JP3135371B2 - Resin molded parts with metal terminals inserted - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molded part made of a polyarylene sulfide resin composition having a metal terminal such as a lead frame inserted therein. More specifically, the present invention particularly relates to a molded part having good adhesion to metal terminals and the like and excellent in general physical properties such as heat resistance.

[0002]

BACKGROUND OF THE INVENTION Problems to be Solved by the Invention
For electronic device component materials, automotive device component materials, and chemical device component materials, thermoplastic resins having high heat resistance, chemical resistance, and flame retardancy have been required. Polyarylene sulfide resin represented by polyphenylene sulfide is one of the resins that meet this demand,
Demand is growing, partly because of a good physical property ratio to cost. In particular, in recent years, demand for molded parts incorporating parts having metal terminals such as electric machines and electronic parts has been increasing. Such a plastic package for functional components often requires a high soldering heat resistance temperature, and requires cleaning.
Since acidic or alkaline solvents are often used, these molded parts also need to have solvent resistance enough to withstand washing. In response to such demands, polyarylene sulfide resin is a material suitable for a plastic package for functional components. However, due to poor adhesion to metal, when cleaning molded parts with metal terminals, etc., the cleaning liquid penetrates through the gap between the metal terminals and plastic and remains, corroding the built-in metal terminals and elements. However, there has been a problem that the contacts are contaminated. Conventionally, in order to compensate for this problem, after applying primer, adhesive, etc. to metal terminals such as lead frames, molding, or epoxy with good adhesion to metal at the base of the terminals coming out of the package after molding Treatments such as potting of resin are being performed. However, such a method requires a complicated process and is very costly. Therefore, it is desired to obtain a molded part having good adhesion to a metal terminal without performing such special treatment. Was.

[0003]

Means for Solving the Problems In view of the above-mentioned problems, the present inventors have conducted intensive searches and studies to obtain molded parts having good adhesion to metal terminals such as lead frames. As a result, a composition containing a polyarylene sulfide resin as a main component and containing a specific phosphate ester has good thermal stability, and at the molding processing temperature, almost no decomposition gas or evaporation gas is generated, and there is no decrease in mechanical properties. In particular, it has been found that by performing insert molding of elements and parts having metal terminals, it is possible to obtain molded parts having good adhesion to metal terminals without performing a special sealing treatment with an adhesive or the like, and to complete the present invention. Reached. That is, the present invention relates to (A) 100 parts by weight of a polyarylene sulfide resin, (B) 0.5 to 30 parts by weight of a phosphoric ester represented by the following formula (1).

[0004]

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(Wherein, R is a divalent organic group, R ¹ is C ₁
Aliphatic group -C _20, a group selected from the aromatic group C ₃ -C ₁₃ alicyclic groups and C ₆ -C _18, may each be the same or different. n is an integer of 0 to 3. (C) A polyarylene sulfide resin molded part using a resin composition containing 5 to 300 parts by weight of an inorganic filler and having metal terminals inserted therein.

Hereinafter, a molding resin material used for producing a molded part of the present invention will be described. The base resin as the component (A) in the resin material constituting the molded part of the present invention is a polyarylene sulfide resin, which is composed of a main repeating unit-(Ar-S)-(where Ar is an arylene group). It is. As the arylene group (-Ar-), for example,
p-phenylene group, m-phenylene group, o-phenylene group, substituted phenylene group (substituent is an alkyl group, preferably a C ₁ -C ₆ alkyl group or a phenyl group), p, p ′
-Phenylene sulfone group, p, p'-biphenylene group, p,
A p'-diphenylene ether group, a p, p'-diphenylenecarbonyl group, a naphthalene group and the like can be used. in this case,
In the arylene sulfide group composed of the arylene group, a polymer using the same repeating unit,
That is, a homopolymer can be used, and a copolymer containing a heterogeneous repeating unit may be preferable from the viewpoint of processability of the composition. As the homopolymer, a substantially linear polymer having a p-phenylene sulfide group as a repeating unit using a p-phenylene group as an arylene group is particularly preferably used. Further, as the copolymer, among the arylene sulfide groups comprising the above-mentioned arylene groups, two or more different combinations can be used. Among them, p-phenylene sulfide groups are mainly used,
A combination containing an m-phenylene sulfide group is particularly preferably used. Among them, a substantially linear one containing at least 60 mol%, more preferably at least 70 mol% of a p-phenylene sulfide group is suitable from the viewpoint of physical properties such as heat resistance, moldability and mechanical properties. In this case, those in which the repeating units of the components are contained in a block form rather than in a random form (for example, those described in JP-A-61-14228).
However, they have good workability, and are excellent in heat resistance and mechanical properties, and can be preferably used. Also used in the present invention (A)
As the polyarylene sulfide resin as a component, it is often preferable to use a high molecular weight polymer having a substantially linear structure obtained by polycondensation from a monomer mainly composed of a bifunctional monomer. Polymers in which the linear polymer has an increased melt viscosity by oxidative crosslinking or thermal crosslinking to improve moldability can also be used. or,
As the polyarylene sulfide resin of the present invention, in addition to the above-mentioned polymer, a branched or cross-linked polyarylene sulfide resin polymerized by mixing and using a monomer having three or more functional groups as a part of the monomer, or A blended resin blended with a linear polymer can also be used, which is preferable. The polyarylene sulfide resin (A) used in the present invention has a temperature of 310 ° C. and a shear rate of 310 ° C.
The melt viscosity measured under the condition of 1200 / sec is 1 × 10-1 ×
Polymers in the range of 10 ⁴ poise, particularly preferably in the range of 100 to 5 × 10 ³ poise, are suitable. If the melt viscosity is too low, the fluidity is so good that the melt processing is difficult, and even if a molded product is obtained, the mechanical strength is unfavorably low. On the other hand, if it is excessively large, the fluidity is poor and the melt processing is difficult.

