JP3434680B2 - Polyphenylene sulfide resin composition for precision molding - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention comprises a polyphenylene sulfide resin composition having no or extremely few burrs during molding, excellent in dimensional accuracy, and improved in moldability and rigidity particularly in injection molding. The present invention relates to a precision molding material.

[0002]

2. Description of the Related Art Conventionally, metals such as aluminum die-cast and zinc die-cast have been used for applications of precision parts represented by optical system parts, electronic / electrical parts, automobile parts and the like. However, the cost of processing a given shape with high dimensional accuracy leads to an increase in product cost,
In recent years, alternatives to thermoplastics, mainly engineering plastics, have been progressing. In other words, a large number of parts can be continuously produced by injection molding even in a complicated shape, so that the parts production cost can be reduced and the number of parts can be reduced by integrating a plurality of parts. Among the thermoplastic resins, polyphenylene sulfide resin (hereinafter abbreviated as PPS) has heat resistance,
Excellent dimensional stability, chemical resistance, flame retardancy, moldability, rigidity,
In this application where dimensional stability is strictly required, fibrous,
PPS in which a plate-like or granular inorganic filler is filled at a high concentration is used.

However, a disadvantage of PPS is that burrs are easily generated during molding. This is PP
The reason for this is that the melt viscosity of S has a small shear rate dependence, and the melt viscosity is relatively low even at locations where the shear rate of the resin is small, such as at the ends of cavities and minute clearances in the mold. With respect to molded products using PPS, the burrs are currently removed by blasting such as spraying fine nylon beads at a high speed, and the number of man-hours required for this is not negligible. In addition, as a recent trend, the switching to the integral molding method with other metal foils is being actively promoted for the purpose of further reducing the cost of parts, and considering the damage to the metal foils, the blast treatment so far has been done. Since it is inevitable that the PPS used for this purpose is deburred, there is a strong demand.

Various methods have been studied so far for reducing the burr of PPS. For example, in order to modify the flow characteristics of PPS, polyamide or liquid crystal polymer may be added to PPS,
There is also a method of adding a specific polyester compound or silane compound, but the burr has not been decisively reduced, and at that time, the rigidity of the material is remarkably reduced, and especially when a polyamide system is added, the water absorption of the material increases. It has fatal problems such as impaired dimensional stability of PPS. on the other hand,
Polyphenylene ether (PPS) in PPS
A composition (for example, Japanese Patent Laid-Open No. 7-53865) is proposed. It is possible to reduce burrs by adding PPE, but in order to extremely suppress burrs or prevent burrs from occurring, PP is used.
It is necessary to increase the compounding amount of E, the moldability of the material,
It has a problem that the rigidity is significantly reduced.

[0005]

PROBLEM TO BE SOLVED BY THE INVENTION It is intended to provide a PPS resin composition which has good dimensional accuracy, is particularly excellent in molding processability and rigidity, and has little or no burrs during molding.

[0006]

The present invention provides (a) 300
300 ° C., shear rate 500 to 60% to 95% by weight of polyphenylene sulfide resin having a melt viscosity of 300 to 3000 poise at 500 ° C. and shear rate 500 sec ⁻¹ .
A resin composition comprising 5 to 40% by weight of a polyphenylene ether resin having a melt viscosity of 5000 to 50,000 poise at sec ^-1 , (b) an inorganic filler composed of kaolin and talc, (c) spherical silica, ( d) A polyphenylene sulfide resin composition for precision molding, which comprises a fibrous filler, another inorganic filler or a mixture thereof.
50 to 2 parts of the component (b) per 100 parts by weight of the component (a).
00 parts by weight, 10 to 60 parts by weight of the component (c) and 10 to 300 parts by weight of the component (d) (however, (b), (c) and (d)).
The total amount of the kaolin is 400 parts by weight or less), and the inorganic filler of (b) is mixed with 20 to 80% by weight of talc with respect to 80 to 20% by weight of kaolin, and the average particle diameter of the kaolin is 0. A polyphenylene sulfide resin composition for precision molding, wherein the talc has an average particle size of 0.3 μm or more and 3 μm or less, and the spherical silica has an average particle size of 0.06 μm or more and 0.6 μm or less. .

