组合物得到的模制品。
11.根据权利要求10所述的模制品，该产品是横向气流风扇或其组件。
12.根据权利要求11所述的模制品，其中横向气流风扇或其组件具有薄壁部件，其厚度等于或小于0.8mm。
13.一种生产具有结合处的模制品的方法，包括结合由模制根据权利要求1-7的任一项的液晶聚合物混合物或权利要求8或9的液晶聚合物混合组合物得到的多于一种组分的步骤，其中结合步骤通过超声波焊接、振动焊接、高频焊接、电磁感应焊接、脉冲焊接或旋转焊接进行。
14.根据权利要求13所述的方法，其中模制品是横向气流风扇或其组件。
CNA2006101647211A 2005-10-28 2006-10-27 液晶聚合物混合物和含该混合物的组合物 Pending CN1974672A (zh)

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