Next, the components of the resin used in the present invention
Any phosphate ester added as (B) is effective as long as it has a structure represented by the formula (1). (1) In the formula, R is a divalent organic group, for example, any of a C _{1 to} C ₂₀ aliphatic group, a C _{3 to} C ₁₃ alicyclic group, and a C _{6 to} C ₁₈ aromatic group. Although it may be, particularly preferably an aromatic group from the viewpoint of heat resistance, for example,

[0008]

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And the like are particularly effective among them. R ¹ is C ₁
Aliphatic group C _20, C ₃ ~C ₁₃ alicyclic group, it is also effective that of any aromatic group C ₆ -C _18, may each be the same or different. Also, that there is no substituent R ^1, i.e., (1)
In the formula, even when n is 0, the adhesion to the lead frame is good and the heat resistance is sufficient. In the case the molecular weight of R ¹ is too large, the effect of improving the adhesion between the lead frame is reduced undesirably. For these reasons, preferred R ¹ is a methyl group or an isopropyl group. Among them, a methyl group is particularly preferable because it balances the effect of improving the adhesion to the metal terminal, the heat resistance, the difficulty of exudation, and the like, which are the objects of the present invention.

[0010] The compounding amount of the compound (B) of the formula (1) is 0.5 to 100 parts by weight of the polyarylene sulfide resin (A).
30 parts by weight, preferably 1 to 15 parts by weight. If the amount is too small, the adhesion to the metal terminal is not sufficient, and if the amount is too large, decomposition gas is generated and physical properties are hindered, which is not preferable.

The inorganic filler (C) blended in the resin used in the present invention is essential for lowering the molding shrinkage and the linear expansion coefficient and for improving the adhesion to the metal terminals. It is a necessary component to keep. This includes fibrous and non-fibrous (powder and granular, plate, spherical (including hollow))
Is used. Among them, powdery, spherical, and plate-like fillers are suitable because they have a large effect of suppressing the anisotropy of the molding shrinkage and the linear expansion coefficient. Examples of the particulate filler include silica, quartz powder, glass powder, aluminum silicate, kaolin, talc, clay, diatomaceous earth, wollastonite, silicate, iron oxide, zinc oxide, metal oxides such as alumina, and carbonic acid. Metal carbonates such as calcium and magnesium carbonate, metal sulfates such as calcium sulfate and barium sulfate, and other metal powders such as silicon carbide, silicon nitride, boron nitride, and glass fillers are used as spherical fillers. Spherical fillers such as balloons and aluminum silicate balloons. Examples of the plate-like filler include mica and glass flake. Among them, silica, talc, glass beads, glass balloons, finely divided mica, glass flakes, aluminum silicate balloons and the like are particularly preferred. The fibrous filler improves mechanical strength, heat resistance, and other properties, and includes glass fiber, silica fiber, silica / alumina fiber, zirconia fiber, boron nitride fiber, silicon nitride fiber, boron fiber, Inorganic fibrous substances such as potassium titanate fiber and other mineral fibers; Note that a high melting point organic fibrous substance such as an aromatic polyamide, a fluorine resin, or an acrylic resin can also be used.

In particular, when mechanical strength is required, a combination of glass fibers having an average fiber length of 30 to 500 μm and one or more of finely divided mica powder, glass flakes, glass beads, glass balloons, and aluminum silicate balloons is used. The effect of improving the adhesion to metals such as lead frames is remarkable. When using these fillers, it is desirable to use a sizing agent or a surface treatment agent (coupling agent) if necessary. Examples of the coupling agent include functional compounds such as an epoxy compound, an isocyanate compound, a silane compound, and a titanate compound. These compounds may be used in advance for the surface treatment or convergence treatment of the filler, or may be added and compounded at the same time as the preparation of the material. In particular, organic silanes, especially aminoalkoxysilanes, epoxyalkoxysilanes, mercaptoalkoxysilanes, and vinylalkoxysilanes are preferred. (C) The amount of the inorganic filler used as the component is the amount of the polyarylene sulfide resin (A) 1
5 to 300 parts by weight per 100 parts by weight, preferably 10 to
250 parts by weight. If the amount is too small, the molding shrinkage and the coefficient of linear expansion are large, and the effect of improving the adhesion to the metal such as a lead frame is small. Comes out.