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention is described in detail below.
The (a) component PPS resin used in the present invention is

[Chemical 1] It is preferable that the content of the structural unit represented by the formula is 70 mol% or more. If the amount is less than 70 mol%, it is difficult to obtain a composition having excellent properties. As a method of polymerizing the PPS resin, a method of reacting sodium sulfide and p-dichlorobenzene in an amide solvent such as N-methylpyrrolidone or dimethylacetamide or a sulfone solvent such as sulfolane is suitable.
At this time, in order to adjust the degree of polymerization, an alkali metal salt of carboxylic acid or sulfonic acid is added, or an alkali hydroxide, an alkali metal carbonate or an alkaline earth metal oxide is added. If it is less than 30 mol% as a copolymerization component, meta bond, ortho bond, ether bond, sulfone bond, biphenyl bond, substituted phenylene sulfide bond (wherein the substituent is an alkyl group, a nitro group, a phenyl group, an alkoxy group). , Carboxylic acid groups, carboxylic acid metal bases),
Even if it contains a trifunctional bond or the like, it does not matter as long as it does not significantly affect the crystallinity of the polymer, but the content of the copolymerization component is preferably 10 mol% or less.

The PPS resin is usually used in the presence of oxygen in the range of 200-
It is used after heat crosslinking at a temperature of 250 ° C. to adjust the melt viscosity. The desirable melt viscosity of PPS used in the present invention is 300-300 at a shear rate of 500 sec-1.
The porosity is 3000 poise, more preferably 600 to 2500 poise. If the melt viscosity is less than 300 poise, burrs are likely to occur, and if it exceeds 3000 poise, moldability is deteriorated. When the filler is compounded at a high concentration, it is desirable to use one having a relatively low viscosity within the above range in consideration of extrusion processability and moldability.

Similarly, the PPE resin used as the component (a) has the general formula

[Chemical 2] (In the formula, at least one of R1 and R2 is a linear or primary or secondary branched C1-C4 alkyl group, an aryl group, and the rest of the halogen atom is a hydrogen atom. May be the same or different from each other), a homopolymer comprising a repeating unit represented by the general formula (1) and a repeating unit represented by the general formula (1).

[Chemical 3] (In the formula, R3, R4, R5 and R6 are each a linear or primary or secondary branched chain alkyl group having 1 to 4 carbon atoms, an aryl group, a halogen atom, a hydrogen atom, etc. And these may be the same or different from each other, but R3 and R4 are not hydrogen atoms at the same time).
Graft copolymers obtained by graft polymerizing styrene with these homopolymers or copolymers are also included.

Typical examples of homopolymers of PPE include poly (2,6-dimethyl-1,4-phenylene) ether, poly (2-methyl-6-ethyl-1,4-phenylene) ether, poly ( 2,6-diethyl-1,4-phenylene) ether, poly (2-ethyl-6-n-propyl-1,4-phenylene) ether, poly (2,6-di-n-propyl-1,4-) (Phenylene) ether, poly (2-methyl-6-n-butyl-1,4-phenylene)
Ether, poly (2-ethyl-6-isopropyl-1,
4-phenylene) ether, poly (2-methyl-6-chloro-1,4-phenylene) ether, poly (2-methyl-6-hydroxyethyl-1,4-phenylene) ether, poly (2-methyl-6) -Chloroethyl-1,4-
Examples thereof include homopolymers such as phenylene) ether. The PPE copolymer may be o-cresol or the general formula

[Chemical 4] (Wherein R3, R4, R5, and R6 have the same meanings as described above), mainly composed of a polyphenylene ether structure obtained by copolymerization with an alkyl-substituted phenol such as 2,3,6-trimethylphenol. And a polyphenylene ether copolymer. The desirable melt viscosity of the PPE used in the present invention is 300 ° C. and the shear rate is 500 sec-1.
At 5000 to 50,000 poise, more preferably 10
It is in the range of 000 to 30,000 poise. If it is less than 5,000 poise, the effect of reducing burrs is small, and if it exceeds 50,000 poise, the moldability is deteriorated. PPS and PPE
The blending ratio of PPE is 60 to 95% by weight of PPE5
-40% by weight, more preferably 70-90% by weight PPS
In contrast, the PPE is 10 to 40% by weight. PPE is 5
When it is less than 40% by weight, the effect of reducing burrs is small, and when it exceeds 40% by weight, moldability is deteriorated.

The kaolin used in the component (b) of the present invention is a white fine clay mineral, generally 2SiO ₂ .Al ₂ O ₃
-The average particle size represented by the composition formula of 2H ₂ O is 0.05μ.
m or more and 0.5 μm or less, and more preferably 0.1 μm or more and 0.4 μm or less. If the average particle diameter of kaolin is less than 0.05 μm, the moldability will be poor, and if it exceeds 0.5 μm, the effect of reducing burrs will be reduced. Talc is generally the average particle size represented by the composition formula 3MgO · 4SiO ₂ · H ₂ O is 0.3μm or more 3μm or less of a plate-like filler, more preferably those of 0.5μm or 2.7μm below. If the average particle diameter of talc is less than 0.3 μm, the effect of improving the rigidity of the material is small, and if it exceeds 3 μm, the effect of reducing burrs is small. The compounding ratio of kaolin and talc is 80 to 20% by weight of kaolin, 20 to 80% by weight of talc, and more preferably 30 to 70% by weight of talc to 70 to 30% by weight of kaolin. 20% by weight of talc
If it is less than 80%, the effect of improving the rigidity is small, and if it exceeds 80% by weight, the effect of reducing burrs is small. The blending amount of the component (b) is 50 to 200 parts by weight, more preferably 60 to 180 parts by weight, relative to 100 parts by weight of the component (a). When it is less than 50 parts by weight, the effect of reducing burrs is small, and when it exceeds 200 parts by weight, moldability and strength are deteriorated.

The spherical silica used as the component (c) of the present invention is added to improve moldability during molding. Spherical silica is a high-purity spherical synthetic silica (SiO2) obtained by igniting metallic silicon powder in an oxygen stream to continuously form a self-combustion flame and by a gas phase reaction at a high temperature of 4000 ° C.
The average particle size is 0.06 μm or more and 0.6 μm or less, and more preferably 0.1 μm or more and 0.5 μm or less. If the average particle size of the spherical silica is less than 0.06 μm, the effect of improving the moldability is reduced, and if it exceeds 0.6 μm, burrs are likely to occur. The compounding amount of the component (c) is 10 to 60 parts by weight, and more preferably 20 to 50 parts by weight, relative to 100 parts by weight of the component (a). If it is less than 10 parts by weight, the effect of improving the moldability is small, and if it exceeds 60 parts by weight, the strength is lowered.

Fibrous filler which is the component (d) of the present invention /
Other inorganic fillers are used to improve various physical properties such as mechanical strength, heat resistance, dimensional stability, and electrical properties of the material (b).
It is desirable to use the component and the component (c) together. Examples of the fibrous filler include glass fiber, carbon fiber,
Asbestos fiber, silica fiber, silica-alumina fiber,
Examples thereof include alumina fibers, zirconia fibers, boron nitride fibers, silicon nitride fibers, boron fibers, potassium titanate fibers, and inorganic fibrous substances such as metal fibrous substances such as stainless steel, aluminum, titanium, copper and brass.

Examples of other inorganic fillers include silicates such as carbon black, glass beads, glass powder, glass flakes, calcium silicate, aluminum silicate, clay, mica, diatomaceous earth, and wollastonite.
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,
In addition, silicon carbide, silicon nitride, boron nitride, various metal powders and the like can be mentioned. Two or more kinds of these fillers can be used in combination. In addition, it is desirable to modify the particle surface with a surface treating agent before use. Examples of the surface treatment agent include functional compounds such as epoxy compounds, isocyanate compounds, silane compounds and titanate compounds. The filler may be used after being surface-treated with these compounds in advance, or may be added at the same time when the materials are mixed.

The blending amount of these fillers is (a) component 10
The amount is 10 to 300 parts by weight, more preferably 50 to 250 parts by weight, based on 0 parts by weight. If it is less than 10 parts by weight, the effect of improving various properties is small, and if it exceeds 300 parts by weight, the moldability is remarkably deteriorated. Particularly in the case of a fibrous filler, this tendency is strong, and further, anisotropy is likely to appear when the molded product shrinks, so that it is desirable to keep the content within the above-mentioned range. Further, the total amount of these fillers and the components (b) and (c) is 400 parts by weight or less based on 100 parts by weight of the component (a), and when it exceeds 400 parts by weight, the moldability is remarkably reduced. To do. Furthermore, in the composition of the present invention, a known substance generally added to a thermoplastic resin and a thermosetting resin, that is, a stabilizer such as an antioxidant or an ultraviolet absorber, an antistatic agent, a flame retardant, a dye or Colorants such as pigments, lubricants and the like can be appropriately added as required.