In addition, a small amount of another thermoplastic resin may be additionally used in the resin material for inserting the metal terminal of the present invention. Any auxiliary resin component may be used as long as it is a thermoplastic resin that is stable at high temperatures. For example, aromatic polyester resins such as polyethylene terephthalate, polybutylene terephthalate, and other aromatic dicarboxylic acids and diols or oxycarboxylic acids, polyamides such as nylon 6, nylon 6-6, nylon 6-10, nylon 12, and nylon 46 Resin, polyolefin resin mainly containing ethylene, propylene, butene, etc., styrene resin such as polystyrene, polystyrene-acrylonitrile, ABS, etc., polycarbonate, polyphenylene oxide, polyalkyl acrylate, polyacetal, polysulfone, polyether sulfone, poly Examples thereof include ether imide, polyether ketone, and fluorine resin. These thermoplastic resins can be used as a mixture of two or more kinds. In addition, known substances generally added to thermoplastic resins, such as stabilizers such as antioxidants and ultraviolet absorbers, antistatic agents, flame retardants, coloring agents such as dyes and pigments, lubricants, crystallization accelerators and the like Can also be appropriately added according to the required performance.

The resin material for inserts of the present invention can be prepared by the equipment and method generally used for preparing synthetic resin compositions. That is, the necessary components can be mixed and formed into a molding pellet using a single-screw or twin-screw extruder.
Any of a molding method and a method of pulverizing, mixing and melt-extruding a part or all of the polyarylene sulfide resin in order to improve the dispersion and mixing of the components can be used. The molded component having the metal terminal of the present invention can be formed by a general metal insert injection molding method using the above-described resin material. That is, a metal terminal such as a lead frame or an element or component attached thereto is mounted at a predetermined position in a mold, and the insert molded product of the present invention can be produced extremely efficiently by injection molding.

[0015]

According to the present invention, a molded part having a metal terminal inserted therein can be efficiently and economically produced.
It is excellent in heat resistance and mechanical properties, particularly excellent in adhesiveness to metal parts, free of corrosion and contamination due to invasion of an interface of a cleaning solution or the like, and suitable as various functional parts.

[0016]

EXAMPLES The present invention will be described in more detail with reference to the following Examples, but it should not be construed that the invention is limited thereto. Examples 1 to 17, Comparative Examples 1 to 4 Polyphenylene sulfide resin (PPS) (manufactured by Kureha Chemical Industry Co., Ltd., trade name "Fortron KPS") (A) 1
The components (B) and (C) shown in Tables 1 to 3 were added to 00 parts by weight, and mixed with a blender for 5 minutes. Next, this was melt-kneaded with an extruder having a cylinder temperature of 310 ° C. to prepare pellets of the polyphenylene sulfide resin composition. The component (B) used for preparing the above resin material is as follows.

[0017]

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Next, using an injection molding machine, FIG.
(a) Attach the lead frame made of metal (copper) shown in 1
Insert molding was performed at a cylinder temperature of 310 ° C. and a mold temperature of 150 ° C. to prepare a test molded part as shown in FIG. 1 and evaluated by the following method. A specific fluorescent ink (Eishin Chemical Co., Ltd.)
As shown in FIG. 1 (b), the ink penetrates into the interface between the metal terminal and the resin, and is immersed in a PEF fluorescent penetrant F-6A-SP (FIG. 1 (b)). (Point E), the adhesion between the metal terminal and the resin was evaluated. For reference, the bending characteristics of a separately molded standard test piece were measured (according to ASTM D-709). The results are shown in Tables 1 to 3.

[0019]

[Table 1]

[0020]

[Table 2]

[0021]

[Table 3]

[Brief description of the drawings]

FIG. 1 is a view showing the shape of a test molded part into which a metal lead frame used in an embodiment of the present invention is inserted,
(a) is a plan view, and (b) is an elevation view, further showing the situation of the ink penetration test.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Metal lead frame 2 Polyarylene sulfide resin molding part 3 Fluorescent ink

Claims (3)

(57) [Claims] (A) Polyarylene sulfide resin 100
(B) 0.5 to 30 parts by weight of a phosphoric ester represented by the following formula (1) (Where R is a divalent organic group, and R ¹ is a C ₁ -C ₂₀ fat)
Family group, a group selected from the aromatic group C ₃ -C ₁₃ alicyclic groups and C ₆ -C _18, may each be the same or different. n is an integer of 0 to 3. (C) A polyarylene sulfide resin molded part in which a metal terminal is inserted using a resin composition containing 5 to 300 parts by weight of an inorganic filler. Wherein R is an aliphatic group of C ₁ -C ₂₀ of formula (1), C ₃ ~C
2 selected from ₁₃ alicyclic groups and C _{6 to} C ₁₈ aromatic groups
The resin molded part according to claim 1, which is a valence organic group. 3. The resin molded part according to claim 1, wherein (C) the inorganic filler is at least one of fibrous, powdery (including spherical) and plate-like inorganic fillers.