The method for producing the composition of the present invention is not limited, but for example, the components may be weighed and then mixed with a blender, a mixer or the like, and melt-kneaded with an extruder to form pellets. Then, glass fibers may be supplied in a fixed amount by a side feeder to be kneaded and pelletized. The pellet-shaped molding material thus obtained is
It is molded into a desired shape by a commonly used thermoplastic resin molding machine, an injection molding machine, an injection compression molding machine, or the like.

[0017]

The present invention will be described in more detail with reference to the following examples, but the present invention is not limited thereto. The components used in Examples 1 to 10 and Comparative Examples 1 to 13 are as shown below. PPS resin: manufactured by Topren Co., Ltd., product name: K-4 PPE resin: melt viscosity 18000, Poise (at 300 ° C., 500 sec ⁻¹ ), kaolin: manufactured by ENGELHARD (US), product name: ASP200 Talc: manufactured by Hayashi Kasei Co., Ltd., product name UPN HS -T0.5 Silica: Made by Admatechs Co., Ltd. Product name Atomafine SO-25R Glass fiber: Made by Nippon Sheet Glass Co., Ltd. Product name RES03-TP29 Calcium carbonate: Made by Shiraishi Calcium Co., Ltd. Product name Whiten P-30

The above components were blended in the compositions shown in Tables 1 to 4, melt-kneaded in a biaxial kneader and pelletized. After dehumidifying and drying the obtained molding material at 140 ° C. for 5 hours, a cylinder temperature of 300 ° C., an injection pressure of 1200 kg / cm ² , an injection speed of medium speed, a mold temperature of 140 using an injection molding machine (IS80EPN manufactured by Toshiba Machine). Molding was performed under the condition of ° C to prepare various test pieces. Using each test piece, bending strength,
Flexural modulus and molding shrinkage were measured according to the ASTM test method. The burr characteristics were evaluated by actually measuring the length of the burr generated in the clearance portion (width 5 mm, depth 20 μm) provided around the cavity when molding at the minimum filling injection speed. Further, the melt viscosity of the material was measured by a capillograph (manufactured by Toyo Seiki) (310
C, shear rate 20-6000 sec ^-1 ). These results are shown in Table 1
Shown in FIG.

[0019]

[Table 1]

[0020]

[Table 2]

[0021]

[Table 3]

[0022]

[Table 4]

[0023]

EFFECTS OF THE INVENTION According to the present invention, it is possible to provide a PPS resin composition having good dimensional accuracy, excellent moldability and rigidity, and having little or no burrs during molding. Such a resin composition can be used for precision parts such as optical parts of optical pickups.

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI C08L 71:12)

Claims (4)

(57) [Claims] 1. (a) 300 ° C., shear rate 500 sec
^{-1 to} 60 to 95 wt% of polyphenylene sulfide resin having a melt viscosity of 300 to 3000 poise,
5000-50 at 300 ° C and a shear rate of 500 sec ^-1
Resin composition prepared by blending 5 to 40% by weight of polyphenylene ether resin having a melt viscosity of 000 poise (b) Inorganic filler made of kaolin and talc (c) Spherical silica (d) Fibrous filler and other inorganics A polyphenylene sulfide resin composition for precision molding, comprising a filler or a mixture thereof. 2. The amount of (b) relative to 100 parts by weight of (a) component.
50 to 200 parts by weight of component, 10 to 60 parts by weight of component (c), 10 to 300 parts by weight of component (d) (however, the sum of (b), (c) and (d) is 400 parts by weight or less) The polyphenylene sulfide resin composition for precision molding according to claim 1, which is compounded. 3. The inorganic filler (b) is kaolin 80-2.
The polyphenylene sulfide resin for precision molding according to claim 1 or 2, which comprises 20 to 80% by weight of talc with respect to 0% by weight. 4. The average particle size of the kaolin is 0.05 μm.
0.5 μm or less, the average particle diameter of the talc is 0.3 μm
m or more and 3 μm or less, the average particle diameter of the spherical silica is 0.0
It is 6 μm or more and 0.6 μm or less.
A polyphenylene sulfide resin composition for precision molding as described in the above.